SPC4SMS

SPC4SMS

By OffRoadPilots

Statistical Process Control (SPC) is a methodology used to monitor and control

processes to ensure that they operate efficiently and produce products or services

of consistent quality. While SPC is often associated with manufacturing, its

principles can also be applied to service industries such as aviation safety

management system to ensure quality service delivery. SPC is a tool applied to

safety management system processes, to monitor and control predictability,

repeatability, and reliability of service. The primary goal of SPC is to ensure that

processes are in-control. It involves the use of statistical techniques to monitor and

control variations in a process.

SPC relies on the collection of data from the process being monitored. This data

can be measurements or observations related to the quality characteristics of the

product or service.

The central tool in SPC are control charts. Control charts are graphical

representations of the process data over time. They typically include a central line

representing the average or target value and upper and lower control limits that

indicate the acceptable range of variation. Deviations from these limits can signal

that the process is out of control.

SPC distinguishes between two types of variations: common cause (inherent in the

process and expected) and special cause (unusual or unexpected). Understanding

and categorizing these variations help in determining whether adjustments to the

process are needed.

SPC often involves analyzing the capability of a process to meet specified

requirements. This includes assessing the distribution of the process data and

determining if the process is capable of producing products or services within the

desired specifications.SPC is closely associated with the concept of continuous improvement. By monitoring processes and identifying areas of improvement, organizations can

enhance efficiency, reduce waste, and consistently deliver high-quality products or

services.

SPC enables organizations to detect variations early on, allowing for proactive

measures to prevent defects or deviations from occurring. This proactive approach

is essential for preventing issues before they impact product quality.

SPC is widely used in industries such as manufacturing, healthcare, finance,

services, and aviation safety management system where consistent and

predictable outcomes are critical. It provides a systematic and data-driven

approach to quality management, helping organizations maintain control over

their processes and achieve long-term improvements in quality and efficiency. 

Statistical Process Control

(SPC) is a quality control

method that uses statistical

tools to monitor and control

processes. While SPC is often

associated with

manufacturing and

production, its principles can

also be applied effectively in

the context of safety.

Early Detection of Trends and

Anomalies:

SPC helps in identifying patterns and trends in data over time. By continuously

monitoring safety-related processes, deviations from normal patterns can be detected early. This early warning system allows organizations to address safety issues before they escalate into more serious incidents.Data-Driven Decision-Making:

SPC relies on objective data and statistical analysis rather than subjective

judgments. This promotes data-driven decision-making in safety management. It

enables organizations to base their safety interventions on real evidence rather

than intuition or guesswork.

Continuous Improvement:

SPC is closely aligned with the concept of continuous improvement. By regularly

analyzing safety data, organizations can identify areas for improvement and

implement changes to enhance safety performance. This iterative process

contributes to an ongoing cycle of improvement in safety protocols and

procedures.

Reduction of Variation:

SPC aims to reduce process variation. In safety management, reducing variability in

safety-related processes and outcomes is crucial for maintaining a consistent and

predictable safety environment. Consistency in safety practices helps prevent

accidents and incidents.

Preventive Action:

Rather than being reactive, SPC encourages a proactive approach to safety

management. By identifying and addressing potential issues early on, organizations

can take preventive action to avoid accidents and injuries.

Resource Optimization:

SPC helps organizations allocate resources more effectively. By focusing on areas

with significant safety-related variations, resources can be directed to where they

are most needed, optimizing safety efforts.

Compliance and Reporting:

Many safety regulations and standards require organizations to monitor and report

safety-related data. SPC provides a systematic approach to meeting theserequirements, ensuring that organizations are in compliance with safety standards

and regulations.

Personnel Engagement:

Involving employees in the SPC process can enhance their engagement in safety

initiatives. When employees see that data is being used to improve safety

outcomes, it can foster a culture of safety awareness and responsibility.

Applying Statistical Process Control in safety management can lead to more

effective risk reduction, increased safety performance, and a proactive approach

to maintaining a safe working environment. By leveraging data and statistical

analysis, organizations can create a safer and more reliable workplace.

Statistical Process Control (SPC) charts, also known as control charts or Shewhart

charts, are graphical tools used in quality control and process improvement to

monitor and control the variability of a manufacturing or business process. They

were developed by Walter A. Shewhart in the early 20th century and are widely

used in various industries to ensure that processes operate within acceptable limits

and produce consistent and reliable results.

SPC charts help identify variations in a process that may be indicative of problems

or changes in the production or service delivery. The key concept behind SPC is to

distinguish between common cause variation (inherent in the process) and special

cause variation (resulting from specific, identifiable factors). By doing so,

organizations can take appropriate actions to maintain process stability and, if

necessary, make improvements.

There are several types of SPC charts widely used for SMS oversight.

Control Limits: These are the upper and lower bounds that represent the

acceptable range of variation for a process. Control limits are typically set at a

distance of three standard deviations from the process mean. Points outside these

limits may suggest the presence of special cause variation.Central Line: This represents the process mean and is the reference point around

which the control limits are set. The central line is calculated based on historical

process data.

