SPC-Plus for Stamping

SPC Plus Image The following lesson outline details the tasks individuals will be able to perform upon completion of each lession. Some of these tasks require the trainee to explain how something works to insure they have the required understanding of the processes and are not simply memorizing procedures. All of the tasks listed will be a part of the Performance Test within each lesson. To learn more about these tests and the training process itself, see the Philosophy section.

This program was specifically designed to enable an individual to apply various SPC methods and troubleshoot the cause of the problem when the tools indicate the process is out of statistical control. The instructional technique employed will enable individuals to understand and correctly apply a variety of statistical quality control techniques with little difficulty. Both existing personnel and new trainees can utilize these training materials to develop or improve their performance.

Lesson 1: The Basics of SPC [ Top ]

  1. Part 1 - What is SPC?
    1. Defining SPC
      1. Basic SPC terminology
      2. How SPC can make the operator's job easier
    2. Causes of variation
      1. Random causes
      2. Assignable causes
  2. Part 2 - The Starting Point
    1. The Capability Study
      1. Why it is performed?
      2. How it is performed?
      3. When it is performed?
    2. Subgroups
      1. What is a subgroup?
      2. Variables which affect size
  3. Part 3 - Histograms and Normal Distribution Curves
    1. The Histogram
      1. Defining the content
      2. Reading the curve
    2. Distribution Curves
      1. What is a normal curve?
      2. Comparing two processes
      3. Variables which affect the curve
  4. Part 4 - Control Charts
    1. Basic control charts
      1. Visualizing the data displayed
      2. Features of a typical chart
    2. Understanding a chart
      1. Out-of-control conditions vs. out-of-tolerance
      2. Why use a control chart?

Lesson 2: Calculating and Plotting X Bar and R Charts [ Top ]

  1. Part 1 - Commonly used Control Charts in the Stamping Industry
    1. The X Bar chart
      1. Defining X and X bar values
      2. Calculating an X bar value.
      3. Plotting an X bar value
    2. The R chart
      1. Defining the R value
      2. Calculating an R value
      3. Plotting an R value
      4. R values and Normal Distribution curves
      5. The importance of using both X bar and R charts
  2. Part 2 - Calculator Usage
    1. Finding control chart values
      1. Clearing the register
      2. Summing X values
      3. Averaging by division
      4. Averaging by multiplication
      5. Calculating an R value
    2. Computing with signed values when using dial indicators
      1. Balanced dial gauges with the nominal at zero
      2. Understanding signed numbers
      3. Finding the sum of like and unlike signed values
      4. Finding the X bar value with like and unlike signed values
      5. Determining the limits of a signed value subgroup
      6. Calculating the R value using signed values

Lesson 3: Troubleshooting Quality Control Problems [ Top ]

  1. Part 1 - Basic Out-of-Control Conditions
    1. Beyond-control-limits conditions
    2. Mid-Point Shifts
    3. Trends
    4. Understanding control chart sensitivity
  2. Part 2 - Using the Press Pocket Troubleshooter
    1. Understanding algorithms
    2. An example X bar chart problem
      1. Identify the out-of-control chart
      2. Identifying the condition
      3. Analyzing potential causes
      4. Taking corrective action
    3. An example R chart problem
      1. Identify the out-of-control chart
      2. Identifying the condition
      3. Analyzing potential causes
      4. Taking corrective action
  3. Part 3 - Common Causes of Out-of-Control Conditions
    1. Math Errors
      1. Where math errors often occur
      2. How to check math errors
    2. Plotting Errors
    3. Gauging Problems
      1. Cleanliness of gauge and part
      2. Variation between operators
      3. Environmental factors
    4. Material Problems
      1. Thickness
      2. Width
      3. Hardness
      4. Camber
      5. Flatness
    5. Die Problems
      1. Visible Die Problems
        1. Debris in the die cavity
        2. Worn or damaged die parts
        3. Nitrogen Cylinder Pressure
      2. Hidden Die Problems
        1. Broken die springs
        2. Incorrect air pin length
    6. Lubrication Problems
      1. Amount or frequency of lube
      2. Type and viscosity of lube
      3. Area of application
    7. Press Adjustments
      1. Shut Height
      2. Press Speed
    8. Feed Adjustments
      1. Feed Length
      2. Feed Speed and timing

Lesson 4: Pre-Control, Median, Attribute, and Individual X and Moving Range Charts [ Top ]

  1. Part 1 - Pre-Control Techniques
    1. When pre-control can be used to control a process
    2. How pre-control limits are established for a dimension
    3. The statistical concepts which allow pre-control methods
    4. How to perform pre-control checks
    5. Pre-control gauges and charts using red, yellow, and green zones
    6. Setup and operation with a pre-control system
  2. Part 2 - Median and Range Charts
    1. The concepts and methods behind the use of Median charts for plotting X values
    2. Range chart concepts and common variations
    3. Subgroup variations and identifying out-of-control points
  3. Part 3 - Attribute Charts
    1. The concepts behind attribute charting
    2. Understanding and using P charts
    3. Understanding and using C charts
    4. Investigating for assignable causes
  4. Part 4 - Individual X and Moving Range Charts
    1. When and where the individual X concept can be applied
    2. Plotting an individual X
    3. Calculating and plotting a Moving Range
    4. The sensitivity of individual X and moving range charts