Statistical Process Control

Programme Summary

Turn production and service data into timely decisions about process stability. Participants select control charts, build reliable baselines and distinguish common variation from signals requiring investigation. Practical datasets connect chart interpretation with sampling, measurement quality and reaction plans, helping teams intervene consistently while avoiding unnecessary adjustments that can increase process variation or hide emerging problems.

Training Objectives

1 Explain process variation and stability concepts; 2 Select charts suited to operational data; 3 Establish reliable baselines and reaction rules; 4 Strengthen interpretation of statistical control signals; 5 Connect monitoring with practical improvement decisions.

Learning Outcomes

1 Select an appropriate process control chart; 2 Calculate and review baseline control limits; 3 Identify statistically meaningful process signals; 4 Write a proportionate process reaction plan; 5 Explain when capability analysis is unsuitable.

Target Audience

Quality Engineers; Process Engineers; Quality Managers; Production Supervisors; Continuous Improvement Specialists.

Target Industries

Automotive Manufacturing; Electronics Manufacturing; Industrial Equipment Manufacturing; Medical Device Manufacturing; Consumer Goods Manufacturing; Industrial Services.

Course Contents

• Module 1 Variation and Process Decisions: Common cause and special cause variation; Stability versus capability and specifications; Consequences of tampering with stable processes.
• Module 2 Data and Measurement Planning: Operational definitions and measurement suitability; Sampling frequency and rational subgroups; Data integrity and collection consistency.
• Module 3 Describing Process Performance: Time ordered data and distributions; Location spread and unusual observations; Stratification before statistical charting.
• Module 4 Chart Selection: Variable and attribute data distinctions; Continuous counts and proportion data; Selecting charts for operational conditions.
• Module 5 Variable Data Charts: Individual and moving range charts; Mean range and standard deviation charts; Subgroup size and interpretation constraints.
• Module 6 Attribute Data Charts: Proportion and count based charts; Variable sample sizes and opportunities; Rare events and specialist chart limitations.
• Module 7 Establishing Control Limits: Representative baseline data and stability review; Calculation of limits and centre lines; Documenting exclusions and revised baselines.
• Module 8 Interpreting Signals: Points beyond limits and nonrandom patterns; Preselected rules and false alarm tradeoffs; Investigating signals with process knowledge.
• Module 9 Reaction Plans: Containment and assigned response responsibilities; Evidence preservation and cause investigation; Criteria for restarting and communicating changes.
• Module 10 Capability Interface: Need for stable representative process data; Measurement adequacy and distribution assumptions; Avoiding misleading capability claims.
• Module 11 Sustaining Statistical Control: Review ownership and visual management; Process changes and recalculation decisions; Monitoring effectiveness of improvement actions.
• Module 12 SPC Application Workshop: Constructing charts from supplied process data; Interpreting signals and investigation priorities; Presenting a justified reaction plan.

Assessment

• 60 single best answer questions, including applied scenarios; one mark per question.
• 90 minute invigilated digital examination with identity verification. Approved accessibility adjustments preserve the assessed competence.
• Supplied reference pack and calculator permitted; external internet and AI prohibited.
• Individual applied assessment (45 minutes): Construct and interpret a control chart from supplied data, identify stability issues and prepare a reaction plan with justified capability limitations.
• Assessment criteria: Correct chart and baseline selection; Accurate signal interpretation; Practical and proportionate reaction decisions.
• Pass each component separately: 45/60 written marks (75%) and at least 70% on the applied task.
• Individual results and feedback are provided. One reassessment may follow coaching under the published enrolment terms.

Certification

• Successful learners receive a TQCSI Arabia digital Certificate of Successful Completion.
• The certificate records the learner name, exact programme title, teaching hours, completion date and unique verification reference.
• Verified identity, full attendance and separate written and applied passes are required; all mandatory critical criteria must be met.
• Proposed issue target: within 30 calendar days of approved results and settlement of applicable fees.
• Records statistical process monitoring skills; it does not establish process capability without suitable measurement and stable representative data.
• Attendance confirmation may record completed hours for unsuccessful learners; it does not certify successful completion.

Programme Profile

Number of daysNumber of daysNumber of days

333

Total teaching hoursTotal teaching hoursTotal teaching hours

18 hours; breaks, pre course work and formal final assessments excluded.18 hours; breaks, pre course work and formal final assessments excluded.18 hours; breaks, pre course work and formal final assessments excluded.

Delegates allowedDelegates allowedDelegates allowed

Maximum 16 delegates.Maximum 16 delegates.Maximum 16 delegates.

Training prerequisitesTraining prerequisitesTraining prerequisites

Basic statistics, spreadsheet skills and familiarity with a measurable operational process are required. Prior knowledge of quality tools is recommended.Basic statistics, spreadsheet skills and familiarity with a measurable operational process are required. Prior knowledge of quality tools is recommended.Basic statistics, spreadsheet skills and familiarity with a measurable operational process are required. Prior knowledge of quality tools is recommended.

Pre course assignment and assessmentPre course assignment and assessmentPre course assignment and assessment

Complete a 30-minute diagnostic on averages, variation and data types using a supplied process dataset.Complete a 30-minute diagnostic on averages, variation and data types using a supplied process dataset.Complete a 30-minute diagnostic on averages, variation and data types using a supplied process dataset.

End of course assessmentEnd of course assessmentEnd of course assessment

60 question written exam (90 minutes) and individual applied task (45 minutes).60 question written exam (90 minutes) and individual applied task (45 minutes).60 question written exam (90 minutes) and individual applied task (45 minutes).

Passing criteriaPassing criteriaPassing criteria

75% written and 70% applied, passed separately; full attendance.75% written and 70% applied, passed separately; full attendance.75% written and 70% applied, passed separately; full attendance.