FOURCAST SPControl is a dual chart system that improves statistical process control (SPC).

Computer Powered Wire(less) Ultra-intelligent Real-time Monitor. Patent pending.

FOURCAST is the engine for performing all calculations for FOURCAST SPControl.

Download FOURCAST SPControl now to see how!

Then, expand your ideas: utilize more data, statistical process control data, a user's monograph + case based & research journal references, and much much more!

For clear SPC problem identification and reliable decision making, you can create:

Examples of clearly labelled and easy to read FOURCAST SPControl charts are temperature and pressure charts, etc. Multiple variables are analyzed for auto and cross correlations. If unacceptable values occur on any of the charts, or if the monitor is disconnected, it will automatically create sound and color alarms that are audible, and visible from a distance. In a noisy industrial environment, the full screen progressive blue-yellow-red color alarms are easy to recognize. Pager/beeper or phone notification also occurs automatically. Up to date charts may also be emailed and/or faxed to a quality control professional anywhere in an industrial plant or anywhere in the word. A hard wire or wireless link between the data collecting sensor and the computer will permit the computer to be placed in a protected environment, remote from the industrial operation being monitored. It is easy to use and ideal for industrial applications or computer room temperature monitoring, etc.

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You have entered the statistical process "quality" control (SPC) page. Here you will find case studies and related data designed to teach the theory and practice of modern model based statistical process control.

Click on the reference below to read a related article.

Single versus Dual process control charts

Click on the reference below to select the teaching case and/or data set that you wish to download. They are designed to work with all versions of the computer software FOURCAST SPControl, including the educational version <(click here to download FOURCAST SPControl then install it). FOURCAST is the engine for performing all calculations for FOURCAST SPControl.

CASE: Common cause Special cause Statistical Process Control

CASE: Pro-active Statistical Process Control

DATA: PHOS.MTW

DATA: MOIST.MTW

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Time series analysis has many applications. How it is applied, depends very much on the particular application. The following information is intended as a guide to statistical process control applications. Statistical process control by a simple control chart of a process variable, is based on the assumption that the process variable is an independent identically distributed random variable. That is, measurements taken on the process result in a sequence of numbers that are unrelated to each other. It is now well known that this is not a valid assumption. In practice the process variable typically contains significant correlations due to persistent common cause effects. These common cause effects become confounded with random one of kind special cause effects. The objective of time series model based statistical process control is to separate the process variable into two components namely the systematic variation due to common cause (contained in the fitted values) and the purely random variation (contained in the residuals). The process can then be controlled by 1) identifying and removing the source of common cause effects and 2) correcting the cause of special effects observed as outliers on a control chart of the residuals. Time domain time series models are limited in their ability to represent cycles in the data. The moving window spectral antithetic (MWSA) time series model is a frequency domain approach. It is an extension of the time series concept, to a generalized automatic system which further decomposes the process variable into trend, periodic components and residuals. However, the main objective of this information, and the test that follows is a critical examination of the the way in which we view this application, and in general, the role of time series analysis special cause charts and common cause charts.

Summary of suggested rules for implementing an SPC plan

ASSUMPTION: SPC data are made up of trend, cyclical, and random components. The random component is plotted on a special cause chart, marked with 3 sigma upper and lower control limits. The systematic trend and cyclical components are plotted on a common cause chart, marked with 3 sigma upper and lower control limits. These charts are continuously updated and made available to process control personnel, who:



1. Examine the special cause chart.
If any plotted data point falls outside the control limits, stop the process and investigate the cause. Since the data on this chart are independent, look for special one of a kind causes, such as a bad batch of raw materials. Something that will not necessarily happen again, or happen in the same way. For example, if a bad batch of raw materials is found, the supplier should be contacted, and notified of the consequences.

2. Examine the common cause chart.
If there is a recognizable pattern, attempt to associate the pattern with its probable cause, likely to continue occuring. For example a cyclical pattern may be due to a worn bearing. If this can be established, then the bearing could be changed during the next scheduled plant maintenance shut down. Otherwise the bearing wear may reduce product quality. It will eventually fail, forcing an unscheduled shut down, a new bearing anyway, and all the attendant costs of a forced shut down. All parts must wear, and must wear out eventually. The time to change the worn bearing, prior to complete failure is an economic decision. One way to use the common chart 3 sigma limits is as follows. If there is a breach of the common chart 3 sigma limits, assume that bearing failure is imminent and replace it as soon as practicable.

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The following block diagram illustrates the separation of special cause and common cause control charts and systems.

