Starting a Small Lot SPC (Statistical Process Control) program

[CMfgT]

I am kinda new to implementing SPC. I have a lot of background in Quality when it comes to training. I am a recent Six Sigma Black Belt for our company and they do NO SPC. I am trying to develop a program to start SPC. Here is my question. Right now I have operators documenting 30 checks for work orders under 150 pieces and 60 for work orders between 151 and 300 pieces. Right now I would consider this just documentation for records, its not really "Process Control". I want to implement a system where the operators can graph or even type what they get when they measure a part and it shows up on a paper chart or on a computer chart. Basically a simple control chart that operators can use. That way they can see what their process is doing. How do I get started???????? I don't know what to research. We have Mazak mills and lathes. Can i get it to where we can type the numbers into the machine? Or should I try getting a system where they place numbers on a paper chart. The paper chart idea sounds the cheapest (for managment.....) but I guess I don't know how to make charts up for a few thousand part numbers and multiple key features. Does anyone have an excel file I could see as an example????????


I know i just typed a ton. I just feel like the lone ranger at my company and I am trying to tackle the world. Any help would be apprecited. I know SPC works, I just need everyone here to see it.


THANKS

 

[Stijloor]

Re: Starting an SPC program

Hello and welcome to The Cove!

Yes, many questions...

However, you may want to begin by conducting a search on The Cove Forums.

For example, I did an advanced (google) search here on: "Starting an SPC Program." Lots of good stuff showed up.

Try it.... You like it and you won't quit.

Stijloor.

 

[CMfgT]

I have done some searching, but I guess I would like to see what everyone else does to graph data points. I am looking for an easy way for our operators to graph data points at the machine for SPC. I don't want them to get caught up or struggle with a control chart calculations. Any suggestions or examples?

 

[Steve Prevette]

I've got some materials, including example Excel files, and example queries using Access at ***DEAD LINK REMOVED*** There are also procedures at ***DEAD LINK REMOVED***.

Added in edit: See new link in Steve's post #7

 

[Marc]

I have removed 2 dead links from the http://www.hanford.gov site in the above post. I do not know if the materials cited are available elsewhere or not.

 

[shamhaider]

dear Cmfgt
First of all one must Know the objective of SPC program .
Usually in a medium size company, you can start with identifying key operations and their variables to be monitored . Control charts are best option in the begining before you opt for any software such as Minitab..
following steps may be considered
1) Identify/develop the team responsible for SPC implemetation
2)gather the data ..initially only on key processes
3)analyze the data..see if tehre are trends
4) Find the root cause and their soluitions
5)Implement the proposed changes
6) Verify your results
7)Sustain the improvement


In later stages you can add MSA, DOE Capability Cpk...in your SPC program..using any software such as Minitab..Good luck in your endevours...

 

[Steve Prevette]

The replacement link for the Hanford materials is http://www.efcog.org/wg/esh_es/Statistical_Process_Control/index.htm

 

[Marc]

Thanks, Steve! We all appreciate it!

 

[KathySmith]

One idea: Find the machinist that is most ready to make a change and stick the cheapest PC at his workstation. The PC only needs MS Office Excel. Have him enter in his inspection results for a couple of weeks. Each day your reviewing the information and tweaking. After a few weeks, decided if there's an benefit. The short term benefit is seeing trends from one lot to the next. Consistency and minimizing variation between builds is what the customer needs. A large Aerospace company with a large, the machinists all enter their inspection data as they build. It's all tracked and charted and kicked in all forms of reports.