STATISTICAL PROCESS CONTROL IMPLIMENTATION FOR

PROCESS OPTIMIZATION AND BETTER QUALITY

1
VAIBHAV SONJE, 2S.B. THORAT, 3S.R. PANDE, 4GIRISH KATKAR
1
Research Scholar, Dept. of Elct. & Comp. Sci, R. T. M. Nagpur University, Nagpur, MS, India
2
Director of Institute of Technology & Management, Nanded, MS, India
3
HOD, Dept. of Computer Science, Shivaji Science College, Nagpur, MS, India
4
HOD, Dept. of Computer Science, ACS College,
Koradi, Nagpur, MS, India
Email: 1vaibhav.sonje@gmail.com, 2Suryakant_thorat@yahoo.com,3srpande65@rediffmail.com,
4
girishkatkar2007@rediffmail.com

Abstract: Process plays an important role in any industry. For any product in any industry better quality product process is
very important. Even a small delay in detecting a quality problem can result in loss in terms of scrap, rework, less profit
margins and loss of customer satisfaction. To overcome the quality and productivity issues process should be monitored
well. Variations in the process lead into scrap and rework. To monitor and manage process statistical process control
techniques are used to minimize the variation in the process. For process control and detect process variation statistical
techniques are used by SPC so that process can be managed and under control. SPC uses different control charts for
measuring the process variations and process can be continuously improved with the help of different tools and techniques
used in the SPC such as seven statistical quality control tools. By implementing SPC benefits in less variation in process and
improves the product quality. This paper shows applicability of the statistical process control techniques in different
manufacturing industry environment. In this research paper various research articles and case studies on implementation of
statistical process control system techniques in the manufacturing industries are selected for review.

Keywords: Quality Control, Statistical Quality Control, Statistical Process Control, Control Charts, Process Variation.

I. INTRODUCTION service processes, and also supportive for staff to

What is Statistical Process Control?
Statistical Process Control is an analytical decision
making tool which allows you tosee when a process
is working correctly and when it is not. Variation is
present inany process, deciding when the variation is
natural and when it needs correction isthe key to
quality control.
Control charts are originally developed for use in
mass production manufacturing. These techniques are
applicable to most other types of activities in all
sectors of the economy including service business,
government, education and health care. According to
Montgomery (2005), quality is one of the most
important verdict factors in the selection of products
and services. Therefore, quality leads to big business
achievement, development, and increases
competitiveness. Ryan (1989) defined quality as a
decision-making technique that uses statistics to
monitor the consistency of a production process and
the resulting product as improves the work
environment. Quality Control (QC) is an important
task in factory as it deals with product inspection
before the product was shipped to customers. SPC is
a dominant tool in order to improve the processes that
augment productivity and quality. Many researchers
have noticed the leaning that service quality
improvement has become a inevitability in many
industries. Wyckoff (1984) claimed that SPC is an
excellent method for service managers to scrutinize
perform self-improvement. Palm et al. (1997) also
barbed out that SPC would have great potential in
tertiary sector of industry, such as health care and
teaching, and has already been established to be
useful in healthcare industry.
SPC is an approach that has been broadly used in
many industrial and non-industrial fields. The
primary application domain for SPC charts is in
process control and improvement in manufacturing.
SPC is a procedure developed based on Shewhart’s
formation of process variability, which generally
applied not only in manufacturing processes but also
in service operations for quality sustainability
purposes. SPC is defined by Montgomery (2009) as a
powerful collection of problem-solving tools useful in
achieving process constancy and improving
capability through the lessening of variability. The
primary purpose of SPC implementation is to
perceive and reduce special cause variations for
process solidity.
Types of control charts:
i. Variable Control Charts for the Continuous data
ii. Attributes Control Charts for the discrete data
The control chart is an important tool for process
improvement. Processes do not naturally operate in
an in-control state, and the use of control charts is an
important step that must be taken early in an SPC
program to eliminate assignable causes, reduce
process variability, and stabilize process
performance. To improve quality and productivity,
we must begin to manage with facts and data, and not

