SPC STEPS with Example Step 1: Define Objectives and Scope Objective: Ensure consistent product quality and minimize defects in the assembly of crushers and screeners. Scope: Implement SPC for critical quality characteristics in the assembly process, such as crusher output capacity and eccentric shaft alignment. Step 2: Select Key Quality Characteristics (KQCs) Example KQCs: 1. Crusher Output Capacity: The number of tons of material crushed per hour. 2. Eccentric Shaft Alignment: The precision of alignment of the eccentric shaft in crushers. Step 3: Data Collection Crusher Output Capacity: Collect data on the hourly production rates for crushers. Record the number of tons processed per hour. Eccentric Shaft Alignment: Conduct alignment checks during the assembly process using alignment tools and record the measurements. Step 4: Data Analysis and Presentation Analyse the collected data using statistical tools like control charts, histograms, and scatter plots. Visualize the data to identify trends and variations in the assembly process. Step 5: Establish Control Limits Calculate control limits for each KQC. These limits can be based on historical data, industry standards, or customer requirements. For example, for Crusher Output Capacity, set upper and lower control limits that represent acceptable production rates. Step 6: Implement Control Charts Create control charts for each KQC. For Crusher Output Capacity, we might use an X-bar and R chart. Use appropriate control charts for other KQCs as well. Step 7: Monitor and Control the Process Continuously collect data for the selected KQCs and update the control charts at regular intervals (e.g., hourly, daily, or per shift). Check for any data points that fall outside the control limits or exhibit non-random patterns. Step 8: Investigate and Address Variations When we detect variations or signals of non-random patterns, investigate the root causes. For instance, if Crusher Output Capacity falls below the lower control limit, determine whether it's due to variations in component quality, wear and tear of parts, or assembly errors. Take corrective actions based on findings. Step 9: Document and Report Findings Maintain detailed records of SPC data, investigations, and corrective actions taken. Report we findings and progress to relevant teams, including production, quality control, and management, on a regular basis. Step 10: Continuous Improvement Continuously monitor the assembly process and look for opportunities to improve efficiency and reduce defects. Use SPC insights to drive process optimization efforts, such as improving the alignment process for eccentric shafts or optimizing screen mesh installation procedures. Step 11: Training and Education Ensure that we assembly team is trained in SPC principles, data collection methods, and problem-solving techniques. Provide ongoing training to keep the team informed and engaged in the SPC process. Step 12: Review and Audit Periodically review the effectiveness of we SPC program. Conduct internal audits to ensure consistent application and identify areas where SPC can be further integrated into the assembly process.
