Fix it: Getting Intelligence from Control Chart Dashboard

We’ve completed our setup with ProFicient and are now collecting process and product data from all of my production lines. Utilizing the dynamic ability of our projects has allowed us to collect all of this data using a minimal number of projects while at the same time making the maintenance of the system simple. We’ve created reporting projects that allow us to look at the high level reports; SPC Monitor, Capability Report, and a Process Event Report and Pareto Chart, that are available in ProFicient. What we really need now is a way to look at the charts we’ve created without either opening all the projects that have been created or creating toolbar buttons that allow a user to change the part, process, test selection on a generic reporting chart. The solution has to have the ability to overcome the fact that our data collection processes include many different sample sizes. Our process data typically has a sample size of 1 while our product data typically has samples sizes greater than 1 and we allow our sample sizes to change based on the requirements at the time of the data collection. We also collect different types of data; variable data and attribute data which can be either defects or defectives. Ultimately we would like to be able to show the charts to anyone who needs to see them and to provide a view to all of our employees.

Fortunately there is a solution to our challenge which is the Control Chart Dashboard application. Control Chart Dashboard attaches to our ProFicient database, similar to SPC Enterprise Edition, and allows us to see all of our data plotted on control charts. There is minimal setup required and Control Chart Dashboard can be configured to automatically scroll through all the charts that make up our SPC deployment. The first step of our configuration is to determine how we want to group the available charts with 4 options available; by Part then by Process or by Process then by Part and each of these may be tied to the workstation that collected the data.

If a workstation is chosen as the first grouping item, the configuration can also be modified to present data either from a single workstation or from the entire database.

Once the grouping is defined, limits are set for the timeframe for the search is defined along with the refresh rate for automatically sequencing from one chart to another. The number of points on a chart, maximum of 25, is also defined.

With the setup complete Control Chart Dashboard can now run on any workstation, or be sent to a large screen display in a public location, and will cycle through all of the control charts in the database based on the grouping defined in the setup. 

The display will show the number of control charts based upon the data collection for the group. In the example above Carrot Juice Line 1 collects 5 variables type characteristics, with a sample size of 1. The background color of the chart is designed to act as a visual indicator of subgroup’s value within the control limits, with the red background indicating that the most current subgroup has exceeded one of the limits on either the average chart or the range chart.

In addition to displaying all of the control charts by group, we also have the ability to drill down into any of the charts to get more details on the data. Double clicking on any chart will give us the raw data, another copy of the control chart, the capability chart and the capability report for the specific items when viewing variables type data. When viewing defects or defectives, the capability chart is replaced by a Pareto chart.

Control Chart Dashboard allows us to view all of our collected data on control charts and provides us the ability to drill down into the chart for more details. On a flat screen display it allows all of my employees, or my customers, to view our SPC process without necessarily needing access to ProFicient data collection software. For users who need access to more of the details of the dataset, the drill down capabilities of Control Chart Dashboard allow a user to review them as necessary.

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