Lesson Plan
Course Title: Manufacturing Engineering
Session Title: Applying Statistical Process Control (SPC)
Performance Objective:
After completing this lesson, students will be able to apply Statistical Process Control (SPC)
concepts and principles in a computer integrated manufacturing process to the teacher’s
satisfaction.
Specific Objectives:
 Discuss the purpose of Statistical Process Control.
 Research and discuss terms used in Statistical Process Control.
 Discuss the types of variation and the use of process maps.
Preparation
TEKS Correlations:
This lesson, as published, correlates to the following TEKS. Any changes/alterations to the
activities may result in the elimination of any or all of the TEKS listed.
Manufacturing Engineering:

130.329(c)(8)(A)
...apply statistical process control.
Interdisciplinary Correlations:
Physics:

112.39(c)(2)(A)(B)(C)(D)
...know the definition of science and understand that it has limitations, as specified in
subsection (b)(2) of this section;
...know that scientific hypotheses are tentative and testable statements that must be
capable of being supported or not supported by observational evidence. Hypotheses of
durable explanatory power which have been tested over a wide variety of conditions are
incorporated into theories;
...know that scientific theories are based on natural and physical phenomena and are
capable of being tested by multiple independent researchers. Unlike hypotheses,
scientific theories are well-established and highly-reliable explanations, but may be
subject to change as new areas of science and new technologies are developed;
...distinguish between scientific hypotheses and scientific theories;
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
112.39(c)(3)(D)
...explain the impacts of the scientific contributions of a variety of historical and
contemporary scientists on scientific thought and society;
English Language Arts and Reading, English I:

110.31(b)(1)(E)
...use a dictionary, a glossary, or a thesaurus (printed or electronic) to determine or
confirm the meanings of words and phrases...

110.31(b)(12) - Reading/Media Literacy.

110.31(b)(19) - Oral and Written Conventions/Spelling.

110.31(b)(24)(A)
…listen responsively to a speaker by taking notes that summarize, synthesize, or
highlight the speaker's ideas for critical reflection and by asking questions related to the
content for clarification and elaboration;

110.31(b)(25) - Listening and Speaking/Speaking.
Occupational Correlation: (reference: O*Net – www.onetonline.org)
Industrial Engineers 17-2112.00
Similar Job Titles: Process Engineer, Engineer, Operations Engineer, Engineering Manager,
Manufacturing Specialist, Plant Engineer, Supply Chain Engineer
Tasks:

Plan and establish sequence of operations to fabricate and assemble parts or products
and to promote efficient utilization.

Review production schedules, engineering specifications, orders, and related information
to obtain knowledge of manufacturing methods, procedures, and activities.

Coordinate and implement quality control objectives, activities, or procedures to resolve
production problems, maximize product reliability, or minimize costs.

Recommend methods for improving utilization of personnel, material, and utilities.

