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Process Superstition Is a Poor Substitute for Process Awareness

Getting the most from real-time SPC charting

Steve Daum
Fri, 10/19/2012 - 09:38
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Papering the walls with printed charts might impress visitors, but anyone who wants to get the most from SPC charting must make the right chart available in the right place at the right time. Consider the weekly or monthly quality review meeting. The right people may be in the room, and the right charts may be shown, but as much as a month may have passed since the data have been gathered. Not much can be done to address something that happened six days or six weeks ago.

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Likewise, if charts are simply displayed on a bulletin board in a hallway or the lunch room, they will probably not be helpful to workers trying to understand recent process changes. Charts must be accessible and visible; they must be in the right place to be useful. Of course, regardless of where a chart is displayed, selecting the correct chart type is critical. The skill of discerning when to use an individuals chart rather than a p-chart can be addressed through SPC training, but either chart will be less valuable when it doesn’t reflect recent or real-time data.

In many plants, it is this last point that undermines the value of their SPC charting efforts. The benefits of real-time SPC charting are many:

 …

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Comments

Submitted by William A. Levinson on Tue, 10/23/2012 - 12:25

Another problem with "wallpaper"

If the charts look like they are for process contol, they must reference a controlled work instruction (and are themselves quality records). If this is not the case, they could easily be cited as an audit finding (uncontrolled process controls for critical to quality characteristics, inadequate control of quality records).
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Submitted by Dr Burns on Tue, 10/23/2012 - 16:19

In reply to Another problem with "wallpaper" by William A. Levinson

Who's win ?

A key aspect of control charts on notice boards is who or what they serve.  A quick survey of posts on the ASQ forum reveals that about half of the posts relate to pieces of paper on walls rather than actually improving processes or benefiting companies.  In other words, the personal win is as important or more important than process improvement.  The color of one's belt and the number of certificates is what gets the pay rise or the new job, not what manufacturing processes have actually gained.  Control charts on notice boards are great for "look at me", "see how clever I am".  The less that others understand, the more impressive they are.  Personal win.  Who believes Deming's "14. The transformation is everyone's job" these days anyway ?

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