Statistical Process Control (SPC)
We deploy control charts with Gauge R and R validation and build capability driven out of control action discipline into daily operation
Statistical Process
Control (SPC)
Our team deploys the Shewhart control chart system across your operation, beginning with measurement system validation through Gauge R and R so that the numbers you act on are trustworthy. We select the right chart for each data type, assess capability through Cp, Cpk, Pp and Ppk, and write Out of Control Action Plans that tell operators exactly how to respond. This is how we carry Six Sigma analytical work down onto the operating floor and keep it living there.
Our implementation model
A practical, phased delivery approach that runs from gap assessment through operational embedding and is built around your regulatory context.
Identify critical to quality (CTQ) variables, map to customer requirements and product specifications.
Validate measurement systems via Gauge R&R, ensure measurement variation is significantly below process variation.
Select appropriate control chart, Xbar R, Xbar S, I MR, p chart, np chart, c chart, u chart, based on data type.
Calculate Cp, Cpk, Pp, Ppk, assess process capability against specifications, identify shift / drift / out of control patterns.
Define OCAP for each chart, diagnostic steps, root cause investigation, corrective action, customer communication.
SPC review cadence, capability tracking, integration with Six Sigma improvement projects.
Statistical Process in full scope
Value of Statistical Process Control (SPC)
- Reducing process variation lowers the incidents it would have caused
- Operators get early warning when a process begins to drift
- Everyone follows the same out of control response
- SPC keeps your operators engaged in their own quality
- We align your SPC practice to the AIAG reference manual
- We give you defensible statistical evidence for ISO 9001 clause 9.1.3
- We meet the SPC requirements your automotive and aerospace customers impose
- We back every specification claim with statistical proof
- Your defect rate falls as the process stabilises
- Capability measured through Cpk steadily improves
- Quality becomes something your operators own
- Customer rejections drop
- You avoid the cost of poor quality before it occurs
- You protect yourself against losing a customer over quality
- Scrap and rework both come down
- You spend less on inspection
Codes & standards we work to
Triggers that signal the need
Where Statistical Process Control (SPC) applies
Wellheads, separators, gas compression, FPSO topsides, produced water systems.
Distillation columns, reactors, heat exchangers, storage spheres, LPG handling.
Cryogenic exchangers, liquefaction trains, BOG compressors, storage and sendout.
Reactive systems, batch reactors, solvent handling, runaway reaction scenarios.
Boilers, HRSGs, steam headers, hydrogen systems, ammonia SCR units.
Sterile vessels, CIP/SIP, pressure fermenters, solvent recovery, spray dryers.
Tangible deliverables
- A register of critical to quality characteristics
- Gauge R and R study reports
- A library of live control charts
- Process capability reports
- Out of control action procedures
- An agreed SPC review cadence
Ready to start your project?
Speak with our team to scope an engagement tailored to your facility, regulatory context, and lifecycle stage.