Qualify SPC charts the right way—before production release

Follow a proven 16‑step SPC control chart qualification process covering measurement readiness, operator certification, pilot control limits, validation runs, correlation analysis, reasonable stability verification, and final chart release. This ensures charts are trustworthy before they are released to production that will drive decisions.

Separate process control from product disposition

Learn the critical difference between: OCAPs (Out‑of‑Control Action Plans) for investigating special causes; and OSAPs (Out‑of‑Spec Action Plans) for containment and disposition. You’ll see why mixing these leads to competing priorities, over‑adjustment, yield loss, and chronic instability—and how to design fast, effective response plans that protects the process.

Use stability—not compliance—to drive capability

Understand when Cp/Cpk are valid (reasonably stable processes) and when Pp/Ppk must be used instead. You’ll learn how to apply the Stability Index (Si) and the 85% Rule so capability metrics reflect reality and support confident decision‑making.

Combine equipment correctly—or not at all

See how to evaluate “Copy Exact” vs. “Copy Similar” equipment using statistical tests, and learn when equipment must remain on separate charts to avoid distorted limits and false OOC events.

Recalculate control limits with discipline

Learn when control limits should be recalculated (and when they should not), based on special cause removal, process changes, and run history—so charts remain current without masking instability.

Set realistic, data‑driven specifications

Learn how to calculate achievable specification limits using: Cpk for “best‑you‑can‑do” process capability; and Ppk for “best‑match‑your‑shipments” performance. This approach helps align engineering, quality, and manufacturing around achievable specs without hiding risk.

Protect your Company during your SPC journey using a Maverick Lot Program

Go beyond traditional SPC by identifying statistically abnormal lots—even when they meet specifications—using the Individuals/Moving Range chart on Final Test Yield.  Learn how this protects your company during your SPC journey and addresses customer Ship-To-Control requirements.   

Audit and sustain an effective SPC program

Use SPC scorecards and audits to objectively evaluate chart quality, OCAP effectiveness, stability, and overall program health. You’ll learn how to distinguish true SPC improvement from cosmetic compliance.

What You'll Learn

Build SPC charts that reflect the true process

Learn how to correctly define processes, CTQs, equipment, and sampling plans so your control charts represent real process behavior—not production lots, noise, or misleading averages. You’ll understand when to use X̄‑s, X̄‑R, or Individuals charts and why sample independence matters.

Eliminate false alarms and wasted reactions

Discover how improper sample sizes, correlated data, and incorrectly combined equipment create excessive Out‑of‑Control signals. You’ll learn how to calculate effective sample size (nₑff) and remove lurking variables that cause unnecessary adjustments and instability.