Manufacturing Engineering
Statistical Process Control (SPC) Tools: Histograms
Lesson Plan
Performance Objectives
After completing this lesson, students will be able to apply statistical process control tools in a computer
integrated manufacturing process using concepts and principles of histogram charts, to the teacher’s
satisfaction.
Specific Objectives
 Discuss the purpose of histogram charts
 Research and discuss terms used in statistical process control
 Create a histogram using production data
Terms
 Variation- defects that occur during the work process
 Random defects- defects that occur when the cause is outside of our control (lightning, earthquakes,
war, terrorist strikes, etc.)
 Specific cause defects- defects that are within our control (preventable accidents such as adding
incorrect ingredients, incorrect temperature settings, or inadequate training)
 Brainstorming- working with a group to create a list of possible options to correct a problem (or
defect)
 Consistency- to maintain a particular standard or repeat a particular task with minimal variation
 Standardization- to remove variations from an item; to cause a product to conform to a standard
 Histogram- used to track data on a bar chart over time to determine the status of the manufacturing
process
Time
When taught as written, this lesson should take approximately 225 minutes.
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)
o (8) The student analyzes quality control systems.
(A) apply statistical process control
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Interdisciplinary Correlations
English Language Arts and Reading, English I 110.31 (b)
o (1) Reading/Vocabulary Development. Students understand new vocabulary and use it
when reading and writing.

110.31 (b)
o (11) Reading/Comprehension of Informational Text/Procedural Texts. Students understand
how to glean and use information in procedural texts and documents.
Algebra I 111.32 (b)
o (1) Foundations for functions. The student understands that a function represents a
dependence of one quantity on another and can be described in a variety of ways.
(E) interpret and make decisions, predictions, and critical judgments from functional
relationships
World Geography Studies 113.43 (c)
o (19) Science, technology, and society. The student understands the impact of technology
and human modifications on the physical environment. The student is expected to:
(A) evaluate the significance of major technological innovations in the areas of transportation
and energy that have been used to modify the physical environment;
(B) analyze ways technological innovations such as air conditioning and desalinization have
allowed humans to adapt to places; and
(C) examine the environmental, economic, and social impacts of advances in technology on
agriculture and natural resources.
 113.43 (c)
o (20) Science, technology, and society. The student understands how current technology
affects human interaction. The student is expected to:
(A) describe the impact of new information technologies such as the Internet, Global
Positioning System (GPS), or Geographic Information Systems (GIS); and
(B) examine the economic, environmental, and social effects of technology such as medical
advancements or changing trade patterns on societies at different levels of development.
Occupational Correlation (O*Net – www.onetonline.org)
Job Title- Industrial Engineers
O*Net Number- 17-2112.00
Similar Job Titles- Operations Engineer, Process Engineer, Engineer, Engineering Manager, Supply Chain
Engineer, Manufacturing Specialist, Plant Engineer
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Tasks
 Apply statistical methods and perform mathematical calculations to determine manufacturing
processes, staff requirements, and production standards
 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
Soft Skills
Critical Thinking/ Judgment and Decision Making/ Complex Problem Solving/ Active Listening
Accommodations for Learning Differences
It is important that lessons accommodate the needs of every learner. These lessons may be modified to
accommodate your students with learning differences by referring to the files found on the Special
Populations page of this website.
Preparation
 Review and become familiar with the terminology, website links, and the slide presentation.
 Have materials, slide presentation, and websites ready to go prior to the start of the lesson
References
 http://www.thefreedictionary.com
 Robinson, T. L., Audibert, R. L., & Zenda, W. (2000, March). Statistical process control: It's a tool, not a
cult. Manufacturing Engineering, 124(3). Retrieved January 8, 2013, from
http://www.sme.org/Tertiary.aspx?id=35080&terms=statistical%20process%20control,(2000)
 Tague, N. (2005). The quality toolbox (2nd ed., pp. 8-296). Milwaukee, WI: Quality Press.
