Statistical Process Control or SPC

. . . is a family of tools used to monitor, control,

and improve processes. The tools involve
tabulating, depicting, and describing data sets by
applying the seven basic tools of quality and a
formalized body of techniques.
Understanding and using SPC does not require
knowledge of statistics. Rather one uses applied
general math and a reliable software program
such as Excel.
The Seven Basic Tools of Quality include
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% 0 01
Start of the steps of a process. trahC ot er aP

FLOWCHART
• Flowchart/process map
Flowcharts are used to
Process “document” a%process. 57 By
Step creating and studying

at aD waR
flowcharts teams % 05 can often
uncover sources of trouble
Decision as well as solutions A Histogram to is a specialized Column Graph used
% 52
problems. Many to illustrate
of us are the stability of a process. The

• Check sheet
visual learners. greatest “Let’s number of units are pictured at the mid
flowchart it” is a most reh tO D C B A
Stop point with roughly an equal number of units on
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rellams eht in
gn il kcaproblem
t naht rab tsel lat eht no gnikrow yb erom n iag yl lareneg ll iw uoY*
either side of that point. See the example below.
planned, to prove the need and demand solving.
of
the customer, or to test a group for HISTOGRAM
determining

• Cause-effect diagram
Process A
quality. Checklist

Frequency
Compile the results 1. xxxxxxxxxx Process C
2. xxxxxxxxxx Process B
using a Checklist 3. xxxxxxxxxx
Process A illustrates greater
and display them variation than Process B.

• Pareto chart
using a Bar Chart, Scores Process C illustrates even less
variation than Process B.
Column Chart, or A Control Chart is simply a Run Chart with statistically
determined upper and lower control limit lines drawn on
Pareto Chart. either side of the process average. Being in control
[meaning no data points fall outside the control limits]
simply means the process is consistent.

• Histogram
CAUSE & EFFECT DIAGRAM [FISHBONE]
CONTROL CHART
A Cause & Effect Diagram is used when you need to
_ _ _ _ _ _ _ _ _ _Upper
_ _ _ _Control
_ _ _ _ Limit
_ _ _ _[UCL]
___
identify, explore, and display the possible causes of a

Measurement
specific problem or condition. “Fishboning” Average
represents a sophisticated form of brainstorming.
_______________ __________

• Control chart/Run Chart

Cause Cause Lower Control Limit [LCL]

Time

EFFECT

• Scatter diagrams Cause Cause Cause

Scattergram
 What are control charts?
How can control charts help
us to understand and
improve processes?
BETTE R
SCATTERGRAM FOR 01/25/02
1 00
Average

90
Lower Control Limit

80

109.07 Upper Con trol Limit

70 98.63 Process Average
PERCENT O F SUCCESS REP ORTED

88.19 Lower Con trol Limit

60 ANALYSIS
Proce ss average appears exce llent, and can be little imp roved
50
upon. A very positive trend is evident when compared to most
previous scatte rgrams. There remain s some variation in the
system b ut no data poin t is reported to be beyond control
40 limits. The sources of variation should b e explored and
remedie d. The system is under statistical process control.
30
Th e Custodial Staff is to b e complemented .

20

10

0
0 10 20 30 40 50 60

NUMBER OF SITES VISITED

Control charts help us to make improvement
decisions by . . .
• Determining if the long term process average is rising,
falling, or remaining the same.
• Identifying common causes of variation in our processes.
Common cause refers to that fact that the processes we use
contain sources of variation. We should seek to reduce or
limit common causes of variation [i.e. improve the process
capability].
• Calling attention to data points which falls beyond the
statistically determined control limits. Such points
generally represent special causes of variation. Sometimes
these data points can be attributed to individuals. By
changing the behavior of some individuals we can improve
results.
An essential element of producing a
high quality product or service is
insuring that the characteristics of
that product remain constant over
time.