Proceedings of Academicsera 20th International Conference, Montreal, Canada, 29th-30th May 2018
14
 Statistical Process Control Implimentation For Process Optimization and Better Quality
simply rely on judgment. Control charts are an
important part of this change in management
approach. Control charts are widely used to establish
and maintain statistical control of a process.
Basic Seven Quality Control (QC) tools
i. Check Sheet: Check sheets are simply charts for
gathering data. They are easy to understand and
very clean to read.
ii. Histogram: A histogram is a snapshot of the
variation of a product or the results of a process.
It often forms the bell-shaped curve which is
characteristic of a normal process. The histogram
helps to analyse what is going on in the process
whether the data is falling inside the bell-shaped
curve and within specifications.
iii. Pareto Chart: The Pareto chart can be used to
display categories of problems graphically so
they can be properly prioritized. Pareto chart is a
vertical bar graph displaying rank in descending
order of importance for the categories of
problems, defects or opportunities.
iv. Cause and Effect Diagram: The Cause and
Effect Diagram display the relationships between
different causes for the effect that is being
examined. The major categories of causes are put
on major branches connecting to the main line,
and various sub-causes are attached to the
branches.
v. Flow Chart: Flow chart breaks the process down
into many sub-processes. Analysing each of
these separately minimizes the number of factors
that contribute to the variation in the process.
vi. Control Chart: As discussed above they are
used to monitor the process.
vii. Scatter Diagram: A Scatter plot is used to show
how a pair of variables is related and the strength
of that relationship. It is constructed by plotting
two variables against one another on a pair of
axes.
II. ADVANTAGES OF SPC
IMPLEMENTATION
SPC implementation is important as it could develop
process performance by reducing product variability
and improves production competence by decreasing
scarp and rework. According to Attaran (2000), in
their attempts to stay competitive, US business had
embarked on Total Quality management (TQM)
techniques such as SPC that leads to higher quality
product by reducing-variability and defects.
Most of the production and quality cost that SPC
aims to reduce such as rework lost of sales and
proceedings are measurable. The success and failure
in SPC operation does not depend on company size or
resources, but it relies on suitable planning and
immediate actions taken by workers with regards to
problem solving. According to Benton and Talbot,
the advantages of implementing SPC could be
categories into the following categories, viz.,
Proceedings of Academicsera 20th International Conference, Montreal, Canada, 29th-30th May 2018
15
maintain a needed degree of conformance to design,
raise product quality, eradicate any unnecessary
quality checks, trim down the percentage of defective
parts purchased from vendors, diminish returns from
customers, lessen scrapand rework rates, afford
evidence of quality, facilitate trends to be spotted,
ability to reduce costs and lead times.
The primary tool of SPC is the Shewhart control
chart. The Shewhart control chart quantifies variation
as either special cause or common-cause (natural)
variation. The control limits on control charts put a
figure on variation as that intrinsic to the process
(natural variation data inside the control limits), or
variation caused by an event or assignable-cause
(special cause variation data located outside the
control limits). Data outside the control limits are also
referred to as “out of control” points. A large variety
of SPC schemes have been developed for quality and
productivity improvement since the 1960s. SPC
utilizes statistical methods to monitor manufacturing
processes with an aim to maintain and improve the
product quality while decreasing the variance. Much
research has been conducted on the issues of SPC and
the consequential developments are readily available
in the literature, see surveys of research on SPC by
Lowry and Montgomery (1995), Woodall and
Montgomery (1999). Nevertheless, conventional SPC
methods are typically restricted to a single process
stage in industrial and service applications are also
some obstacles to applying SPC in services, such as
what to measure and how to measure. The main
difference between a manufacturing system and
service system is that customers are involved into
service operations. How to measure the customers
professed quality is a challenge. Therefore,
researchers investigated modification of quality
definition in services.
Erwin M. Saniga (1989) He has applied statistical
constraints on economic models to provide designs
that meet industry's demand for less process variation
and quality of the product. He hasexplained the
control charts which may be designed by usinga
simple rule recommended by Shewhart, by a
statistical norm, or by a financially viable criterion.
He illustrated its use in the joint design of an X bar
chart and an R chart. He developed a method to find
the most economical statistical design for Shewhart-
type control charts and have applied it to the joint
determination of the parameters of X bar chart and R
charts.
Nigel P.Grigge (1998) Explained a case study that the
use of statistical processcontrol in fish product
packaging which demonstrated the simplicity of
applications of the off-the peg system. Such system
can reduce unnecessary check weighs rejections and
product give away, assist the packer to maintain the
lowest possible legal target quantity.
Andras Ittzes (2000)This paper explains and
evaluated applications of SPC, theseveral variance
components of the variable in the control of the dry
 Statistical Process Control Implimentation For Process Optimization and Better Quality
matter content in butter cream. He evaluated the data
of Analysis of Variance (ANOVA) based on the
nested model. He also referred Snedecor and Cochran
(1967) or Steiner (1984).
Ben Mason and Jiju Antony (2000) They have
discussed in their paper about the ingredients that
areneeded for the victorious performance of SPC.
They attempt to eradicate the myth that SPC is
concerned with only the control charting of processes.
A major issue addressed by them in this paper is the
need for the organized and realistic methodology for
the execution of SPC in industry.
Khong sak Srikaeo (2004) They adopted SPC
techniques such as histogram to found that the data
were not normally distributed ANOM detect an
association between the production line from the
grand mean in all product variables, p-control charts
showed that the process is not in statistical control for
some variables. They analyzed that the association
betweenraw material variables and product variables.
Since they use the historical data the out of control
points where removed to simulate the situation where
the process is in statistical control for further studies.
With the process can capability studies the process
precision and accuracy can be clearly assessed.
Gauge R and R studies suggest that the variations