Instructional Aids
 Statistical Process Control (SPC) Tools: Histograms slide presentation and notes
 Statistical Process Control (SPC) Tools: Histograms Matching Terms and Definitions handout for each
student
 Statistical Process Control (SPC) Tools: Histograms Matching Terms and Definitions Answer Key
 Warm-up Activity (slide 3)
 SPC Tools: Histogram Chart Project worksheet for each student
 SPC Tools: Histogram Chart Project worksheet answer key
 Statistical Process Control (SPC) Tools: Histograms Quiz for each student
 Statistical Process Control (SPC) Tools: Histograms Quiz Key
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Introduction
The main purpose of this lesson is to help students understand the purpose of histogram charts and how to
create a histogram using production data.
Ask: Have you ever thought about why we always expect the products we buy to be free of defects?
Ask: How does it make you feel to have to return a product because it was defective?
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Outline
MI
NOTES TO TEACHERS
OUTLINE
I.
Introduction and start of lesson
A. Bell Work Activity
B. Warm-up Activity
II.
Statistical Process Control (SPC)
A. Overview
B. Tools used in SPC
C. Purpose of histograms
D. Understanding histograms
III.
Histogram project
A. Histogram example
B. Project worksheet assignment
IV.
Administer quiz at end of lesson
Begin the Statistical Process
Control (SPC) Tools:
Histograms slide
presentation.
Have students work on the
Bell Work Activity. (slide 2)
Warm-up Activity: Distribute
Statistical Process Control
(SPC) Tools: Histograms
Matching Definitions
handout and have
students(in pairs) teach each
other the terms and
definitions. They may do
computer-based research to
look up the meaning.
(slide 3)
Discuss the overview of
Statistical Process Control.
Ensure students understand
the purpose of histograms
and definition of each term.
(slides 4-9)
Carefully discuss the various
types of histograms.
(slides 10-13)
Continue slide presentation.
(slides 14-17)
Distribute quiz and
worksheet and use answer
keys to grade the project
worksheet and quiz.
Review the histogram
example and the project
worksheet.
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Multiple Intelligences Guide
Existentialist
Interpersonal
Intrapersonal
Kinesthetic/
Bodily
Logical/
Mathematical
Musical/Rhythmic
Naturalist
Verbal/Linguistic
Visual/Spatial
Application
Guided Practice
The teacher and students search the Internet to find different sources to gain more insight into
 Unique ways histograms are created and used in SPC in various manufacturing environments
 How companies use SPC to increase market share and increase efficiency
Independent Practice
 Students will write a 50 word essay on one of the other SPC tools on the list in the presentation.
 Students will go online and research the history of SPC in America and in Asia.
Summary
Review
Students review the terms from the Warm-up Activity and key points from the slide presentation.
Evaluation
Informal Assessment
Teacher will assess learning through oral questions and answers. Students will discuss terms, definitions, and
key points from the Statistical Process Control (SPC) Tools: Histograms slide presentation.
Formal Assessment
Teacher will administer the Statistical Process Control (SPC) Tools: Histograms Quiz.
Enrichment
Extension
Students will write a paper about W. Edward Deming and his contributions to Statistical Process Control.
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Name_______________________________________Date______________________Class________________
Manufacturing Engineering
Statistical Process Control (SPC) Tools: Histograms
Matching Terms and Definitions
Directions- Match the terms in Section 1 with the definitions in Section 2.
Section 1-
Section 2-
A. Variation
1. _____ working with a group to create a list of
possible options to correct a problem (or defect)
B. Random defects
C. Specific cause defects
2. _____ defects that occur when the cause is outside
our control (lightning, earthquakes, war, terrorist
strikes, etc.)
