Tips to Implement SPC Program in a Manufacturing Firm

SPC, or statistical process control, is a quality management procedure based on statistical methods that typically apply in a manufacturing environment. SPC helps monitor the manufacturing function by controlling and mapping processes based on randomly selected sample measurements. The most important objective of spc software for manufacturing is to ensure that the expected process performance is achieved and that customer requirement is met. To achieve such process control, this post showcases the ideal steps of implementing SPC in a manufacturing firm.

Bring Awareness

working teamIf you have decided to implement SPC, awareness should be the first step. Make sure your employees know the basics of SPC and how to apply it on their own. This step explains why SPC leads from detection to prevention.

Everyone needs to realize that SPC is a whole new way of doing things, delegating tasks and responsibilities to the lowest level of your organization. Operators, in particular, are more concerned with and have greater responsibility for the operation of production processes. Your management should form a steering committee to create an SPC implementation plan.

Execute a Training

To maintain a successful SPC program, you must initiate and maintain a comprehensive training plan. You can conduct in-house training or bring in a professional from a consulting firm. For the engineers, the training must cover the basic statistical concepts of SPC. Operators should understand the importance of their role in the process and will need to train on proper calculations and plotting since this is their core SPC function. You may conduct in-house training or get a professional from a consulting company.

Implement Integral SPC

Your steering committee will oversee the implementation of SPC activities on the production line. Practitioners will identify weak processes and bring them to the attention of management. This will be achieved through spot checks, where you will take some items from the production line for testing and inspection. During the tests and inspections, you will measure their characteristics and display control charts. From these measurements, you generate statistical indicators that are used to assess the current state of the production process. Use the clues from the charts to make decisions about what needs to be improved, possible tactics to generate findings, and next steps.

Set the Stage for TQM

capabilityBy the time your manufacturing process is under control, the operators and staff involved should be on the lookout for process deviations to ensure continuous improvement.

At this stage, you should extend the SPC approach to non-production segments of the company, such as purchasing, to ensure complete control. Also, errors in incoming materials, resources, and machinery can be avoided by multiplying SPC across suppliers. When SPC is integrated into most aspects of your business and includes both customers and suppliers, the plan is the result of TQM or total quality management.