Statistical Process Control

Statistical Process Control

Purpose
Introduce the concepts of Statistical Process Control

Objectives
1. Be able to use “Xbar and S Charts” for analysis of
continuous data.
2. Be able to use “p” Control Chart for analysis of
discrete data.
3. Be able to determine control limits for each type of
chart.
4. Be able to interpret charts and determine when a
process is “Out of Control”.
5. Be able to explain the importance of taking action
based on the chart information.

06A.1
Statistical Process Control

What is: Statistical

Process Control (SPC)
Statistical -- Probability based decision rules.

Process -- Any repetitive task or steps.

Control -- Monitoring of process performance.

The analysis is based on the same concept as

the “t test” hypothesis test. It allows decisions
about the process to correct problems before
they affect the output.
SPC will signal when the
process is “out-of- control”.
Your mission is to find out
why, then fix it so it will
never happen again

SPC signals when the steady-

state process variation has
been influenced by outside
assignable causes.

06A.2
Statistical Process Control

Six Sigma and SPC

Six Sigma Quality focuses on moving
the control upstream in a process to
leverage control of the input
characteristics or vital X’s.

Provide increased

X stability to
Dependent variables;
Responses Y1,Y2,..., Ym
Control Charts applied to
Process variables;
Independent variables;
Design variables X1, X2,..., Xk

06A.3
Statistical Process Control

When is SPC used?

• What do I want to know?

– Has the critical process variable
(X or Y) output changed over time?
(i.e., Is the process stable?)
• How do I want to see it?
– Real time data based graphical
display showing process changes.

SPC is a rigorous process which requires

active engagement of the operational
team to collect and analyze the data.

06A.4
Statistical Process Control

Control Chart Components

X Bar Chart

102.00
UCL Upper Control Limit
101.00

100.00 Avg
X LCL-A
99.00 Grand Average
Avg-Gd
Central Line
98.00 LCL UCL-A

97.00
Out of Control Condition,
96.00 Record action taken to fix. Lower Control Limit
1 3 5 7 9 11 13 15 17 19 21 23 25

Sample / Subgroup (time ordered)

Sigma Chart
7.00

6.00 UCLs
5.00 Range
4.00 LCL-R
Average Sigma
3.00
s AVG-R
Central Line
2.00 UCL-R

1.00

0.00 LCLs
1 3 5 7 9 11 13 15 17 19 21 23 25

06A.5
Statistical Process Control

Control Charts
Developed in the 1920s by Dr. Walter Shewhart of
the Bell Laboratories, Statistical Process Control
charts provide a graphical comparison of a measured
process observation against statistically computed
“control limits”(expectation).

• Plot performance over time.

• A process change could involve mean and/or
variance differences, so we always plot average
and variance control charts in pairs (Xbar and S)
• Control limits for the Mean represent two tail
hypothesis test limits to infer sameness or
difference of the observed sample mean.
• The control limits for Sigma or Range represent
where variance would show difference.

06A.6
 Statistical Process Control

Hypothesis test?
A Control Chart is a graphic display of a continuing two
tailed test with HO and HA defined as:

Ho: i

Ha: i

/2 For 3s limits,  = 0.00135

UCLx

Note: the approximate

X
confidence level is 99.7%.

LCLx

/2

When a subgroup average falls outside of the control

chart limits, it makes a graphical statement that a
difference exists between the mean of that sample
and the historical average.

06A.7
Statistical Process Control

Process Stability
The graphic below shows a variety of unstable
process examples. Control chart interpretation
can assist in identifying when these are
occurring as well as what condition exists.

Condition C1: C2: C3: C4: C5:

Time t1:

t2:

t3:

t4:

t5:

t6:

t7:

Mean: SUSTAINED IRREGULAR TREND CONSTANT IRREGULAR

SHIFT SHIFT
Stdev: CONSTANT CONSTANT CONSTANT DECREASED IRREGULAR

Copyright 1995 Six Sigma Academy, Inc.