Statistical process control charts are

widely used to determine whether a
process is stable and to monitor that
process over time.
The process average is the sum of the
observations divided by the number of
the observations. The control limits are
the process average plus or minus three
standard deviations.

Upper Control Limit [UCL]

MEASUREMENT

process average

Lower Control Limit [LCL]

OVER TIME
Applying Statistical Process Control to Education
directs us to . . .
Continually
improve the system
until the entire
Control Chart curve shows
upper statistical control limit
improvement.
process average

lower statistical control limit

Less spread
Shrink overall and higher
variation by average on
Over Time
removing the curve
special causes means less
of variation. variation.
Control Chart
upper statistical control limit Those in the
process average
middle, let them
do their job.
lower statistical control limit

Help those learn from

on the low those on the
A Point In Time side . . . high side.
 A Control Chart can also take the form of a stratification
study a single data point from another run or control chart
where several observations have been averaged into a single
data point. [Example the entire chart on the right can be a
detailed look at the farthest data point to the right in the
runChart
A Control of data points
is a method under
of judging the the magnifying glass.
effectiveness of a process.
The process average is the sum of the observations
divided by the sum of the observations. The control
limits are the process average plus or minus three

MEASUREMENT
standard deviations. Upper Control Limit [UCL]
Upper Control Limit [UCL]
MEASUREMENT

process average
process average

Lower Control Limit [LCL]

Lower Control Limit [LCL]
TIME

MOMENT IN TIME
Standard deviation is a statistical
term that provides a good indication
of the spread, or variability, of a data
set. It measures how widely values
are dispersed from the average.
The distribution on the left illustrates more variation than
the distribution on the right.

Standard deviation has a complicated definition: take the

distance of each number from the mean, square it, average
the result, then take the square root.
 Control Limits
UCL = Process Average + 3 Standard Deviations
y LCL = Process Average - 3 Standard Deviations

Upper Control Limit UCL

+ 3
Central Line or Process Average CL

- 3

Unacceptable Deviation,
Lower Control Limit LCL
beyond control limits

x
TIME
 BETTER
MEAP Summary – Average of All Subjects
UCL
100

80 CL

60

40 LCL

20

0
92 93 94 95 96 97 98 99 00 01 02 03 04
116.05 Upper Control Limit
78.14 Process Average
39.23 Lower Control Limit
ANALYSIS

This chart is constructed yearly averages. Results are excellent, the process average is
improving, and the process is under statistical process control due to all points falling
control limits. Remaining sources of variation should be explored, root causes
identified, and eliminated.
 2003-2004 SAFE/CLEAN WORK ENVIRONMENT DISTRICT BETTER

AUDIT SUMMARY
This report is based on Scattergram averages for the dates shown.

100 UCL

98
96 CL

94
92 LCL

90
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

100.47 Upper Control Limit

96.54 Process Average
92.61 Lower Control Limit
ANALYSIS

Results are excellent. The process illustrates statistical process control due to all
data point falling within statistically determined control limits. The process average
has improved since the previous audit. Remaining sources of variation should be
explored, root causes identified, and eliminated.
 BETTER
Safe/Clean Work Place Scattergram for 1/10/05
Process Note: This report is based on room average samples which are used to create building and district averages.
100
CL
90
LCL
80

70

60

50
40

30

20
10

0
0 10 20 30 40 50 60 70 80

109.91 Upper Control Limit

97.57 Process Average
85.34Lower Control Limit
ANALYSIS

This chart is constructed using room averages. Results are excellent; however, the
process is technically not under statistical process control due to one data point falling
outside statistically determined control limits. Remaining sources of variation should
be explored, root causes identified, and eliminated.
Control charts translate into
measurable
future needs of users characteristics
or
Control Chart
upper statistical control limit
design target values
process average

lower statistical control limit

Control Chart
Over Time upper statistical control limit
so that
process average

lower statistical control limit

A Point In Time

product and service can be designed and built to

give satisfaction at a price the user will pay.