D. Brainstorming
E. Consistency
F. Standardization
G. Histogram
3. _____ defects that are within our control
(preventable accidents like adding incorrect
ingredients, incorrect temperature settings, or
inadequate training)
4. _____ used to track data on a bar chart over time
to determine the status of the manufacturing
process
5. _____ to maintain a particular standard or repeat a
particular task with minimal variation
6. _____ defects that occur during the work process
7. _____ to remove variations from an item; to cause
a product to conform to a standard
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Manufacturing Engineering
Statistical Process Control (SPC) Tools: Histograms
Matching Terms and Definitions
Answer Key
1. D. Brainstorming- working with a group to create a list of possible options to correct a problem (or
defect)
2. B. Random defects- defects that occur when the cause is outside our control (lightning, earthquakes,
war, terrorist strikes, etc.)
3. C. Specific cause defects- defects that are within our control; (preventable accidents like adding
incorrect ingredients, incorrect temperature settings, or inadequate training)
4. G. Histogram- used to track data on a bar chart over time to determine the status of the
manufacturing process
5. E. Consistency- to maintain a particular standard or repeat a particular task with minimal variation
6. A. Variation- defects that occur during the work process
7. F. Standardization- to remove variations from an item; to cause a product to conform to a standard
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Name___________________________________Date_______________________Class_______________
Manufacturing Engineering
Statistical Process Control (SPC) Tools: Histograms
Quiz
1. We define _______________________________ as studying the statistical data of a work process to
help understand the cause of ____________________.
2. In SPC, we cannot control ___________________________________ without using the proper tools.
3. A ____________________ is used to track data on a bar chart over time to determine the status of the
______________________________.
4. Identify the type of histogram where production process data indicates measurement spikes above
both the upper and lower control limits. ___________________________________________
5. ____________________ are designed to indicate ___________________________ (measurements) of
product design.
6. Identify the type of histogram where production process measurement data indicates alternating tall
and short bars. ______________________________
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Manufacturing Engineering
Statistical Process Control (SPC) Tools: Histograms
Quiz Answer Key
1. We define Statistical Process Control (SPC) as studying the statistical data of a work process to help
understand the cause of variation.
2. In SPC, we cannot control variation and reduce defects without using the proper tools.
3. A histogram is used to track data on a bar chart over time to determine the status of the
manufacturing process.
4. Identify the type of histogram where production process data indicates measurement spikes above
both the upper and lower control limits. double peak distribution histogram
5. Control limits are designed to indicate specific parameters (measurements) of product design.
6. Identify the type of histogram where production process measurement data indicates alternating tall
and short bars. comb distribution histogram
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Name____________________________________Date______________________Class_______________
Manufacturing Engineering
Statistical Process Control (SPC) Tools: Histogram
Chart Project
Directions- Using the information below (and graphing/spreadsheet software), create a histogram chart.
Histogram Chart Project- Label defects on plastic juice bottles.
Listed below is data collected on the number of defective labels found on juice bottles during a specific
production period.
USL = Measurement 12
LSL = Measurement 8










Measurement 1-2
Measurement 2-3
Measurement 3-4
Measurement 4-5
Measurement 5-6
Measurement 6-7
Measurement 7-8
Measurement 8-9
Measurement 9-10
Measurement 10-12










Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
Measurement
11-13
12-15
13-16
14-18
15-22
16-21
17-14
18-10
19-7
20-2
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Manufacturing Engineering
Statistical Process Control (SPC) Tools: Histogram
Chart Project
Answer Key
Using the data, allow students to create their own histogram chart. Charts can be created using presentation
and spreadsheet software or online programs. In the histogram assignment above, the SPC team gathered
data on the number of defective labels found on juice bottles during a specific production period. The data
indicates a right skewed distribution. Measurements 1-7 and 13-20 indicate the number of defective labels
that were identified. Measurements 8-12 were within specifications. The majority of labels were found to be
either above or below the specification limits. The production process must be investigated to determine the
root cause of the problem.
Skewed Histogram- production process data is right skewed. The product is beyond the upper control limit
and is out of specification. The production process must be investigated to determine the root cause of the
problem.
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