An unstable process has no

predictable behavior and good
performance may not be
sustainable.
06A.8
Statistical Process Control

Process Stability
• A process output is considered stable when it
consists of only common-cause variation.
• Subgroup averages and variation measures
are between their control limits and display
no evidence of assignable-source (special-
cause) variation.
• If non-random patterns of data appear on the
control chart, or when a point is beyond the
control limits, then this is a strong signal that
assignable-source (special-cause) variation
is present in your process.
region of assignable-source variation
UCL

region of stable process variation

X
(only common-cause variation)

LCL
region of assignable-source variation

A stable process will rarely produce an output

outside of the plus and minus three sigma region.

06A.9
Statistical Process Control

Types of Control Charts

Types of Control Charts
There are two types of
Variables Charts Attributes Charts control charts:
for monitoring for monitoring
continuous X's discrete X's Variables charts -
Used for monitoring X
Ave & Range Fraction Defective
X bar & R p Chart variables that are
n < 10, typically n > 50
typically 3 - 5 tracks dpu/dpo continuous, such as a
diameter or consumer
Average & Number Defective
Std Deviation np Chart satisfaction rating.
X bar & s n > 50 (constant)
n > 10 tracks # def

Median & Range Number of

X&R Defects
n < 10, c Chart Attribute charts -
typically 3 - 5 c>5
Used for monitoring
Individual & Number of discrete X variables,
Moving Range Dev / Unit
XmR u Chart such as good/bad
n=1 n variable
counts, or inventory
levels.

In order to select the appropriate control

chart to monitor your process, first
determine if the key process variables (X’s)
are continuous or discrete.

06A.10
 Statistical Process Control

The X Bar Sigma

(Xbar-S) Control Chart
Xbar/S Chart for Evaluations

4.3
Used to analyze and
3.0SL=4.232
4.2
4.1 X=4.096
control continuous process
4.0
3.9
-3.0SL=3.959
variables.
3.8
1
3.7
Subgroup 0 5
1
10 15 20 25
You can use Xbar-S charts
0.6
1
– In Measure, to
0.5
0.4
0.3
graphically separate
0.2
0.1
3.0SL=0.2409
S=0.1403
common causes of
0.0
-3.0SL=0.03982
variation from special
causes
The Xbar-S chart is best – In Analyze and Improve
generated using Minitab or to check for process
other statistical software stability before
package. If software is not completing a hypothesis
available, use Xbar-R or test.
other manual control – In Control to verify
charts. process control following
improvement work.

06A.11
Statistical Process Control

Constructing Xbar-S
using Minitab
File: GEAPPS>6Sigma>Minitab>Training>Minitab>
Session 4> control chart.mtw
Select Stat > Control Charts > Xbar-S

06A.12
 Statistical Process Control

Constructing Xbar-S
using Minitab
Select the column with the response data and either
enter a value for the subgroup size or identify the
subgroup subscript column(in this case, “Week”)

Select “Tests”.

Determine the criteria

for “Out of Control
Conditions”. Select
either “Perform all
eight tests” or choose
between the eight
tests provided.
06A.13
 Statistical Process Control

Voila!!… Now What?

Minitab generates the
Xbar/S Chart for Evaluations
Xbar-S chart . It 4.3
3.0SL=4.232

automatically 4.2

Sample Mean
4.1 X=4.096
4.0

calculates the control 3.9

3.8
-3.0SL=3.959

1 1

limits. The out-of- 3.7

Subgroup 0 5 10 15 20 25

control points are 0.6

0.5
1
Sample StDev

0.4

shown on the graph 0.3

0.2
3.0SL=0.2409
S=0.1403

and summarized in 0.1

0.0
-3.0SL=0.03982

the session window.

The numbers on the chart correspond to the eight tests

used to determine an “Out of Control” condition.

