paul, just a few points though by now i'm sure you've attended to the matter. sounds like you had some good advice from fellow netters. On point of control charting etc make sure you do this manually and not via some software package. Do this for some time it's the only way to learn on such matters.
Secondly, make sure that process operators become involved in this process, ie, they contribute their wealth of knowledge and experience in determining what makes the process tick (ie, causes of varuiation)..
Thirdly, before you undertake to determine process capabilities you must firstly acknowledge whether or not the process is stable else all other efforts could prove futile.finally,is there anyone else in the plant who could undertake this study? If there isn't then something's wrong!
good luck with everything anyway.