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The following classifications of common cause chart patterns are useful for diagnosing out of control conditions.

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The following diagram illustrates a feedforward control system for maintaining a constant water level in a tank. Based on a historical pattern of demand for water, the water level is adjusted ahead of time so as to minimize devations from the desired water level. The application depicted is chosen for its simplicity so as to focus on understanding the method of feedforward control. In practice, the application requiring feedforward control may be far more complicated.

FOURCAST is the engine for performing all calculations for FOURCAST SPControl.

Download FOURCAST SPControl now to see how!

Then, expand your ideas: utilize more data, statistical process control data, a user's monograph + case based & research journal references, and much much more!

Test your FOURCAST SPControl IQ.

Instructions

This review is designed to determine how well you understand what FOURCAST SPControl does, and how to put it to work for you. When you are satisfied that you have answered the questions correctly, you are ready to use the program. Please feel free to use this self-evaluation test as often as you like (In order to receive anonymous feedback, click on the score button at the end of the test.)

Questions
Answer each of the following multiple choice review questions by
selecting the response which is most immediately appropriate.

1. FOURCAST SPControl is a computer program for

2. FOURCAST SPControl is used for

3. FOURCAST SPControl analyses historical data by examining

4. Typical process measurements are comprised of

5. When a series of measurements shows a systematic pattern, this should be interpreted as

6. The 3 sigma limits of a special cause chart is breached. This should be interpreted as

7. The 3 sigma limits of a common cause chart has been breached. This is interpreted as

8. Applying a single process control chart to correlated process measurements can

9. Splitting the control chart into residuals and fitted values can

10. Applying a dual chart process control system can

11. An effective way to close the loop in a process control system is with

12. The model used by FOURCAST SPControl is

13. The MWSA model is

14. A process control engineer wants to use a neural network to diagnose correlation structure. Data for the network should be

FOURCAST is the engine for performing all calculations for FOURCAST SPControl.

Download FOURCAST SPControl now to see how!

Then, expand your ideas: utilize more data, statistical process control data, a user's monograph + case based & research journal references, and much much more!

You can create Special cause SPC charts of residuals, Common cause SPC charts of fitted values for clear problem identification and reliable decision making.

If your web browser does not support forms, then scroll past the following form for insrtuctions on how to order FOURCAST SPControl.


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Operating system: Select one of the following (scroll right for specifications on what each purchase includes). *$10 FOURCAST SPControl Upgrade (Upgrades any version of FOURCAST SPControl software to the latest version) *$10 FOURCAST SPControl Educational (Includes demonstration charts) Each one of the following purchases includes software only. Sensor harware is sold separately. +$299 FOURCAST SPControl1 (Monitor one variable only. Example: temperature.) +$495 FOURCAST SPControl3 (Monitor up to 3 variables. Example: temperature, pressure + one more.) +$995 FOURCAST SPControl7 (Monitor up to 7 variables. Example: temperature, pressure + up to 5 more.) Trade-Up-Allowance (software only): There is no penalty for buying low now (1 variable or 3 variable) and trading up later (1 variable to 3 variable or 7 variable, 3 variable to 7 variable). You will receive a 100% trade-in credit from the prior purchase. The trade-in 1 variable or 3 variable monitor must be accompanied by proof of the original purchase. Specify trade-up-allowance, if applicable: Allowance: Optional Quantity Discount: Each additional purchase of the same program 1 variable, 3 variable or 7 variable will be discounted by 30%. Specify quantity: DEALER(Customer sales & service representative): Optional
*+Note: All selections will download software to your computer. You may proceed to use the software immediately. If for any reason, downloading was unsuccessful, contact us immediately so that a diskette may be sent through the mail. It is important that your mailing address be correct. The selections marked (*) include adequate software help files. Selections marked (+) carry a 30 day 100% money back guarantee less 15% restocking fee, include hardware for measuring heart rate, additional software and documentation which must be shipped & emailed to you. The per item shipping and handling charge is: U.S. Customers $10, Canadian customers $15, International customers $20.

If unable to use order form, send check or money order to:

Engineering Management Consultants, Inc., P.O.Box 12518, Centerville Road, Tallahassee, FL 32317-2518.
Or call in your visa or master card number to Engineering Management Consultants, Inc. at Tel (850)668-0635 Fax (850)668-5937.
Or send your address, phone#, visa or master card number and expiration date to email:fourcast@fourcast.net

Remember to specify which FOURCAST SPControl system you are ordering.


Thank you and have a nice day.