Itru E- Learning by Teaching Series










Application of Knowledge Based SPC for Textile Mills





Version 1.1 with Itru SPCv software Parts I and II





Contentszzzzzzzzz










Overview

Qualifications

Course content

Teaching & Training

Support





Methods of Evaluation and Certification

Course Enrollment Fees and Registration for Entrance





Introduction





SPC (STATISTICAL PROCESS CONTROL) is still widely used in Textile industry to analyse mainly off standard running processes. Application of SPC starts from raw material selection to ready made garments. In this training course examples were included from actual mill practice of SPC in spinning, weaving and finishing mills.


What's new in Knowledge Based SPC


Knowledge Based SPC system considers most of the statistical systems as a whole and combines them with all process /material factors not only taking ± 3 sigma control charts into consideration . In addition to this there are two new charts 95 % Upper and Lower limits of Coefficient of Variations and 2S bar with whole single values in one line for each group . Intention of SPC is to improve process by minimizing the defects, intention of Knowledge Based SPC integrated to Knowledge Based Quality Management is to minimize cost and optimize quality according to customer requirements.


Therefore, SPC concept in this training course should be considered in relation to Knowledge Based Quality Management.

SPC is a useful tool for textile mills to control and improve quality. In this training course most of the terms, definitions and derivation of full formulas that are used in existing textile testing equipment were included so that these systems could be more effectively used.


Trainees are also supported with Itru SPC- ver 1.0 PC-Program and Spread Sheet Exercise Examples to make their knowledge enhanced and practical. After a completing the course a trainee could establish and or improve SPC- System in their field. Support will be given for those who enroll the course and as well as in actual mill practices.


SPC is also closely related to Quality/Process Control procedures in spinning, weaving and finishing mills as well as a part of Knowledge Based Quality Management System.


SPC ver 1.1 for Textiles is a part of Itru SPCv1 for Textiles Software. This software covers most of the chapters that are explained in this course. SPCv1 makes it simple to adapt SPC systems in textile industry. After completing this course the candidates will make use of Spread Sheet software and Itru SPCv1 more effectively.


Requirements: In order to enroll this course the candidate should have a minimum of BSC in Science. Since course is intended for Textile Mills technicians and engineers. Hence candidates are obliged to send a scanned copy a of diploma

Requirements: In order to enroll this course the candidate should have a minimum of BSC in Science or Engineering










1-2 General Overview of the Course









This training course has main four parts.


Part I-I covers from Chapters 1 to 4

Part I-II from Chapters 5 to 6

Part I-III from Chapters 7 to 8

And finally Part II-1 from Chapter 10 to 12


Part I-I

Chapter 1 Introduction to Knowledge Based SPCv ver 1.1

1 Introduction

1-2 Main Items of SPC

1-3- 1 Deriving Number of Tests per group and Total

1-3-2 Sample Selection (Simple Random Sampling and Random Numbers Generating ) 1-3-3 CV % , Set Error % and Sampling Relations

1-4 Determination of Off-Standard Process with the aid of 95 % Confidence Limits

1-5 Evaluation of Off-Standard Results

-How to decide number of tests per unit(samples) and total number of samples
-How to find which sample is out of tolerance (off-std)
-How to find the confidence limits of mean
-How to find confidence limits of CV%
-How to analyse variation within sample and variation between samples and how to evaluate them
-How to make use of Relative Frequency Charts to find the different samples within one sample

Chapter 2 Process Improvement (Before and After Test)

Chapter 3- Control Charts and General Statistical Terms and definitions

3-1 3 s Control Charts (3 Sigma Control Charts) and Basics of Statistics

3- 2 Confidence Range of Mean with t-table calculations (unknown Population sigma )

3-3 Confidence range of standard deviation and CV%

3.4 Card Sliver Count Control and Control Charts

3-5 Process out of Control

What is 3 s Control Charts (3 Sigma Control Charts) and how can be used ?
What is meaning of Confidence Range of Mean ?
What is the Confidence range of standard deviation and %?
How could carding machines be controlled with 3 s Control Charts?

Chapter 4 Frequency Distribution and Analyses

4-1 Summary of Terms Used and Derived from Relative and Cumulative Frequency Diagrams

Part I-II covers ;Differences Between Averages and Variances ; and ;Significant Difference between Nominal and Actual Value ;

Is the difference between samples statistically significant?
Which sample to decide?
Is T-test always significant?
How Correlation R could be used to check material and process instead of T-Test ?
How removal short fibers efficiency of carding machines could be checked by Reg-Test ?