06A.14
Statistical Process Control

Analyzing the Control Charts

Xbar/S Chart for Evaluations

4.3
3.0SL=4.232
4.2
Sample Mean

4.1 X=4.096
4.0
-3.0SL=3.959
3.9
3.8
1 1
3.7
Subgroup 0 5 10 15 20 25

0.6
1
0.5
Sample StDev

0.4
0.3
3.0SL=0.2409
0.2
S=0.1403
0.1
-3.0SL=0.03982
0.0

• The week 7 & 16 evaluation averages fell below the

lower limit of 3.957. . . They are out of control.
• This change was driven by some assignable cause
(either system-related or region-initiated).
• Investigate, identify and fix the assignable source of
the variation. Record this on the chart at the time of
occurrence.
• The variation among the regional centers for week 7 is
larger than expected. This also requires investigation,
correction and notation.

An “out-of-control” indication can come

from either chart.

06A.15
Statistical Process Control

Calculating Average Chart

Control Limits
To determine the value of the control limits for mean, you
must first calculate the Overall Process Average
(Grand Mean):

X
X 1  X 2  ... X k  Overall Process Average
k
where k = the # of subgroup averages

The Upper Control Limit:is found by the following formula:

UCL X  X  3s / n
The formula for the Lower Control Limit:

LCL X  X  3s / n

For larger sample sizes, the limits for a given process

will be narrower, and the chart sensitivity greater.

06A.16
Statistical Process Control

Calculating Variation Chart

Control Limits
• To define the control limit for “s”,
first calculate “s” for each
subgroup.

 (x
Where ni=number
si  ij  xi ) 2
(ni  1) of observations in
j the ith subgroup.

• Next calculate average “S”

s   si  k
Where k= the number of subgroups

• Determine the control limit lines.

– Calculations are based on concepts
similar to Mean chart, but are complex.
Luckily, Minitab calculates these limits.

06A.17
 Statistical Process Control

Larger Subgroup Size

Increases Sensitivity

n=3 n = 10 n = 25
UCL
UCL
UCL
LCL
LCL
Copyright 1995 Six Sigma Academy, Inc.
LCL

As sample size increases, the control limits draw closer

together. This increases the sensitivity. That is, it
increases the probability of detecting a change.
Control Chart sensitivity is relative to the ratio of the
square roots of the sample size. i.e., a sample size of
25 is 2.5 times as sensitive as a sample of 4 (5/2).
To take advantage of the Central Limit Theorem,
subgroup size must be greater than 2.

06A.18
B22.14
Statistical Process Control

Why Three Sigma

Control Limits?
• Three sigma limits have withstood the test of time.
• The 3 sigma limit results in an  of approximately
.00135. This gives a low chance of reacting when
the process did not truly change. This is important
since there are a large number of tests being
conducted over time.

2 s - 95% Confidence Interval for an average

3 s - =.003 (Reason: Many sequential tests;
reduces potential for error.)
4.5 s - Long term process performance goal for
individual measurement compared to
customer requirement.
6.0 s - Short Term process variation goal for
individual measurement compared to
customer requirement.

3 s limits provide good sensitivity to change

with low potential for over-reacting
when the process is stable.

06A.19
Statistical Process Control

Variables control chart Example

A consumer services organization wants to monitor
“consumer satisfaction” for their company. Each week, a
survey from each of the company’s ten regional service
centers is evaluated and the scores are tabulated. The
following is an example of how an Xbar-S control chart could
be used to monitor “consumer satisfaction.” (In this example,
higher is better.)
The vital information for creating an Xbar-S control chart:
Total subgroups = 25
Subgroup size, n = 10
Grand average, X = 4.096
S=.1403

Control Limit Formulas:

UCLX  X  A3  s
LCLX  X  A3  s
UCLs  B4  s
LCLs  B3  s
Actual Control Limit Calculations for the Data
See the SPC
UCL = 4.096 + (.975 x 0. 1403) = 4.232 table of
constants
LCL = 4.096 - (0.975 x 0.1403) = 3.959 on the next
page
UCLR = 1.716 x 0.1403 = 0.2408
LCLR = 0.284 x 0.1403 = 0.0398

