Control Charts—Key Exercises

IMPORTANT
It is extremely important that you set up and work within your own site to maintain your data integrity. If you work within any other site, you will compromise your own exercise data as well as the data of other students. Predictable exercise results require that your data be isolated in your own site.

Basic Data Setup

Viewing the Control Plans

Purpose: The purpose of this exercise is to view the control plans that are required for running this particular functionality.

Menu Path: Quality Management/Control Plan/Control Plan – Purchasing
Quality Management/Control Plan/Control Plan – Manufacturing
Quality Management/Control Plan/Control Plan – Inventory

  1. Open the Control Plan – Purchasing window.
  2. Query for part no. 29-320, Valve Cover.
  3. View the control plan and verify that it has Active status.
  4. Open the Control Plan – Manufacturing window.
  5. Query for part no. 29-321, Camshaft.
  6. View the control plan and verify that it has Active status.
  7. Query for part no. 29-523, Rocker Arm.
  8. View the control plan and verify that it has Active status.
  9. Open the Control Plan – Inventory window.
  10. Query for part 29-521, Intake Valve.
  11. View the control plan and verify that it has Active status.

General Exercise for Control Plan—Purchasing

General Exercise for Control Plan—Manufacturing (Shop Order)

General Exercise for Control Plan—Manufacturing (Production Schedule)

General Exercise for Control Plan—Inventory

Required Data

Viewing the Created Analyses

Purpose: The purpose of this exercise is to show the required data that is used in the exercises below.

Menu Path: Quality Management/Control Plan/Control Plan – Purchasing
 Quality Management/Control Plan/Control Plan – Manufacturing
Quality Management/Control Plan/Control Plan – Inventory

  1. Open the Control Plan – Purchasing window.
  2. Query for part no. 29-320, Valve Cover.
  3. Click the Purchase Order Analysis tab and verify that at least two analyses with Confirmed status are available.
  4. Open the Control Plan – Manufacturing window.
  5. Query for part no. 29-321, Camshaft.
  6. Click the Shop Order Analysis tab and verify that at least two analyses with Confirmed status are available.
  7. Query for part no. 29-523, Rocker Arm.
  8. Click the Production Schedule Analysis tab and verify that at least two analyses with Confirmed status are available.
  9. Open the Control Plan – Inventory window.
  10. Query for part no. 29-521, Intake Valve.
  11. Click the Inventory Analysis tab and verify that at least two analyses with Confirmed status are available.

General Exercise for Analysis and Results for Purchasing

General Exercise for Analysis and Results for Manufacturing (Shop Order)

General Exercise for Analysis and Results for Manufacturing (Production Schedule)

General Exercise for Analysis and Results for Inventory

Main Exercises

Creating an Attribute Chart (u Chart) for a Purchased Part

Purpose: The purpose of this exercise is to show how to create control charts for a purchased part.

Menu Path: Quality Management/Control Plan/Control Plan – Purchasing
Quality Management/Analysis/Analysis Results – Purchasing

  1. Open the Control Plan – Purchasing window and query for part no. 29-320, Valve Cover.
  2. Verify that the control plan has Active status.
  3. On the Control Plan Line tab, select the Nondestructive Test control plan line. Then right-click and click Create SPC Chart. The Create SPC Chart window appears.
  4. Under Analysis Date, enter dates in the From and To fields.
  5. Click OK. The chart appears.
  6. View the chart. In accordance with the selection made during SPC setup, a u chart is shown. One point for each analysis appears on the x-axis.
  7. Verify that mean value, standard deviation, upper control limit (UCL), centerline (CL), and lower control limit (LCL) are calculated and shown in the left part of the window.
  8. Verify that the diagram status is Out of Control if at least one analysis falls outside the control limits, or that it is In Control if all analysis data is within the control limits.
  9. Take a closer look at the chart. Do you see any points out of control? Do you see any obvious non-random patterns?

Note: You can also create a chart from the Analysis Results – Purchasing window. To do so, select the test operation line, right-click, and then click Create SPC Chart.

Creating a Variable Chart (Xbar & R Chart) for a Manufactured Part

Purpose: The purpose of this exercise is to show how to create control charts for a part that is manufactured in a shop order–based environment.

