SPC CALIPSO

From Wikipedia, :

“Statistical process control (SPC) is a method of quality control which uses statistical methods. SPC is applied in order to monitor and control a process. Monitoring and controlling the process ensures that it operates at its full potential. At its full potential, the process can make as much conforming product as possible with a minimum (if not an elimination) of waste (rework or scrap). SPC can be applied to any process where the “conforming product” (product meeting specifications) output can be measured. Key tools used in SPC include control charts; a focus on continuous improvement; and the design of experiments. An example of a process where SPC is applied is manufacturing lines.”

How to translate in simple words the concept of Statistical Process Control?

Albert Einstein was saying:

“If we keep on doing what we always did, in the same way we always did it, we will always get the same result”.

 

The great physician used this statement to suggest the need of innovating, of thinking in a different way. But at the same time, we can have a fully positive interpretation of this principle: to be able to repeat a successful process exactly in the same way it was done previously, will certainly deliver again as good as the previous ones.

Let us transfer the concept in our world, the hot forging of metals. Here is an example:

If with a forging cycle we have obtained parts that, after dimensional, aesthetical and quality testing, are verified to be perfectly complying with the order prescriptions, it is highly possible that the next cycles, if repeated exactly with the same parameters, will lead to the same production result.

During a component hot forging cycle process, there are so many parameters that can influence the result and therefore the quality of the produced parts and that are peculiar of that specific cycle, among these are:

• • Temperature of the billets,
  • die closing force,
  • force applied by the coring punches,
  • total cycle time,
  • stroke of the punches,
  • speed of the punches,
  • weight of the unloaded forged piece…

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