Quality Control

Statistical Process Control

Dr.-Ing. Amr Nounou

Learning Objectives

➢Understand the basic tools of SPC; the histogram or stem-and-leaf plot, the check
sheet, the Pareto chart, the cause-and-effect diagram, the defect concentration diagram,
the scatter diagram, and the control chart

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality Control:

A Modern Introduction, 7th edition, John Wiley & Sons Inc.,
2 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
Statistical Process Control
A methodology for monitoring a process to identify special causes of variation and signal
the need to take corrective action when appropriate

Statistical Process Control Source: Dale H. Besterfield, Quality Improvement, 9th

edition, Pearson, 2012. (Book and book support
3 resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
Basic SPC Tools

SPC can be applied to any process. Its seven major tools are;
1. Histogram or stem-and-leaf plot
2. Check sheet
3. Pareto chart
4. Cause-and-effect diagram
5. Defect concentration diagram
6. Scatter diagram
7. Control chart

THE “MAGNIFICENT SEVEN”

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality Control:

A Modern Introduction, 7th edition, John Wiley & Sons Inc.,
4 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
Histogram

❑ Displays large amounts of

data that are difficult to
interpret in tabular form
❑ Shows centering, variation,
and shape
❑ Illustrates the underlying
distribution of the data Histogram for Hole Location

❑ Helps to answer the question

Graphically shows the process capability and, if
“Is the process capable of
desired, the relationship to the specifications and
meeting requirements?” the nominal

Statistical Process Control Source: Dale H. Besterfield, Quality Improvement, 9th edition,
Pearson, 2012. (Book and book support resources)
5
Dr.-Ing. Amr Nounou - Spring 2024-2025
Check Sheets

❑ The main purpose is to ensure that

the data are collected carefully and
accurately by operating personnel for
process control and problem solving
❑ The form of the check sheet is
individualized for each situation and
is designed by the project team
❑ Check sheets are designed to show
location

Check Sheet for paint non-conformities

Statistical Process Control Source: Dale H. Besterfield, Quality Improvement, 9th edition,
Pearson, 2012. (Book and book support resources)
6
Dr.-Ing. Amr Nounou - Spring 2024-2025
 Check Sheets

❑ Creates easy-to-understand data

❑ Builds, with each observation, a
clearer picture of the facts
❑ Forces agreement on the
definition of each condition or
event of interest
❑ Patterns in the data become
obvious quickly
❑ Creativity plays a major role in the
design of a check sheet

Check Sheet for swimming pool

Statistical Process Control Source: Dale H. Besterfield, Quality Improvement, 9th edition,
Pearson, 2012. (Book and book support resources)
7 27
Dr.-Ing. Amr Nounou - Spring 2024-2025
Check Sheets

Using check sheets is a common

activity in the Measure step of
DMAIC

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality Control: A

Modern Introduction, 7th edition, John Wiley & Sons Inc., 2013,
8 (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
The Pareto Principle
Vilfredo Pareto was an economist who is credited with establishing what is now widely
known as the Pareto Principle or 80/20 rule.

When he discovered the principle, it established that 80% of the land in Italy was owned
by 20% of the population.

Later, he discovered that the pareto principle was valid in other parts of his life, such as
gardening: 80% of his garden peas were produced by 20% of the peapods.

Statistical Process Control Source: Dale H. Besterfield, Quality Improvement, 9th edition,
Pearson, 2012. (Book and book support resources)
9
Dr.-Ing. Amr Nounou - Spring 2024-2025
The Pareto Principle
Some Sample 80/20 Rule Applications
❑80% of process defects arise from 20% of the process issues.
❑20% of your sales force produces 80% of your company revenues.
❑80% of customer complaints arise from 20% of your products or services.
(The above examples are rough estimates.)

The Pareto Diagram

❑ Graph that ranks data classifications in descending order from left to right
❑ Pareto diagrams are used to identify the most important problems
❑ Advantage: Provide a visual impact of those vital few characteristics that need
attention

Source: Dale H. Besterfield, Quality Improvement, 9th edition,

Statistical Process Control
Pearson, 2012. (Book and book support resources)
10
Dr.-Ing. Amr Nounou - Spring 2024-2025
Constructing a Pareto Diagram
Steps:
1. Determine the method of classifying the
data: by problem, cause, type of
nonconformity, etc
2. Decide if dollars (best), frequency or percent
is to be used to rank the characteristics
3. Collect data for an appropriate time interval
4. Summarize the data and rank order
categories from largest to smallest
5. Compute the cumulative percentage if it is
to be used
6. Construct the diagram and find the vital few

Statistical Process Control Source: Dale H. Besterfield, Quality Improvement, 9th edition,
Pearson, 2012. (Book and book support resources)
11
Dr.-Ing. Amr Nounou - Spring 2024-2025
The Pareto Diagram

Pareto charts are often used in

both the Measure and Analyze
steps of DMAIC.

Source: Douglas C. Montgomery, Statistical Quality

Statistical Process Control Control: A Modern Introduction, 7th edition, John Wiley &
12 Sons Inc., 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
Cause-and-Effect Diagram

❑ It was developed by Dr. Kaoru Ishikawa in 1943

❑ Picture composed of lines and symbols designed to represent a meaningful relationship
between an effect and its causes
❑ Effect (characteristics that need improvement) on the right and causes on the left
People Materials Work Methods

Primary
Cause

Causes Quality
Effect
Secondary Cause Characteristic

Environment Equipment Measurement

Cause-and-Effect Diagram

Statistical Process Control Source: Dale H. Besterfield, Quality Improvement, 9th edition,
Pearson, 2012. (Book and book support resources)
13
Dr.-Ing. Amr Nounou - Spring 2024-2025
Cause-and-Effect Diagram
The cause-and-effect diagram is useful in the
Analyze and Improve steps of the DMAIC.