found in the process are caused by the measurement
system used in the plant.
Rami Hikmat Fouad (2010) in their paper identified
the key ingredients forsuccessful quality management
in any industrial organization. They discussed about
seven QC tools, and how to effectively implement
and to earn the full strength of these tools. They also
carried out a case study to monitor real life data in a
Jordanian manufacturing company that specialized in
producing steel and found that the steel tensile
strength is the vital few problem and account for 72%
of the total results of the problems. They specified the
major causes of nonconformities and root causes of
the quality problems and possible remedies were also
proposed. They also explained the necessity of SPC
tools in Jordan Steel to introduce ongoing education
and training programs of management and line staff.
Dr. D. R. Prajapati (2012) adopted some SPC
techniques in the industry for variousapplications in
the automotive industry. He explained the power of
SPC lies in the ability to examine a process and the
sources of variation in the process. He used only two
main techniques i.e. cause and effect diagram and
control charts are implemented in industry out of
seven SPC techniques. Finally he found in his case
study that after implementing the SPC tools to
remove the root causes, the percentage refutation is
reduced from 9.1% to 5% and process capability of
0.953 is achieved.
Muhammad Riaz (2012) strongly recommended that
the control charts worth inthe manufacturing industry.
They also suggested that monitoring the key
characteristics is most important in any
manufacturing industry. They strongly believed that
Proceedings of Academicsera 20th International Conference, Montreal, Canada, 29th-30th May 2018
16
the inefficient of a quality control section may cause
poor quality of a product.
Zhonghua li (2012) in their paper designed
Conventional Phase II SPC chartsusing control limits.
They suggested designing the SPC charts using p
values. They demonstrated the p value approach to
consider univariate process monitoring by cumulative
sum control charts in various cases. They also
proposed designing control charts using p values and
a significance level.
Ali Mostafaeipour(2012) in their paper they discussed
that SPC technique in ceramic tile manufacturing
plant. They suggested SPC for reducing the unwanted
ceramic tile defects and wastages. They adopted
pareto chart to group different causes for
inappropriate effects and its category. Also they
adopted six-pack charts to offer six different packs in
the format of one diagram. They applied control chart
like R, ̅ and range control charts to manage the
process variations. They also adopted dispersion
diagram to evaluate and to compare process
performances during various periods. Data are
categorized in a specific format by using Histogram.
Also process capability is one of the significant items
in production. Finally they recommended
implementing the correct SPC frequently in the
manufacturing plant to minimize ceramic tile waste.
Yonatan Mengesha Awaj (2013) recommended SPC
tools in theproduction processing in order to
condense defects by identifying where the highest
waste is occur at and to give idea for improvement.
They adopted, Pareto chart/analysis and control chart
(p-chart). They mainly explained how to create
consciousness to quality team how to use SPC tools
in the problem analysis, particularly to train quality
group on how to held an successful brainstorming
session, and make use of these data in cause-and-
effect diagram construction, Pareto analysis and
control chart construction. After detail observation
and interview they suggested that SPC tools needed
to minimize or reduce the problem and the more
proficient technique is long run. Finally they
recommended that the company should make every
effort for the implementation of SPC tools for
productivity improvement.
Ved Parkash (2013) They explain about the SPC, its
advantages, limitation,applications and information
regarding the control charts. They also introduced the
primary groups of input for man, machine, material,
method and milieu. They explained the application of
SPC into three main sets of activities, the first
understands the process and is achieved by business
process mapping, the second is measuring the sources
of variation assisted by the use of control charts and
the third is eliminating assignable (special) sources of
variation. They suggested SPC, can be used in
various industries for improving the quality of the
product and helps in lowering the product costs as it
provides a better product and/or service.
 Statistical Process Control Implimentation For Process Optimization and Better Quality
Gasper Skulj (2013) this paper discusses service
approach of SPC and discussedthrough an industrial
case study. They clearly explained the successful
development and implementation of SPC as a service.
They also discussed how to use the SPC service in a
small company to increase its capabilities in process
quality management and process control through a
case study.
Ranjit Sabhapandit (2014) in their paper described
about some of the softwaretools and their capabilities
that are used for applying SPC techniques. They also
suggested the need for applying statistical process
control in software development process. They
discussed about few most repetitively applied
software tools such as WinSPC, Zontec,
XLSTAT,SCADA and Minitab. They sternly said
that the organization has to opt the proper tool that
suit best to its needs in order to have the most
effective output.
III. DISCUSSIONS
This paper represents an understanding report on
defining and carrying out a systematic review on
SPC, which is well known in industrialized contexts.
Implementation of SPC tools at the company is
expected to develop its processes and condense
variability or waste because it may not be possible to
completely eliminate variability. With reduced
variability the cost of dealing with scrap, rework, and
other losses created by defectives which is an
enormous drain on the company will be greatly
reduced. This review indicates that SPC is applied in
the industry with huge benefits in the business to
diverse. Although there are limitations and barriers
impeding the implementation, if the implementation
was done correctly and greatly facilitated, SPC can be
a flexible technique for control quality improvement
in the industry and sustaining the quality of the
product. This review suggests that SPC is a powerful
technique when implemented in the industry. The
production is under the control and the quality of the
component gets improved in automobile industry
through Statistical Process Control.
CONCLUSIONS
In conclusion manufacturing industry should
implement the statistical process control techniques
for early detection of causes of variation to improve
productivity, better performance and ameliorate in
quality of the finished product. It can help to improve
the performance of the process by obviate variations
in the process. It improves production quality by
minimizing scrap, rework which results into overall