06A.20
Statistical Process Control

Control Chart Constants

& Control Limits
The following table contains the various constants
that are used for constructing SPC control charts.
Variables Control Chart Control Limit Constants
n A2 A3 D3 D4 B3 B4 d2 c4
1 2.660 3.760 - - - - - -
2 1.880 2.659 0 3.267 0 3.267 1.128 0.7979
3 1.023 1.954 0 2.575 0 2.568 1.693 0.8862
4 0.729 1.628 0 2.282 0 2.266 2.059 0.9213
5 0.577 1.427 0 2.115 0 2.089 2.326 0.9400
6 0.483 1.287 0 2.004 0.03 1.970 2.534 0.9515
7 0.419 1.182 0.076 1.924 0.118 1.882 2.704 0.9594
8 0.373 1.099 0.136 1.864 0.185 1.815 2.847 0.9650
9 0.337 1.032 0.184 1.816 0.239 1.761 2.970 0.9693
10 0.308 0.975 0.223 1.777 0.284 1.716 3.078 0.9727

• The standard deviation used to calculate the

control chart limits is is based on the kind of chart
being plotted.
s For the Xbar chart, it is the standard deviation
of the subgroup means. This is similar to a
pooled standard deviation.
s For the S chart, it is the standard deviation of
the subgroup standard deviations.
• Both formulas are dependent on the size of the
subgroup.

06A.21
 Statistical Process Control

Control Chart Use

Control charts can be used in the Measure
and Analyze phases to track process
changes. Analyze for significant changes and
record.
What
Xbar/S Chart for two
caused
54 1
1
1 1
this?
53 1 1111
Sample Mean

5 5 2 2 3.0SL=52.63
52 5
2
51 22 2
50 X=50.00
49
48
-3.0SL=47.37
47
Subgroup 0 50 100

4 3.0SL=3.849
Sample StDev

2 S=1.842
2
1

0 -3.0SL=0.00E+00

Control Charts are used in controlling a

process to sustain the improvement.
– Use the chart to monitor and record an
input variable (X), analyze for changes
and control.

06A.22
Statistical Process Control

Changing Control
Chart Limits
• It is best to use historical stable process
limits for control charts, versus limits
which change with each observation.
Historical limits define the “expected”
range of data, or the “null hypothesis
(Ho)”. (Use Historical settings in Minitab)
• Change limits when:
– A process change is made and is determined to be
statistically significant(I.e. Ha.).
– A definable practical process change is completed.

06A.23
Statistical Process Control

Chart Interpretation

Charts are interpreted before establishing

Process Capability and on an ongoing
process control basis.

– Interpret Sigma chart first.

– During the initial capability analysis, if you can

identify the special cause variation which
causes “OOC” conditions, you can remove
these points from consideration when you
calculate the control limits.

06A.24
 Statistical Process Control

Normal Process
Variation
“Boring…”
Xbar/S Chart for sd5

53
3.0SL=52.45
52
Sample Mean

51
50 X=50.00
49
48
-3.0SL=47.55
47
Subgroup 0 5 10 15 20 25

4
3.0SL=3.414
Sample StDev

2
S=1.507
1

0 -3.0SL=0.00E+00

This chart represents a predictable process in which

variation is subject only to random variation.

The points move up and down unpredictably, but tend to

cluster ( however, not too closely) around the centerline
and stay inside the control limits.

This pattern is the target for any control chart. It does not
necessarily indicate the best capability of the process nor
that the process can meet the specification, but it
indicates that the process is stable.

06A.25
 Statistical Process Control

Special Cause Change

“What happened?”

Occasionally a factor will

enter a process and cause a
sudden, short-lived change.