Although Ring Span yarn as an average exhibits higher strength than compare to rotor span yarn may lead to more end break rate in weaving due to weak places in the yarn. Therefore, Coefficient of variation in other words distribution of yarn strength becomes more significant than average value .


It is the F-Test that compares two samples distribution.

How to control Nominal Set Value and Actual Measured Value in Process?


Part I-III


Chapter #7 Normal Distribution Curves

How can Normal Distribution Curves be used in testing and what are their limits?


Chapter #8 SPC Distributions


Application of Binomial, Poisson;s , Confidence Limits of Mean of Poisson;s Distribution and c²

Distribution (Chi-Square) are explained.


Part II-I SPC Charts, which is the main part of the E-Learning Course


The Knowledge Based Management System Structure is to conglomerate mathematical models between raw material, semi product and end product quality parameters. The factors of this model are defined as System Factors.


In order to make use of Knowledge Based SPC we have to take into consideration of Control Factors and Interference Factors in SPC Charts. It is not sufficient to control the process within limits but also minimize the steps in process and reduce the management and manufacturing cost to minimum levels We call this Optimum Quality Minimum Manufacturer Costs with Zero Defects fulfilling customer Requirements.


Which type of SPC charts should be used to control Process?

There are mainly 7 control SPC-CHART that are used these are:

1-X- bar (Normal distribution)
2 R- bar (Normal distribution)

3 2S-/CV bar (Normal distribution)
4-P -bar (Poisson;s)
5-pn-bar (Poisson;s)
6- c-bar (Poisson;s)

7- u-bar (Poisson;s)

How can defects be annualized and Off-Standard Reports are implemented.











2- Qualifications and Goals





The aims of this e-learning SPC-ver.1.1 for textiles could be

-More effectively using the existing textile testing equipment
-Applying SPC systems to quality control and process control
-Revising existing SPC-SYSTEMS and developing further
-Improving quality, productivity and machine and material performance and reducing waste and optimization test total


The candidate will be able to control quality level in fibers, yarns and fabrics as well as spinning  and weaving and knitting mill performance.This course will help to apply and improve the ISO-9000 standard procedures. Itru SPCv1 software could also be used for process improvement in spinning, weaving and knitting and processing mills.


Any candidate who completes and passes the main two exams will be able to take over the tasks of Quality /Process Control management of Spinning, Weaving and Knitting Mills and will have a certification signed and approved by Itru Group Ltd.










3- Course content





The main course is written in PDF file format which covers main subject,exercises and examples. The course is divided into 12 chapters .


Each chapter does not exactly follow one another. The content moves forward and backward and then forward up to Chapter 11 Defects Probability Effect Analyses. This procedure intentionally done this way to make the candidate to learn to tackle problems and read further readings to solve the problems more effectively.


The content has been designed to learn basic statistical methods and adapt to practical mill conditions and then move into more advanced topics . The content starts with SPC Control Charts and end up with Control Charts which is the core of SPC systems . Therefore , when candidate completes the course who will be able to apply this system in practice.


Table of Contents PART I-I
Chapter 1 Introduction to Knowledge Based SPCv ver 1.1 4
1- 1 Introduction 4
1-2 Main Items of SPC 5
1-3- 1 Deriving Number of Tests per group and Total 6
1-3-2 Sample Selection (Simple Random Sampling and Random Numbers Generating ) 6
1-3-3 CV % , Set Error % and Sampling Relations 9
1-4 Determination of Off-Standard Process with the aid of 95 % Confidence Limits 11
1-5 Evaluation of Off-Standard Results 15
Chapter 2 Process Improvement (Before and After Test) 18
Chapter 3- Control Charts and General Statistical Terms and definitions 20
3-1 3 s Control Charts (3 Sigma Control Charts) and Basics of Statistics 20
3- 2 Confidence Range of Mean with t-table calculations (unknown Population sigma ) 21
3-3 Confidence range of standard deviation and CV% 22
3.4 Card Sliver Count Control and Control Charts 23
3-5 Process out of Control 25
Chapter 4 Frequency Distribution and Analyses 26
4-1 Summary of Terms Used and Derived from Relative and Cumulative Frequency Diagrams 28

Table of Contents PART I- II
Chapter 5 Differences Between Averages and Variances 4
5-1 Two Samples Z-Test Mean Values Comparison 4
5-2 Two Samples Z-Test for Proportions 7
5-3 T- Test with Equal and Unequal Variances of Averages of Two Samples 8
5- 4 Difference between deviations (F-TEST) 11
5-5 Differences between samples in terms of standard deviations 12
5-6 Comparison of Standard Error and F-Tests 12
5-7 Comparison of two standard deviations 13
6- Significant Difference between Nominal and Actual Value 14
6-1 Z- Test One Sample (Sample Difference from Nominal Value) 15
6-2 T- Test One Sample (Sample Difference from Nominal Value) 17


