SPC

SPC Analysis - Shopfloor-Online Quality

Industry leading SPC analysis software with automated process data capture

 

Real-time SPC analysis tools to reduce the impact of process variation on quality and production costs

What is SPC?

SPC (Statistical process control) is the methodology used to control a manufacturing process, using statistical techniques. SPC tools and analysis will help you monitor process behaviour, uncover internal systems’ issues, and find solutions to improve the process.

Why Use SPC tools?

World-class manufacturers use Statistical Process Control (SPC) and Process Capability tools to ensure quality, satisfy customer needs and drive improvements.

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How Does Shopfloor-Online’s SPC Analysis Software Work?

Shopfloor-Online seamlessly integrates MES software and SPC software to control, analyse and manage processes, meet standards and ensure conformance.

Implement Shopfloor-Online’s SPC software module, in combination with the Quality module, to:

  • Obtain real-time SPC analysis to ensure your process is stable
  • React faster when process abnormalities arise
  • Measure process capability and produce capability reports
  • Add SPC data to conformance certificates
  • Predict the amount of non-conforming product 
  • Reduce material costs by maintaining the process at "the sweet spot"

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What are the benefits of the SPC Analysis software module?

  1. Improve Quality – managing and reducing variation not only avoids waste, but can reduce the impact of variation further down the value chain, reducing issues, reducing the need to make process adjustments
  2. Meet customer requirements – many customers demand that you use SPC analysis software and understand process variation. Easily provide the reports you need to show you are in control
  3. Reduce scrap -  the system alerts operators in real-time when problems occur and enables them to act before scrap is produced
  4. Lower the cost of quality – knowing the process capability allows you to set an appropriate sample regime. Don’t waste time collecting data you don’t need to
  5. Improve process capability – by analysing the data and understanding sources of process variation
  6. Improve effectiveness - one place to analyse all quality data, whether captured from testing equipment or manually, easily accessible to all through a user-friendly tool
  7. Support continuous improvement – measure process capability over time, track and sustain improvements
 

SPC Analysis Software Module Features

Configure your SPC Charts

  • Automatically generate SPC charts from any and all quality data collected
  • Calculate and set up control limits
  • Set up hierarchical SPC analysis e.g. across a line, drill into machines within a line, drill into heads on a machine

Real-time SPC analysis and alerting

  • Real-time SPC charts
  • All data is analysed as it input, regardless of whether a chart is currently being viewed
  • Be alerted to violations: out-of-control measurements, outside control limits, violating trend rules etc.

SPC charts for line operatives 

  • Define what SPC charts to display and which calculations to show
  • Design screens to help line operatives who are responsible for the quality of the process. There might be several features to control; you might want to create screens with the key features side by side

Further process variations analysis

  • Select the SPC charts you need from: XR, XS, IXMR, MXMR, Histograms, X and individuals, Capability Overviews, 3D charts, NP,P, C,U, Pareto charts…
  • Multi-headed analysis – there are many processes that are in fact parallel connected but separate processes e.g. multi-die/cavity tools, multi-lane/channel, multi cutting/slicing/laying. In these processes there is a shared and individual source of variation. Understanding the common and individual sources of variation is crucial.
  • Create multiple views of SPC charts 
  • Generate views for different people and purposes e.g. look at the capability of a produced product across multiple production runs; or view the process trend even when the process switches from one product to another.

Calculate process capability 

  • Cp, Cpk
  • Pp, Ppk
  • Generate conformance certificates 
  • Using key characteristics and data collected during each production run.

SPC Software Module Case Studies

See how manufacturers are using the Shopfloor-Online MES SPC software module and to what benefit:

Automotive

►Le Bélier case study
Leading parts manufacturer improves quality management system to schedule over 100,000 quality checks per year, installing the SPC module to detect trending and alert operators to components out of specification.

►Nissan (Sunderland) case study
Well-known vehicle manufacturer increases efficiency and reduces warranty claims with improved quality management software and SPC tools.

►Bulten case study
Automotive supplier upgrades quality control system with automated data collection, quality checks and real-time SPC analysis.

Medical Devices

►Plastibell case study
Injection moulding manufacturer gains increased efficiency through automated quality checks and production of Certificates of Analysis.

Packaging / FMCG

►Allied Glass case study
Premium UK bottle manufacturer improves quality control and efficiency with automated collection of SPC and non-conformance data.

The Shopfloor-Online MES SPC analysis software requires the Quality module to collect data for analysis, which can be further enhanced with: