This course covers the Process Control requirements for AS13100 and AESQ Reference Manual RM13006 - Process Control Methods. This course outlines the competitive advantages of effective process control strategies along with the benefits of value added controls within the control plan. It supports the goal of zero defects, defect prevention and the reduction of variation and waste.

The use of statistical techniques and other proven methods will result in improved quality and manufacturing maturity. The AESQ Reference Manual RM13006 helps organisations to select the appropriate control strategies when developing Control Plans and to demonstrate their effectiveness through statistical analysis.

This course is designed for Process Design Practitioners, Process Improvement Teams, Implementation Teams, Internal Auditors and others involved in the implementation or auditing of Process Control strategies and techniques. 

The Importance of Process Control

• Examples and discussion on process control failures
• Reputational impact
• Effects on the Aerospace industry
• Benefits of achieving design nominal
• Closed loop control system
• Effectiveness of in process control over end if line inspection

Process Capability Analysis

• Tests for Special Causes
• Process Capability assessment (Cp, Cpk, Pp, Ppk)
• Incorrect assumptions about Cpk
• Process Capability prerequisites
• Handling non-normal data
• Statistical software

Process Control in Context of Quality Planning

• Linkage of PFMEA and Control Plans
• Purpose and content of Control Plan

Basic Root Cause Analysis and Process Improvement

• Appropriate reaction to special causes of variation vs common cause variation
• Options for confirmation of change effectiveness

Selection of Process Control Methods
• Basic overview and explanation of the various control methods

Data Collection

• Importance of time sequence
• Importance of reliable measurement systems
• Importance of non-biased data and operational definition for data collection
• Sample size considerations

Application of Control Charts

• I-MR
• Rational Subgrouping
• X-Bar / & R Chart
• I-MR-R/S - Between / within (3 way chart)
• Attribute charts (P, C, NP & U)
• Charts for rare events
• Pre-Control Charts

Process Capability Analysis

• Basic statistical terms
• Process stability assessment using control charts

Error Proofing

• Error proofing principles, devices and strategies
• Levels of error proofing
• Automated Control Systems

Delegates will be competent in the importance of process control, understanding and implementing the 9 control methods. They will be able to perform statistical analysis on data and interpret the outputs. Know how to use SPC control charts for continuous and attribute data, how to calculate and interpret the results of capability studies, whilst identifying potential issues. They will also have an understanding of the linkage of the process controls with other quality tools such as Process Failure Mode and Effects Analysis, Control Plans and Measurement System Analysis.

Upon completion of the course, you will receive an Industry Forum AS13100_RM13006 Process Control Methods Practitioner Certificate.