Table of Contents PART I-III

7-Normal Distribution Curves 5
7-1 Calculation of frequencies in Normal Distribution curves 7
8- Random Events SPC Distributions 11
8-1 Binomial Distribution 11
8-2 Poisson's Distribution 14
8-2 1 Confidence Limits of Mean of Poisson;s Distribution 17
8-3 Chi Square Distribution (Chi-Square) 18
8.4 Probabilities and Proportion 20
8-5 Exercises and Questions 24

Table of Contents PART II-I
10- 1 Introduction 4
10-2 Organization Structure of Knowledge Based System 5
10 -3 Statistical Process / Quality Control Charts 6
10-3-1 Normal Distribution SPC-Charts with known standard deviation 7
10-3-2 SPC-Charts with unknown Standard Deviation 10
11 Defect Probability Effect Analyses 12
11 -1 P-bar Defect analyses 13
11-2 Pn bar Analyses 15
11-3 C-bar Analyses 16
11-4 Process Quality Control Charts 18
12- 1 Designing , Analyzing and Implementation of SPC 22
12-2 An Example of Designing , Analyzing and Implementation of SPC with Itru SPCv Software 26
12-3 Process Improvement with Linear and Multiple Regression Analyses 30
12-3-1 Correlation Coefficient and Regression Equation 30
Appendix -1 Summary of Terms 33
Appendix 2 -Tm Distribution Table 34
Appendix 3- Normal Distribution Table Z value 35
Appendix 4- CHIINV(CHIINV(0,995;3)) 36
Appendix 5- F - DISTRIBUTION 37
Appendix 6- Process Improvement Work Plan 38
Appendix 7- Process Flow Control Plan 38

Time schedule : Any candidate could start the course any time of the year. However, total time
for any candidate is scheduled for 38 weeks. This covers exercises solving, Home-works and mill
practical works.

Course Content Learning Period Weeks
1- Part I-I 8
2- Part I-II 6
3 Part I-III 5
4- Part II-I 12

Questions for Examinations for Part I- I 1
Questions for Examinations for Part I-II 1
Questions for Examinations for Part I-III 2
Questions for Examinations for Part II-I 3

Total 38











4-Teaching-training activities






The core of the system is Learning Path, which covers

a) Reading Chapters

b) Understanding examples

c) Solving exercises

d) Passing the test at the end of the course.

e) Submitting assignments to course administrator and further reading related documents from Wiki and prepare Home Works

f) Submitting questions and answers to Forum

g) Suggestions new subjects to main course to be included or excluded











5 -Support





Training course has self-supporting system. Each candidate will submit their questions to Forum and will be answered by the forum or course Administrator










6 - Human and Physical Resources





SPC ver 1.1 Software , Spread Sheet Examples and practical mill samples applications.










7- Methods of Evaluation and Certification





This course has been intended to give training for Quality Technician and Quality Manager certifications for textile industry. Therefore, there are two main exams one for Quality Technician and two for Quality Management.



Exam I ( Part I ) for Quality Technician

Exam II (Part II ) Quality Manager


The evaluation is a total of

a) Exercises solving ( % 20)
b) Home work written documents (%20)
c) Final Exams performance for the candidate (%45)
d) Deriving Questions , answers and mill practical samples for the related topics ( %15)


This procedure covers from part I to Part II . The candidate who passes Exams of Part I then continues to Part II ( at least 50 % Total ). Those who pass the both exams with 85 % success will be awarded with Itru SPCv1 PC-program. Any candidate who can not complete the course for a given period of time automatically deleted from the course without any refunding . Any misuse of the system resources may lead to canceling of enrollment without any refunding and notification .






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8- Course Enrollment Fees and Registration for Entrance





Requirements : A diploma of minimum of BSC. in Science or Engineering ,Internet connection and familiarity with spread sheet software.

Ms-windows Operating System XP,Vista or Windows 7 , Open office ver 3.4.0 English version and Adobe Reader

Course Fee :

For individuals = 440 USD per person

For companies = 440 USD per group ( Each group has 1 to maximum 4 members )

Registration : Click here for registration to SPC

Validation of Registration : An e-mail will be send to you for validation of your registration including information about payment and a scanned copy of the diploma.

Read before enrollment

Distribution - License File -Limited Warranty And Disclaimer Of Warranty- And Terms Of Use








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