It’s difficult to manage quality when you don’t have all the data you need at your fingertips.
After all, in manufacturing, final product quality is dependent on the precision of the processes used to make it. Without accurate data, it’s hard to tell whether a process works within the desired parameters.
It’s a recipe for defects and non-compliance.
That’s why more and more manufacturers are turning to Statistical Process Control (SPC) software.
The American Society for Quality defines statistical process control as using mathematical techniques to control a production method or process.
In other words, SPC applies statistical methods to analyze data and manage processes. It helps you to:
- keep track of production processes,
- monitor for system issues,
- and take action that results in quality improvements.
This article will talk about 5 benefits of using statistical process control in manufacturing. It will also explain how to implement it effectively.
What Is Statistical Process Control (SPC)?
SPC is a statistical method used to measure, monitor, and control manufacturing processes. It helps counteract the challenges of rising costs and more competitive markets. Instead of focusing on detection, SPC prevents problems before they occur.
Statistical process control involves:
- finding key processes that impact output quality,
- defining what can be measured (such as thickness in a metal manufacturing plant or temperature during chemical reactions),
- sampling the measured data,
- analyzing it,
- and generating insights for better decision-making.
The data analysis process involves the use of SPC charts to monitor process behavior and control limits. This helps identify variations, whether random or assignable.
For instance, the SPC toolkit in AlisQI streamlines quality data management by removing the need for extensive searching or data cleansing. It also uses a range of SPC charts and tools, including:
- Control Charts: Various SPC control charts to monitor and improve processes, including traditional X-bar and R charts, which help track the mean and range of grouped data and individuals. Moving range (I-MR) charts are used to monitor single data points over time.
- Histograms: Show the distribution of process data, allowing users to visualize the frequency of data points and identify patterns or anomalies.
- Box Plots and Scatter Plots: Identify outliers and understand the variability within data. Scatter plots help determine the relationship between two variables.
- Correlation Plots: Assess the strength and direction of a relationship between two continuous variables.
- Capability Indices (Cpk and Ppk): Measure how well a process produces output within specified limits.
- Automated Shewhart Pattern Detection: Based on Nelson rules, this feature helps automatically detect patterns that indicate process instability.
Overall, SPC provides a robust framework for continuously monitoring and improving quality and efficiency in manufacturing. In the next section, we’ll look more closely at the benefits this approach brings.
5 Benefits of Using Statistical Process Control Software In Manufacturing
1. Catch Problems Early
Statistical process control software helps you spot potential quality problems before they blow up into bigger issues. It saves time and money. It means fewer non-compliances, customer complaints, and potentially reputation-damaging product recalls.
With real-time monitoring and alerts, SPC systems let you know when measurements slip outside predefined limits. It spots subtle shifts or trends in a process. This lets you make minor adjustments to machines or processes before things spiral out of control.
Statistical process control software often has built-in root cause identification and analysis tools. These drill down into the root causes of quality issues.
For example, if there's a deviation in a bolt tightening process, SPC data and root cause analysis (RCA) pinpoints exactly where the torque problem is occurring.
If you add historical data into the mix, you can spot whether it’s an “inherent” process variation (which is normal) or a “special cause” variation that requires intervention. This stops you overreacting to normal fluctuations, while making sure real problems are picked up and addressed.
2. Reduce Waste & Cost
Catching quality problems early with SPC reduces the amount of scrap and rework required. You save resources and material, which boosts sustainability and keeps your costs down.
Over time, SPC helps you identify the best settings for your processes. It also highlights capabilities and variability. This leads to more consistent output and fewer rejected items.
The data insights help to plan production and supply chains more effectively, reducing the chance of overproduction. It also helps you to use energy, labor, and equipment more efficiently.
Implementing a good SPC system such as AlisQI can reduce waste by 15% and increase production efficiency by up to 20%. Total Cost of Quality (TCoQ).
3. Make Smarter Decisions
SPC provides current data and analysis to help you better understand your processes. This information is more accurate than other methods. It gives you a clearer picture of what is happening in your operations.
Visualization SPC tools such as control charts and Pareto diagrams give you the clarity you need to grasp the current state of play and identify areas needing attention.
ou can gain accurate insights by combining pattern identification, trends, root cause analysis, and process capability analysis. This will help you make faster decisions. The system gathers information from various production lines or plants. This helps to pinpoint specific areas that will benefit the most from improvement efforts. By focusing on these areas, the system can make a significant impact.
4. Ensure Compliance
Statistical process control software collects and stores data from various production activities. It automatically compiles all the records and reports you need. You’ll have proof of compliance ready at your fingertips when the auditors turn up.
When process deviations occur, SPC systems document the issues and allow you to record any corrective actions taken. This helps to prove to auditors that you have robust quality procedures in place.
Advanced SPC software, such as AlisQI, also includes traceability features. This lets you track products throughout the manufacturing process. This is important for industries with strict regulatory requirements such as chemical manufacturing and pharmaceuticals.
5. Everyone Can Use It
If you’re looking to create a culture of quality across your organization, SPC tools are ideal. A good user-friendly SPC toolkit, such as the one included with AlisQI, can be used by everyone on the team from shop floor workers to senior managers. Everyone has access to real-time quality data and uses it to inform decisions.
AlisQI’s SPC software for manufacturing is easy to use, even for people who are not technically-minded. The platform simplifies complex statistical data into actionable insights, making it accessible to all team members.
Automated SPC tools reduce the need for manual data entry and analysis, which is error-prone and time-consuming. This makes it easier for all users to stay informed with accurate data collection, before taking the necessary corrective actions.
Get All Your Quality Data & Insights In One Place with AlisQI SPC Software
AlisQI is the best SPC software available for keeping a close eye on your manufacturing processes and quality outcomes.
AlisQI empowers your team with the right tools to make informed decisions quickly. It helps you identify trends, spot potential quality issues before they blow up, and ensure that all your production processes run smoothly.
Your data is always accessible – whether you’re on the factory floor, in the office, or even on the go, using our mobile app.
Let’s discuss how AlisQI real-time SPC software can level up your quality control and quality management – book a call here.