Menu Path: Quality Management/Control Plan/Control Plan – Manufacturing
Quality Management/Analysis/Analysis Results – Manufacturing

  1. Open the Control Plan – Manufacturing window and query for part no. 29-321, Camshaft.
  2. Verify that the control plan has Active status.
  3. On the Control Plan Line tab, select the Measure Outside Diameter control plan line. Then right-click and click Create SPC Chart. The Create SPC Chart window appears.
  4. Under Analysis Date, enter dates in the From and To fields.
  5. Click OK.
  6. A message will appear, and you will be asked whether you want to view the chart. Click Yes. The chart appears.
  7. View the chart. In accordance with the selection made during SPC setup, an Xbar & R chart is shown. One point for each analysis appears on the x-axis.
  8. Verify that mean value, standard deviation, upper control limit (UCL), centerline (CL), and lower control limit (LCL) are calculated and shown in the left part of the window.
  9. Verify that the diagram status is Out of Control if at least one analysis falls outside the control limits, or that it is In Control if all analysis data is within the control limits.
  10. Remember to always analyze the range chart first. Do you see any points out of control? Do you see any obvious non-random patterns?
  11. Analyze the x chart (average). Do you see any points out of control? Do you see any obvious non-random patterns?

Note: You can also create a chart from the Analysis Results – Shop Order window. To do so, select the test operation line, right-click, and then click Create SPC Chart.

Creating a Variable Chart (X & MR Chart) for a Manufactured Part

Purpose: The purpose of this exercise is to show how to create control charts for a part that is produced in a repetitive manufacturing environment.

Menu Path: Quality Management/Control Plan/Control Plan – Manufacturing
Quality Management/Analysis/Analysis Results – Manufacturing

  1. Open the Control Plan – Manufacturing window and query for part no. 29-523, Rocker Arm.
  2. Verify that the control plan has Active status.
  3. On the Control Plan Line tab, select the Measure Inside Diameter control plan line. Then right-click and click Create SPC Chart. The Create SPC Chart window appears.
  4. Under Analysis Date, enter dates in the From and To fields.
  5. Click OK.
  6. A message will appear, and you will be asked whether you want to view the chart. Click Yes. The chart appears.
  7. View the chart. In accordance with the selection made during SPC setup, an X & MR chart is shown (MR sample size = 2). One point for each analysis appears on the x-axis.
  8. Verify that mean value, standard deviation, upper control limit (UCL), centerline (CL), and lower control limit (LCL) are calculated and shown in the left part of the window.
  9. Verify that the diagram status is Out of Control if at least one analysis falls outside the control limits, or that it is In Control if all analysis data is within the control limits.
  10. Remember to always analyze the range chart first. Do you see any points out of control? Do you see any obvious non-random patterns?
  11. Analyze the x chart (average). Do you see any points out of control? Do you see any obvious non-random patterns?
    Remember that this type of chart is not as sensitive other variable charts, but obvious patterns should not be overlooked.

Note: You can also create a chart from the Analysis Results – Production Schedule window. To do so, select the test operation line, right-click, and then click Create SPC Chart.

Creating an Attribute Chart (p Chart) for an Inventory Part

Purpose: The purpose of this exercise is to show how to create control charts for an inventory part.

Menu Path: Quality Management/Control Plan/Control Plan – Inventory

  1. Open the Control Plan – Inventory window and query for part no. 29-521, Intake Valve.
  2. Verify that the control plan has Active status.
  3. On the Control Plan Line tab, select the Seat Leak Check control plan line. Then right-click and click Create SPC Chart. The Create SPC Chart window appears.
  4. Under Analysis Date, enter dates in the From and To fields.
  5. Click OK.
  6. A message will appear, and you will be asked whether you want to view the chart. Click Yes. The chart appears.
  7. View the chart. In accordance with the selection made during SPC setup, a p chart is shown. One point for each analysis appears on the x-axis.
  8. Verify that mean value, standard deviation, upper control limit (UCL), centerline (CL), and lower control limit (LCL) are calculated and shown in the left part of the window.
  9. Verify that the diagram status is Out of Control if at least one analysis falls outside the control limits, or that it is In Control if all analysis data is within the control limits.
  10. Take a closer look at the chart. Do you see any points out of control? Do you see any obvious non-random patterns?