
Two-part course on SPC and process capability empowers manufacturing quality by mastering statistical process control, reducing process variations, optimizing supplier quality, and embracing industrial 4.0 for defect prevention.
Explore a toothbrush manufacturing process, measure width with a vernier caliper, and analyze variation using histograms, run charts, and statistics like mean, median, mode, and standard deviation.
Learn to distinguish common cause and special cause variations in manufacturing, assess their impact on process outputs, and apply Six Sigma and corrective actions to stabilize quality.
Learn to apply statistical process control to monitor process stability with run charts and control charts, identifying common and special causes and using Excel SPC tools.
Identify variable and attribute data; explore gauge-based measurement and resolution; apply x-bar and individual charts for variable data, and p, c, and u charts for attribute data.
Master variable control charts, including bar charts for small subgroups and IMR and X-bar range charts, and learn rational subgrouping, measurement analysis, and deriving 25-point control limits.
Construct the imr chart from individual measurements, using the x chart for averages, the moving range for variability, and apply control limits with n=1 and at least 25 data points.
Learn to plot the X bar chart, using constant subgroup sizes (typically 2–5, hourly sampling) to detect shifts, calculate control limits, and understand average run length.
Explore attribute control chart, including defects per area and defective units, using C, U, and P charts with constant or changing samples, and 25 data points for limits.
learn to plot a p chart, a proportion of defects over total units, with variable sample sizes and dynamic control limits, using a ready-made template that auto populates the chart.
Learn to plot a p chart with fixed sample size, calculate upper and lower control limits, and use the AMP template to record defect counts and chart results.
Plot a u chart for defects per unit using average defects with variability, and set upper and lower control limits from the process average and u over n.
Master the c chart for fixed sample sizes, calculating the average defects as total defects over total samples, and apply the embedded control-limit formulas to PCB solder joints.
Learn to read control charts, distinguish common from special cause variation, apply Western Electric rules, and use zone a, zone b, zone c signals to detect shifts and improve processes.
Establish control limits by removing special-cause influence, confirm data normality, and use 25–40 points for reliable SPC; regularly review limits and recalculate only after major process changes supported by evidence.
Learn to audit supplier SPC readiness, establish governance, select critical parameters, define control points, and implement robust control charts with clear reaction plans.
Learn SPC and Cpk the way real engineers use them — now enhanced with AI prompts for faster analysis and better decisions.
Are you a quality engineer, supplier quality engineer, manufacturing engineer, or fresh graduate who wants to move beyond theory and learn how SPC and Process Capability are actually used in real factories?
Many engineers know the words: control chart, common cause, special cause, Cp, Cpk, process capability, and corrective action. But when the production line has variation, a supplier submits unstable data, or a customer asks for evidence of process control, many professionals still struggle to decide what the data really means and what action to take.
This course is designed to close that gap.
SPC, Cpk & AI for Manufacturing Quality teaches you how to use Statistical Process Control and Process Capability as practical decision-making tools for manufacturing quality improvement. You will learn how to identify critical process control points, construct and analyze SPC charts, interpret process variation, calculate and interpret Cp and Cpk, and recommend improvement actions based on real manufacturing scenarios.
This is not a theory-only course. It is built from more than 30 years of manufacturing quality and supplier quality experience, using practical examples, Excel templates, case studies, and structured thinking that you can apply immediately at work.
The upgraded version of this course now includes practical Generative AI applications. You will learn how to use AI prompts to identify SPC control points, analyze SPC charts, calculate process capability indices, interpret Cpk results, and recommend process improvement actions. AI is positioned as your additional quality engineering assistant — helping you analyze faster, think more clearly, and prepare structured reports more efficiently.
You will also experience an AI role play exercise that helps you practise real workplace decision-making in a manufacturing quality scenario.
By the end of this course, you will be able to move from firefighting and guessing to structured, data-driven quality control. You will understand not only how to calculate SPC and Cpk, but how to interpret the results and decide what action is needed.
This course is ideal for quality engineers, supplier quality engineers, manufacturing engineers, process engineers, production professionals, and fresh graduates who want practical, real-world quality engineering skills enhanced with AI.
If you want only textbook theory, this may not be the course for you. But if you want practical SPC, Process Capability, and AI-assisted quality decision-making that you can apply in real manufacturing work, this course is designed for you.