S A cause such as this will be

seen in the xBar chart as a
cluster of points at an out-of-
control level. The S chart will
Some Typical Causes: generally not be affected by
• Introduction of a batch of these shifts.
out-of-spec material into
the process
• A temporary shift in
measurement calibration
• A different inspector
• A different type of tool

06A.26
 Statistical Process Control

Process Outliers
“Ah Ha! Now here’s something
interesting.”
Hiccup
Hiccup
Xbar/S Chart for repmstd
Sometimes a process
53

will get the hiccups and

1 1
52 3.0SL=52.25
51
50 X=50.00
49
48
47
-3.0SL=47.75
as a result these
“mavericks” or “fliers”
1
46
Subgroup 0 5 10 15 20 25

Hiccup
4

3
1
1
3.0SL=3.132
will occur as occasional
2

1
S=1.382 values that are clearly
0 -3.0SL=0.00E+00
not a part of the basic
process distribution.
After one occurs, the
Some typical Causes:
• Mistake in measuring
process behaves in its
• Bottom piece (or top piece normal manner until the
in stack) next hiccup.
• End of bar, coil, etc.
• Dirt or foreign material

06A.27
 Statistical Process Control

Sudden Process Shift

“What did you do?”

Symptom:
Nine points in a row one
side of center
Xbar/S Chart for repmstd After a change, the
52.5 3.0SL=52.25
process makes the
51.5

50.5
2
parts larger on the
2
49.5
X=50.00
average or the yield
48.5

47.5
-3.0SL=47.75 greater or the
Subgroup 0 5 10 15 20 25 hardness higher and
3 3.0SL=3.132 so on.
2
S=1.382
The basic variability
1
of the process has not
0 -3.0SL=0.00E+00
changed, and the
range chart does not
show a change.
Some typical Causes:
• Mis-adjustment or
improper setting
• Change of material or
lubricant,
• Shift change

06A.28
Statistical Process Control

Process Trend
“Where’s it going?”
Symptom:
A trend is a gradual • 7 points in a row trending up.
shift of the process • 7 points
Xbar/S in aforrow
Chart trending down
repmstd
level, reflected on the 53 1 1

xBar chart alone. 2 2 2 3.0SL=52.25

Sample Mean

52
51
50 X=50.00

Sometimes raw 49
48
47
-3.0SL=47.75

material, Subgroup 0 5 10 15 20 25

measurement or 3 3.0SL=3.132
Sample StDev

human factors can 2

S=1.382
1
cause a trend but this 0 -3.0SL=0.00E+00

is unlikely. The
trouble is usually in Some typical Causes: :
the equipment itself,
• Often associated with “tool wear”
in the power supply or
since it often shows tool wear
prior process (usually of an aging or wear out
environment. nature)
• Example:
• bath depletion in a plating
operation or various chemical
operations
• tube wearout in an electronic
circuit

06A.29
Statistical Process Control

Zone Testing
Process is “Out of Control” if

Test Zone Test Criteria

1 • 1 point above +3 sigma

2 A+ 2 out of 3 in A+ or above
3 B+ 4 out of 5 in B+ or above
4 C+ 7 out of 8 in C+ or above
5 C- 7 out of 8 in C- or below
6 B- 4 out of 5 in B- or below
7 A- 2 out of 3 in A- or below
8 • 1 point below -3 sigma
Copyright 1995 Six Sigma Academy, Inc..

The Zones of Probability

A
+
B+
C
+
C
-B-

A
-

06A.30
 Statistical Process Control

Average and Range

Charts (Xbar - R)
Xbar/R Chart for Evaluations

• Since Sigma 4.3

4.2
3.0SL=4.229
Sample Mean

calculations are 4.1

4.0
X=4.096

-3.0SL=3.963
cumbersome when 3.9
3.8
1
done manually, the 3.7
Subgroup 0 5
1
10 15 20 25

Xbar - R chart is the 1.5

1
Sample Range

preferred method for 1.0

3.0SL=0.7673
manual control 0.5 R=0.4318

charts. 0.0
-3.0SL=0.09634

• Variation is shown by a calculation of the Range

of data within the subgroup (Largest - smallest).
• Use A2R bar as approximation of 3s/sqrt(n). Use
D3 and D4 times Rbar to find the lower and upper
control limits for Range variation.
• Analysis is done in similar fashion to Xbar - S.

