13 templates
Control chart (SPC) templates
Statistical process control charts — I-MR, X̄-R, X̄-S, p, np, c and u — with the centre line and control limits computed from the data by the standard unbiasing constants (d2, d3, c4, A2, A3, B3, B4, D3, D4), never typed in. All eight Nelson rules run over the plotted series and every violation is marked and listed, and process capability (Cp, Cpk, Pp, Ppk) is computed when specification limits are given. A chart whose limits were guessed is not a control chart.
X̄-R Chart — Bottle Fill Volume
Twenty-two subgroups of four bottles from a rotary filler, with X̄ and R limits from A2/D3/D4 and Cp/Cpk/Pp/Ppk against a 495–505 ml specification; a late head adjustment shows up as rule 1, 5 and 6 signals.
Lean & FlowX̄-S Chart — Moulded Boss Diameter
Fourteen subgroups of nine mouldings with limits from A3/B3/B4, showing a tool-wear drift that rules 1, 3 and 5 catch and a Cpk of 0.90 against a 12.40–12.60 mm print tolerance.
Operations & Opsu Chart — Central-Line Infections
Twenty-one months of CLABSI counts over a varying number of catheter-days, plotted as infections per 1,000 catheter-days with limits that step with the exposure and a rule-2 run confirming the insertion-bundle rollout worked.
Scientific Plotsp Chart — Call Abandon Rate
Twenty-one days of abandoned calls against a daily volume that swings from 780 to 1,540, giving stepped binomial limits around a 5.1% centre line and isolating the storm-day spike as the only genuine special cause.
Operations & Opsc Chart — Body-in-White Weld Defects
Twenty-four consecutive vehicle bodies inspected for weld defects on a constant area of opportunity, with Poisson limits at c̄ ± 3√c̄ and one body beyond the upper limit after a robot tip-dress was missed.
Lean & FlowX̄-R Chart — API Assay Concentration
Sixteen release batches assayed in triplicate by HPLC, showing a stable process centred 0.33% above label claim with Cp 1.63 and Cpk 1.52 against the 95–105% compendial specification.
Scientific PlotsI-MR Chart — API p95 Latency
Thirty fifteen-minute windows of p95 latency as individuals and moving range against a 250 ms SLO, where the deploy spike inflates the moving range and drives Cpk 2.23 apart from Ppk 1.46 — the gap between short-term and long-term spread.
Data & SchemaX̄-R Chart — Paint Film Thickness
Twenty subgroups of five dry-film-thickness readings in microns, catching a starved-bell subgroup with rule 1 and reporting Cp 1.22 against Cpk 0.94 — a process that is precise enough but centred too low.
Lean & Flownp Chart — Invoice Error Count
Twenty-four weeks of errors found in a constant audit sample of 200 invoices, plotted as counts rather than proportions, with binomial limits around np̄ = 8.79 and a rule-5 signal as the new billing rules bed in.
Data & SchemaI-MR Chart — Reactor Peak Exotherm
Twenty-six batches of peak exotherm temperature as an I-MR pair, with rules 5 and 6 flagging the upward shift after the coolant changeover and Cpk 1.16 against the 78–84 °C batch record limits.
Scientific PlotsI-MR Chart — Tablet Press Weight
Twenty-six hourly tablet weight checks from a rotary press, where Cpk 1.23 sits well above Ppk 0.86 because a punch-wear drift over the final shift makes the press unstable rather than incapable.
Lean & FlowI-MR Chart — Stroke Door-to-Needle Time
Twenty-four consecutive thrombolysis cases plotted as individuals and moving ranges, where a pre-alert and direct-to-CT pathway change at case 17 produces the run below the centre line that rule 6 catches.
Operations & Opsc Chart — Reflow Solder Defects
Twenty-six inspected panels of a fixed-area PCB assembly counted for solder defects, where a paste printer nozzle blockage produces the excursion past the upper control limit that rules 1 and 5 isolate.
Lean & Flow