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How can Statistical Process Control improve your production processes in real-time?

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If you are a control engineer, you know how important it is to monitor and improve the quality of your production processes. But how can you do that in real-time, without waiting for the results of offline tests or inspections? One possible answer is Statistical Process Control (SPC), a powerful method that uses data analysis and feedback to detect and correct variations in your processes. In this article, you will learn what SPC is, how it works, and how it can benefit your production processes in real-time.

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KENNETH KOZOL

ELECTRICAL ENGINEER SPECIALIST

1 What is SPC?

SPC is a technique that applies statistical methods to measure, analyze, and control the quality of a process. It is based on the idea that every process has a natural variation, but some variations are abnormal and indicate problems. By collecting and plotting data from your process, you can identify the normal variation (called common cause) and the abnormal variation (called special cause) and take appropriate actions. SPC can help you reduce waste, defects, and costs, and improve customer satisfaction and productivity .

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KENNETH KOZOL

ELECTRICAL ENGINEER SPECIALIST
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Statistical Process Control is a mathematical method to assess stability of a "system", based on data samples. It employs statistics to grade variability of a data stream. These methods can be used on real time data, or data obtained from designed tests. For example, accuracy and repeatability of measurement data. It doesn't "improve" your system, but it provides tools to reliably measure improvement or degradation.

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Timóteo Cuete

Electrical Supervisor at ANGOHORIZON
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Implementing Statistical Process Control enhances real-time production by providing continuous monitoring and immediate detection of variations, enabling timely adjustments for improved quality and efficiency.

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2 How does SPC work?

SPC uses different tools and charts to monitor and control your process. The most common ones are control charts, which plot the data points and the limits of the normal variation (called control limits). Control charts can show you if your process is stable (within control limits) or unstable (out of control limits), and if there are any patterns or trends that indicate a problem. You can use control charts for different types of data, such as variables (like temperature, pressure, or speed) or attributes (like defects, errors, or complaints).

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KENNETH KOZOL

ELECTRICAL ENGINEER SPECIALIST
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To fully appreciate the benefit from SPC, critical variables require identification. Tracking data that doesn't contribute to your goals is pointless and wasteful. SPC takes a lot of effort, so choose wisely. I would suggest using your best knowledge of your process to choose, then testing these assumptions. For example, if you choose temperature of the material, but find defects are produced while the temperature is stable, may indicate temperature isn't a defining factor. It will take some trials to hit on the data, or groups of data that make the difference.

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3 How can SPC improve your processes in real-time?

Using SPC can help you improve your processes in real-time, providing timely and accurate information about the performance and quality. This can enable you to detect and correct problems before they affect the output or customer, as well as prevent them from happening by identifying and eliminating root causes of variation. Furthermore, SPC can be used to optimize your process by finding and maintaining the best settings and conditions, along with allowing you to continuously improve your process by setting and achieving quality goals and standards.

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KENNETH KOZOL

ELECTRICAL ENGINEER SPECIALIST
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Once relevant data is being tracked, any deviations can be corrected, preventing long runs of defective product. This is the basic principle. In practice, I have seen it isn't only one or two variables, but a entire data set that needs to be managed to within an operating window. Deviations can also be used to better understand the interactions. This needs talented engineers that are both experienced and innovative. Don't expect SPC to magically reduce defects or increase production, without careful study of the data and work to make changes. Don't expect an AI that mined these answers to do you much good.

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4 What are the benefits of SPC for control engineers?

SPC can offer many benefits for control engineers, including reducing rework, scrap, downtime, and warranty claims; improving the reliability and consistency of the process; delivering high-quality products and services that meet or exceed customer expectations; using data and facts instead of opinions and guesses for decision making and problem solving; and involving and empowering the team and stakeholders to develop a culture of quality and improvement. Ultimately, these advantages can save time and money while increasing efficiency and productivity.

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5 What are the challenges of SPC for control engineers?

Successfully implementing and maintaining SPC requires challenges and efforts, such as collecting and analyzing enough and relevant data from a process, using appropriate tools and methods. It is important to choose and apply the right control charts and rules for a process, depending on the type and purpose of the data. Interpreting and communicating the results and actions of SPC should be done in a clear and simple manner, with visuals if necessary. Training and motivating your team and stakeholders to understand and use SPC is also essential, as well as participating in the improvement process. Finally, your SPC system should be reviewed and updated regularly, to ensure its effectiveness and relevance.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can Statistical Process Control improve your production processes in real-time?

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1 What is SPC?

2 How does SPC work?

3 How can SPC improve your processes in real-time?

4 What are the benefits of SPC for control engineers?

5 What are the challenges of SPC for control engineers?

6 Here’s what else to consider

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