Apply statistical methods and perform mathematical calculations to determine
manufacturing processes, staff requirements, and production standards.
Soft Skills:
Judgment and Decision Making; Complex Problem Solving; Critical Thinking; Active Learning
Listening
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Teacher Preparation:
Teacher should review all supporting documents such as the Applying Statistical Process
Control (SPC) presentation and notes, Matching Terms and Definitions handout, and Applying
Statistical Process Control (SPC) worksheet. Teachers are also encouraged to conduct their
own research on lesson material. Locate a variety of modern computerized manufacturing
images to show students during the presentation.
References:
1. O*Net – www.onetonline.org
2. Statistical Process Control: It's a Tool, Not a Cult,
http://www.sme.org/Tertiary.aspx?id=35080&terms=statistical%20process%20control,(2000)
3. The Secretary of Labor’s Report on OSHA Program Activity,
http://www.osha.gov/dep/fap/Final_Report_10_7_09.pdf, P. 126, (2000)
Instructional Aids:
1. Applying Statistical Process Control (SPC) presentation and notes
2. Matching Terms and Definitions handout and answer sheet
3. Applying Statistical Process Control (SPC) worksheet and answer key
4. Warm-up activity (slide 3)
Materials Needed:
1. Matching Terms and Definitions handout for each student
2. Applying Statistical Process Control (SPC) worksheet for each student
3. Pen or pencil
4. Paper
Equipment Needed:
1. Computer
2. Internet access (optional)
3. Overhead projector
Learner Preparation:
Students must have basic computer skills.
Introduction
Introduction (LSI Quadrant I):
SAY: Having an understanding of Statistical Process Control will greatly contribute to your
career success.
ASK: Have you ever thought about how we expect the products we buy to be free of defects?
SHOW: Images of common products we purchase - phones, computers, shoes, cars and
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gaming equipment.
SAY: Statistical Process Control processes in manufacturing help eliminate defective products
from store inventory.
ASK: When was the last time you had to return a product to the store because it was
defective?
SHOW: Online videos of manufacturing processes that operate efficiently and address defects
that occur during the production process.
Outline
Outline (LSI Quadrant II):
Instructors can use the presentation, slides, handouts, and note pages in
conjunction with the following outline.
MI
Outline
Notes to Instructor
I. Introduction and Start of Lesson
Begin Applying Statistical
Process Control (SPC)
presentation. Have students
work on the Bell Work Activity.
Slide 2
Warm-up Activity: Using the
Matching Terms and
Definitions handout, students
will pair-share and teach each
other the terms and
definitions. They may do
computer-based research to
look up the meaning.
Slide 3
II. History of Statistical Process
Control
A.
Contributions of W.A.
Shewhart
B.
Contributions of W.E.
Deming
III. Overview of Statistical Process
Control
A. SPC defined
B. Variation and SPC Terms
Discuss the importance of the
contributions of each one of
these SPC Pioneers and how
their research impacted the
growth of SPC.
Slide 4-5
Discuss the purpose of SPC,
examples of variation and SPC
terms.
Slides 6
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Verbal
Linguistic
Logical
Mathematical
IV. Process Mapping and Variation
A. Overview and purpose of
process mapping
B. Overview of variations
Discuss process mapping the
workflow. Review the notes
provided in the Applying
Statistical Process Control
(SPC) presentation. Discuss
the effects and types of
variation. Ensure students
understand the concepts.
Have some background
knowledge, and challenge the
students to make some
contributions to the
discussion.
Slides 7-8
Each slide is meant to be
discussed.
V. SPC Worksheet
A. Assign worksheet
B. Teacher will go over
worksheet in class
Distribute and assign the
Applying Statistical
Process Control worksheet to
the students. Teacher will go
over the answers in class for
better understanding.
Visual
Spatial
Musical
Rhythmic
Bodily
Kinesthetic
Intrapersonal
Interpersonal
Naturalist
Existentialist
Application
Guided Practice (LSI Quadrant III):
Using Matching Terms and Definitions handout, students will pair-share and teach each other
the terms and definitions. They may do computer-based research to look up the meaning.
Independent Practice (LSI Quadrant III):
Students will complete Warm-up Activity, doing computer-based research to look up and match
the meaning of words on the handout, writing out definitions on a sheet of paper. Students will
complete the Applying Statistical Process Control (SPC) worksheet.
Summary
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Review (LSI Quadrants I and IV):
Question: How has SPC impacted the manufacturing industry?
Answer: SPC has contributed to the drastic reduction of defects and quality
improvement of products in many industries. Products have fewer defects and this
increases customer satisfaction, resulting in more products being sold.
Question: Identify the types of variation that can be controlled.
Answer: Specific cause variation, examples: providing unskilled workers with proper
training to reduce accidents. Creating procedures so workers know the correct type and
amount of ingredients to use in making products.
Question: What is necessary to become skilled in the SPC Process?
Answer: training and experience
Evaluation
Informal Assessment (LSI Quadrant III):
Oral question/answer. Students will complete definitions teacher has on the board from terms
in the Matching Terms and Definitions handout. Students will complete the Applying Statistical
Process Control (SPC) worksheet and will go over it in class with the teacher.
Formal Assessment (LSI Quadrant III, IV):
No formal assessment in this lesson.
Extension
Extension/Enrichment (LSI Quadrant IV):
1. Students can work in groups to find examples of manufacturing processes that have
been improved using SPC. Study them and discuss the results within the group.
2. Students can conduct research and identify a nearby manufacturing facility that has
implemented SPC successfully, then contact the plant manager and request a tour of the
facility to find out more about how the plant prepared for and implemented SPC. If
allowed they can take photos and conduct interviews and create a presentation for class.
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Name______________________________Date_________________Class_________
Manufacturing Engineering
Applying Statistical Process Control (SPC)
Matching Terms and Definitions
Directions: Match the terms in Section 1 with the definitions in Section 2.
Section 1:
A. Variation
B. Random defect
C. Specific cause defect
D. Process mapping
E. Brainstorming
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Section 2:
1.____using a visual flowchart to identify the sequential steps in a work
process
2.____defects that occur during the work process
3.____working with a group to create a list of possible options to correct a
problem (or defect)
4.____defects that are within our control (preventable accidents like adding
incorrect ingredients, incorrect temperature settings, inadequate training)
5.____defects that occur and the cause is outside our control (lightening,
earthquakes, war, terrorist strikes, etc.)
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Manufacturing Engineering
Applying Statistical Process Control (SPC)
Matching Terms and Definitions Answer Key
 D. Process mapping: using a visual flowchart to identify the sequential
steps in a work process
 A. Variation: defects that occur during the work process
 E. Brainstorming: working with a group to create a list of possible options
to correct a problem (or defect)
 C. Specific cause defect: defects that are within our control (preventable
accidents like adding incorrect ingredients, incorrect temperature settings,
inadequate training)
 B. Random defect: defects that occur and the cause is outside our control
(lightning, earthquakes, war, terrorist strikes, etc.)
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Name______________________________Date_________________Class_________
Manufacturing Engineering
Applying Statistical Process Control (SPC)
Worksheet
Directions: Using information from the class discussion, answer the five
questions below.
1. What were the contributions of Walter A. Shewhart to the development of
SPC?
2. What were the contributions of W. Edwards Deming to the development of
SPC?
3. Why is it important to study and analyze the work process during SPC,
before making improvements?
4. Is it important to focus most of our attention on random defects?
5. Why is it important to develop a process map?
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Manufacturing Engineering
Applying Statistical Process Control (SPC)
Worksheet Answer Key
Directions: Using information from the class discussion answer the five
questions below.
1. What were the contributions of Walter A. Shewhart to the development
of SPC?
Answer: He used mathematical statistical formulas to give us
a better understanding of variation.
2. What were the contributions of W. Edwards Deming to the development
of SPC?
Answer: He added a strong statistical foundation to quality
control by gathering data on defects that occur during the
manufacturing process.
3. Why is it important to study and analyze the work process during SPC,
before making improvements?
Answer: to identify the root cause of the defects
4. Is it important to focus most of our attention on random defects?
Answer: No, because random defects are usually out of our
control (earthquakes, lightning strikes, etc.)
5. Why is it important to develop a process map?
Answer: To gain a better (visual) understanding of the work
process
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