Proceedings of Academicsera 20th International Conference, Montreal, Canada, 29th-30th May 2018
17
vantage. It helps to increase overall profit in terms of
time, money and customer satisfaction by reducing
scrap and rework. It is concluded that SPC technique
helps the organization to observe the process
activities.
REFERENCES
[1] Ved Parkash, Deepak Kumar, and Rakesh Rajoria,
“STATISTICAL PROCESS CONTROL” IJRET:
International Journal of Research in Engineering
andTechnology eISSN: 2319-1163 | pISSN: 2321-7308.
Volume: 02 Issue: 08 | Aug-2013.
[2] Ali Mostafaeipour, Ahmad Sedaghat, Ali Hazrati and
Mohammadali Vahdatzad, “The use of Statistical Process
Control Technique in the Ceramic Tile manufacturing: a
Case Study”. International Journal of Applied Information
Systems 2(5):14-19, May 2012.
[3] Knongsak Srikaeo, John E. Furst, John Ashton,
(2004).“Characterization of Wheat-based biscuit cooking
process by statistical process control techniques”, Food
Control 16(2005) 309 – 317.
[4] Ben Mason, Jiju Antony, (2000),"Statistical process control:
an essential ingredient for improving service and
manufacturing quality", Managing Service Quality: An
International Journal, Vol. 10 No. 4 pp. 233 – 238
[5] Dr. D. R. Prajapati, “Implementation of SPC Techniques in
Automotive Industry: A Case Study”, International Journal
of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, Volume 2,
Issue 3, March 2012.
[6] Gasper Skulj, Rok Vrabic, Peter Butala, Alojzij Sluga,
“Statistical process control as a service: An Industrial Case
Study”. Procedia CIRP 7(2013) 410 –406.
[7] Lowry, C.A. and Montgomery, D.C. (1995) ‘A review of
multivariate control charts’, IIE Transactions, Vol. 27,
pp.800–810.
[8] Muhammad Riaz and Faqir Muhammad,” An Application of
Control Charts in Manufacturing Industry”, Journal of
Statistical and Econometric Methods, vol.1, no.1, 2012, 77-
92 ISSN: 2241-0384 (print), 2241-0376.
[9] Nigel P. Grigg, Jeannette Daly and Marjorie Stewart,
(1998).”Case Study: the use of statistical process control in
fish product packaging”. Food Control, Vol. 9, No. 5,
pp.289 – 297.
[10] Rami Hikmat Fouad, Adnan Mukattash. “Statistical Process
Control Tools: A Practical guide for Jordanian Industrial
Organizations.
[11] Mechanical and Industrial Engineering. Volume 4, Number
6, December 2010 ISSN 1995-6665 Pages 693 – 700.
[12] Andras Ittzes (2000) “Statistical process control with
several variance components in the dairy industry”. Food
control 12 (2001) 119 – 125
[13] Yonatan Mengesha Awaj, Ajit Pal Singh, Wassihun Yimer
Amedie, (2013) ” Quality Improvement Using Statistical
Process Control Tools In Glass Bottles Manufacturing
Company”, International Journal for Quality Research 7(1)
107–126 ISSN 1800-6450.
[14] Zhang WU & Qinan Wang (2007), “An NP Control Chart
Using Double Inspections”. Journal of Applied Statistics,
Vol.34, No. 7, 843 – 855, September 2007.
[15] Zhonghua Li. Peihua Qiu, Snigdhansu Chatterjee,
Zhaojun Wang (2012). “Using p values to design statistical
process control charts”. Springer – Verlag, Stat Papers
(2013) 54:523 – 539.