06A.31
 Statistical Process Control

Individuals and
Moving Range Charts
(XmR)
I and MR Chart for Evaluations The Individual X -
4.5
1
3.0SL=4.517
Moving Range chart is
X=4.096
appropriate where there
4.0
-3.0SL=3.675
is no measurable
1
3.5 1
1
11 variation within a
3.0 11 subgroup (such as
Subgroup 0 50 100 150 200 250
process temperature,
1.5
1 pressure or other
1 homogeneous
1.0

1
1
1
1 1
measurement), or when
0.5 3.0SL=0.5171
rational sub grouped
R=0.1583
0.0 -3.0SL=0.00E+00 data is not available (due
to cost or other limiting
factors).
Caution
• When used inappropriately with a process having “within
subgroup” variation, (example control chart data shown above)
the resulting chart sometimes is difficult to read and use.
• When tracking individual measurements, there is no information
about short term and long term variation differences.

06A.32
Statistical Process Control

Exponentially Weighted
Moving Range (EWMA)
Charts
The EWMA Chart is EWMA Chart for Evaluati

4.15 3.0SL=4.148

much more sensitive than

any of the Shewhart EWMA
4.10
X=4.096

Control Charts. Each 4.05

EWMA Chart data point 0 5 10 15 20 25

-3.0SL=4.043

incorporates information Sample Number

from all of the previous observations, and the chart

can be configured to detect any size shift in the
process. This programmable sensitivity makes them
an excellent tool for monitoring in-control processes.

Note the appearance of the EWMA chart for the same

data we used for the continuous data charts earlier.
We can note trends up in the average broken by
significant average shifts down.

06A.33
Statistical Process Control

Attribute Control Charts

• np
• p

Principle Attribute Charts

• np - Measures counts of defects. Control
limits are based on the Binomial Distribution.
Because raw counted defects are recorded,
subgroup size needs to be equal.

• p - Records the fraction defective for a

sample. Control limits are based on the
Binomial Distribution. Because the proportion
is a ratio of defects to sample size, sample
size does not have to be equal.

06A.34
Statistical Process Control

Attribute Control Chart Example

A local dental group wanted to know why a lot of their patients fail to
keep their appointments. A problem solving team was assembled,
and decided to use a p Chart to track the percentages of “no
shows”. The dental clinic began logging monthly percentages of “no
shows” for each month. Since a “no show” is a defective
appointment, the average total fraction defective is called p.
Calculate control chart limits based on the first 6 months. Use
sample size (n) of 100 appointments per month.
Year 1996
Month Jul Aug Sep Oct Nov Dec
% Failed 40 36 36 42 42 40
Year 1997
Month Jan Feb Mar Apr May Jun
% Failed 20 26 25 19 20 18
Month Jul Aug Sep Oct
%Failed 16 10 12 12

p Chart Formulas:

number of nonconform ing units in sample( d )

p
sample size (n )
total number of defective units in all samples (d 1  d 2  ...d n )
p
n1  n2  ...  nk
   
p  1  p  p  1  p 
UCL = p  3 and LCL  p  3
n n

p = 236/600 = 0.393, where Sdi = 40+36+36+42+42+40 = 236

Sni=600, the total number sampled in 6 months

UCL = .393+3((.393*.607)/100)½ = 0.5395

LCL = .393- 3((.393*.607)/100)½ = 0.2465

06A.35
 Statistical Process Control

Measurement Performance
Over Time
Percentage of Appointment "No Shows"

