We are attempting to "reset" our product specifications based on process capability, which, one might agree, is the way to go. However, I have run into a significant problem. Since our process is not very capable (statistically) we would end up with very broad specs that the customer would not agree to. In addition to that, our batch process involves adjusting the material into spec anyway, so we are not really basing our specs on the real process data and our specs would be even wider! Ultimately, we need to get better control of our process but we have not determined any factor yet to control (and it may end up to be costly!)

Any thoughts or suggestions on problems of this nature? How can we use statitical controls in our batch process?