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality Control: A

Modern Introduction, 7th edition, John Wiley & Sons Inc.,
14 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
Cause-and-Effect Diagram

Advantages:
1. Analyzing actual conditions for the purpose of product or service quality
improvement
2. Elimination of conditions causing nonconforming product or service and customer
complaints
3. Standardization of existing and proposed operations
4. Education and training in decision-making

Source: Dale H. Besterfield, Quality Improvement, 9th

Statistical Process Control edition, Pearson, 2012. (Book and book support resources)
15
Dr.-Ing. Amr Nounou - Spring 2024-2025
Defect Concentration Diagram
It is a picture of the unit, showing all relevant views and the various types of defects are drawn on
the picture.
The diagram is analyzed attempting to find useful information about the potential causes of the
defect.
It is very useful in the Analyze step of DMAIC.

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality Control:

A Modern Introduction, 7th edition, John Wiley & Sons Inc.,
16 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
Scatter Diagram
The simplest way to determine if a potential relationship exists between two variables..

Statistical Process Control Source: Dale H. Besterfield, Quality Improvement, 9th edition,
17 Pearson, 2012. (Book and book support resources)

Dr.-Ing. Amr Nounou - Spring 2024-2025

Control Charts

❑ Focuses attention on
detecting and
monitoring process
variation over time
❑ Distinguishes special
from common causes of
variation
❑ Serves as a tool for on-
going control
❑ Provides a common
language for discussion
process performance
❑ Can serve as a tool for
process improvement
Example of a method of reporting inspection results
Source: Dale H. Besterfield, Quality Improvement, 9th
Statistical Process Control
edition, Pearson, 2012. (Book and book support resources)
18
Dr.-Ing. Amr Nounou - Spring 2024-2025
Control Chart
A control chart contains
A center line
An upper control limit Out-Of-Control-Action Plans (OCAP)
A lower control limit

A point that plots within the control limits indicates

the process is in control
No action is necessary

A point that plots outside the control limits is

evidence that the process is out of control
Investigation and corrective action are
required to find and eliminate assignable
cause(s)

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality Control:

A Modern Introduction, 7th edition, John Wiley & Sons Inc.,
19 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
Example
Important quality characteristic in hard bake is resist
flow width

Process is monitored by average flow width

Sample of 5 wafers
Process mean is 1.5 microns
Process standard deviation is 0.15 microns

Note that all plotted points fall inside the control limits

Process is considered to be in statistical control

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality Control:

A Modern Introduction, 7th edition, John Wiley & Sons Inc.,
20 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
An Application of SPC
SPC methods were used to improve quality and productivity in a copper plating
operation at a printed circuit board fabrication plant.

This process was characterized by high levels of nonconformities such as brittle copper
and copper voids.

An improvement team was composed and the DMAIC process was used.
Source: Douglas C. Montgomery, Statistical Quality Control: A Modern Introduction, 7th edition, John Wiley & Sons Inc., 2013, (Book and book
support resources)

Important: In the course project it is required to focus on quality improvement not

productivity improvement.

Statistical Process Control

21
Dr.-Ing. Amr Nounou - Spring 2024-2025
An Application of SPC – Define

The team decided to concentrate on reducing the flow time through the process. After
this aspect of the process was improved, the team directed its efforts to reducing the
number of nonconforming units produced by the process.

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality Control:

A Modern Introduction, 7th edition, John Wiley & Sons Inc.,
22 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
An Application of SPC –
Measure

Source: Douglas C. Montgomery, Statistical Quality Control: A

Statistical Process Control Modern Introduction, 7th edition, John Wiley & Sons Inc., 2013,
23 (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
An Application of SPC – Analyze

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality Control: A

Modern Introduction, 7th edition, John Wiley & Sons Inc.,
24 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
An Application of SPC – Analyze

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality

Control: A Modern Introduction, 7th edition, John Wiley &
25 Sons Inc., 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
An Application of SPC – Analyze

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality Control: A

Modern Introduction, 7th edition, John Wiley & Sons Inc., 2013,
26 (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
An Application of SPC – Improve

One alternative is to
accomplish Improve step
applying designed experiments

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality

Control: A Modern Introduction, 7th edition, John Wiley &
27 Sons Inc., 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
An Application of SPC – Improve

Another alternative is to accomplish Improve step applying control charts and SPC
techniques Source: Douglas C. Montgomery, Statistical Quality
Control: A Modern Introduction, 7 edition, John th

Wiley & Sons Inc., 2013, (Book and book support

resources)

Source: Dale H. Besterfield,

Quality Improvement, 9th edition,
Pearson, 2012. (Book and book
support resources)

Statistical Process Control

28
Dr.-Ing. Amr Nounou - Spring 2024-2025
An Application of SPC – Control

Control charts
and
OCAP (out-of-control-action plans)

Statistical Process Control Source: Douglas C. Montgomery, Statistical Quality Control:

A Modern Introduction, 7th edition, John Wiley & Sons Inc.,
29 2013, (Book and book support resources)
Dr.-Ing. Amr Nounou - Spring 2024-2025
 Thank you for your attention ...
Statistical Process Control
30
Dr.-Ing. Amr Nounou - Spring 2024-2025