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Course Overview

This course covers the Process Control requirements for AS13006 – 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.

Process control concerns the mechanisms by which the output of a specific process is maintained within a desired range to ensure the resultant characteristic meets the requirements. This course introduces Statistical Process Control (SPC) from the basics, creating charts by hand, before then using more advanced methods to monitor and improve process control.

The use of statistical techniques and other proven methods will result in improved quality and manufacturing maturity. The AS13006 standard helps organisations to select the appropriate control strategies when developing Control Plans and to demonstrate their effectiveness through statistical analysis.

This course has been endorsed by Rolls-Royce civil aerospace as meeting their requirements for supplier training to the AS13006 standard.

Who Should Attend?

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.  

Benefits and Learning Objectives

Delegates will become competent in:

  • The importance of process control
  • Understanding and implementing the 9 control methods
  • Perform statistical analysis on data and interpret the outputs
  • The use of SPC control charts for continuous and attribute data
  • How to calculate and interpret the results of capability studies, whilst identifying potential issues
  • Understanding the linkage of the process controls with other quality tools such as Process Failure Mode and Effects Analysis, Control Plans and Measurement System Analysis

Topics Covered

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 of line inspection

Process Control in Context of Quality Planning

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

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

Process Capability Analysis

  • Basic statistical terms
  • Process stability assessment using control charts


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

Basic Root Cause Analysis and Process Improvement

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

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

Error Proofing

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

Course Delivery

This highly participative course is based on a series of modules using tutorials, exercises and open forum discussion. The course is highly practical with the aim of developing effective problem solving skills that can be quickly applied in the work place.

Pre-requisites

Please note that delegate should bring a laptop with Minitab installed as this will be used during the course. If required a free trial version of Minitab can downloaded here

Why choose Industry Forum


Through partnerships with both trade associations and leading companies in the Automotive, Aerospace and other engineering industries Industry Forum is able to keep up to date with the latest requirements in APQP.

Industry Forum can provide training and consultancy support to help embed robust new product introduction processes and practices into organisations.

Training can be offered either through open courses or in-house to suit the customer requirements.

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Course booking details

Date & Time Company Venue Cost Availability Take Action
23/03/2020 - 24/03/2020
08:30 - 16:30
SMMT Industry Forum Birmingham
United Kingdom
£475 Spaces Available Book
15/06/2020 - 16/06/2020
08:30 - 16:30
SMMT Industry Forum Birmingham
United Kingdom
£475 Spaces Available Book
30/09/2020 - 01/10/2020
08:30 - 16:30
SMMT Industry Forum Birmingham
United Kingdom
£475 Spaces Available Book

Further information