0.6
1996 1997
3.0SL=0.5395
0.5
Proportion

0.4 P=0.3930

0.3

-3.0SL=0.2465
0.2
1 1 1 1
1
0.1 1 1
1

Subgroup 1 6 9 12 16
Month July December March June October

Control Limits based on 1996 data

• Control limits were established from the 1996 “no show” data.
• The advocacy team examined and prioritized the various
reasons why patients were missing their appointments.
• The team determined that providing flex-time for patients
resulted in fewer missed appointments.
• A new flexible appointment policy was adopted in January 1997.
• The control chart shows a dramatic reduction in the number of
missed appointments after the implementation of the flex-time
policy.
• By adopting the new appointment policy, the team was able to
reduce the average percentage of “no shows” from 40% to 20%
(20% is the new average for 1997 data only).

06A.36
 Statistical Process Control

Creating the P Chart

File: GEAPPS>6Sigma>Minitab>Training>Minitab
>Session 4>Patients.mtw
Data Sheet Stat>Quality Tools>P Chart

You’ll need
two columns
on the
spreadsheet,
one for the
count data
and a second
to identify the
subgroup

Once you have opened

the dialog box, identify
the count column for
the “Variable”. Fill in
the subgroup size (n),
and the historical value
for p (in this case, the p
for the 1996 year data).

06A.37
Statistical Process Control

Improving the Graphic Output

Select the
“Annotate>Title”
button. Enter the
graphic title using the
available lines and
format. Click OK

Next, select the “Stamp”

button.
In that dialogue box,
identify the subgroup
identification
information; I.e.,
months. Click OK.

Next, select the

“Frame>Tick” button.
In that dialogue box,
identify any special
settings of the axis
ticks to make the
graphic easier to
use.

06A.38
Statistical Process Control

Fine Tuning
If there is important
information you want
footnoted, use the
Annotate>Footnote
button. In this case,
the historical P value
reference.

If a reference line is
desired, use the
Frame>Reference button.
In this case, the line at
December 1996 to show
end of year.

Finally, with the graphic

showing, double click the
graph window to open the
editing palettes. These
were used to insert the
year dates and to color
them

06A.39
Statistical Process Control

Some Practical Concerns

in Applying
Statistical Process Control
• Requires a disciplined approach to process
management and data gathering.
• Works best within an automated or semi-automated
environment. (It is a real-time process monitoring tool.)
• Requires an appropriate response to an “out-of-control”
condition.
• The sensitivity of a control chart to detect non-random
variation can be improved by increasing the subgroup
sample size.
• It may be appropriate to recalculate control limits from
rebaseline or confirmation run results.
• Recalculate new control limits only when the process
variation has truly changed (stabilized).
• While it is acceptable to compute temporary control
limits after 5 to 10 subgroups, permanent limits require
at least 25 subgroups of data points that are “in-control”
for both the average and sigma charts.

06A.40
Statistical Process Control

SPC Chart Goals

Continuous Data Discrete Data

Target

0% Rejected

SPC for continuous variables is used to steer a

process towards a target. Attribute (Discrete)
SPC charts are used to minimize defects.

06A.41
Statistical Process Control

Key Concepts: Tab 3 - SPC

• Statistical Process Control is an excellent upstream
process control tool. Control charts are ideally
suited for monitoring and controlling your “Vital
Few” X variables.
• Control charts monitor the process variation and
generate a signal when the process variation is
influenced by special cause variation.
• SPC Control charts can be used to monitor:
Continuous Variables
Xbar & S
Xbar & Range
Individuals & Moving Range (XmR)
EWMA Control Charts
Discrete Variables (Attribute)
p Chart
np Chart
• Basic tactics for using control charts:
– Plot data immediately.
– Identify and react to “out-of-control” conditions.
– Points outside the control limits
– Search for root cause for “out-of-control”.
– Put a permanent fix in place.
– Do not make adjustments if the process is not out-
of-control.
06A.42