Data Points: These are the

actual observations or

measurements taken from

the process over time. They

are plotted on the control

chart to visually depict the

trend and variation in the

process.

X-bar and R (or X-bar and S)

charts: These are used for monitoring the central tendency (mean) and dispersion

(range or standard deviation) of a process.

Individuals charts (I-MR charts): These charts are used when it's not practical to

collect data in subgroups. They are based on individual measurements and the

moving range between consecutive measurements.

P charts: These are used for monitoring the proportion of defective items in a

process.

C charts: These are used for monitoring the count of defects in a process.

SPC charts are valuable tools for continuous improvement efforts, allowing

organizations to identify problems early, reduce waste, and enhance overall

process performance. They are commonly used in conjunction with other quality

management techniques, such as Six Sigma methodologies.The Pareto Control Chart is a powerful tool in quality management as it helps organizations allocate resources efficiently by addressing the most critical factors affecting the quality of a process. It provides a visual representation of both the

significant contributors and the stability of the process, aiding in continuous

improvement efforts.

A Pareto Control Chart is a graphical tool that combines elements of both Pareto

analysis and control charts. It is used in quality management and process

improvement to identify and prioritize the most significant factors contributing to

variations or defects in a process.

Pareto principle is also known as the 80/20 rule, suggests that roughly 80% of the

effects come from 20% of the causes. In the context of a safety management

system, it means that a small number of factors often contribute to the majority of

hazards.

A Pareto chart is a bar chart that arranges causes or factors in descending order of

frequency or impact. It helps identify the most significant contributors to a

problem.

A Pareto Control Chart uses the Pareto chart to identify the most significant factors

contributing to process variation. The control chart element helps monitor and

control the process over time.

The most critical factors identified by the Pareto chart are then monitored using

the control chart. This allows organizations to focus their efforts on addressing the

most impactful issues that contribute to process variability. The success of an SMS

enterprise is to focus on the vital few as opposed to the trivial many.

The vital few and trivial many principle, also known as the Pareto Principle or the

80/20 Rule, is a concept that suggests that, in many situations, roughly 80% of the

effects come from 20% of the causes. The principle is named after Italianeconomist Vilfredo Pareto, who observed in the early 20th century that approximately 80% of Italy's land was owned by 20% of the population.

In a broader sense, the Pareto Principle has been applied to various fields,

including business, economics, time management, quality improvement, and the

safety management system. The idea is that a small percentage of inputs or efforts

often lead to a large percentage of the results or outcomes.

The specific percentages (80/20) may vary, but the underlying concept remains the

same that a small portion of inputs or efforts tends to have a disproportionately

large impact on outcomes. This principle is frequently used as a guiding principle

for resource allocation, focusing efforts on the most critical factors that contribute

significantly to desired results.

Two control charts (www.spcforexcel.com) that are highly effective to use for an

SMS enterprise are the Pareto Chart, and the X-mR Individuals Chart. Pareto

analyses the 80/20 rule, and the X-mR analyses variations over time, and if a

process is in-control or out-of-control.

PARETO CHART

Pareto Chart example

below is for bird strikes

at one airport and

classified by runways.

There are three

runways at the airport,

and one approach to

each of the six runway

thresholds.

RWY 09/27, RWY

14/32, and RWY 17/35.Runways 32 and 35 have the most birdstrikes during the year. The Pareto Chart

shows that these to runway accounts for 78% of all birdstrikes at the airport. An

SMS analysis is the next step to decide what corrective action plans to implement to reduce birdstrikes at these two runways.

The Pareto analysis shows that runway 35 and runway 32 are the runways to focus

on, since these two runways count for approximately 80% of all birdstrikes. The

next step is to learn when birdstrikes happened. To learn this, use the Variable

Control Chart, X-mR Chart.

The X-mR chart shows that the airport operator does not have a bird-control

process in place that is effective. Their decision is to use Falconry.

X-mR CHART

X-mR Chart example below is for SMS reports received during the month of

October. The first chart show that the process is in-control, and the second chart

an out-of-control process.

Reports received

during the month of

October are within

the upper and lower

control limits. 

This is an in-control

process, which tellsa story of compliant personnel, who are submitting reports as expected when they are observing hazards.

X-mR chart below shows an out-of-control process.

For reports received during the month of October there is a data-point beyond the

upper control limit (UCL). This process is out-of-control since there was one day

with an excessive number of SMS reports. SPC data points are neutral and a data

point beyond the UCL is a special cause variation and requires a root cause

analysis. Discovery from the root cause analysis was on that day there was a

runway excursion and personnel submitted their SMS observation reports that

day. The process became out of control because of an incident. However, the SMS

reporting process was in-control since personnel submitted their observations. It is

crucial for the integrity of their SMS that an SMS enterprise is applying an SPC

system.

Maintaining an effective data collection system is crucial to develop control charts

to display the health of airport and airline operations. The most effective tool for

collecting safety reports can depend on the specific needs and context of the SMS

enterprise. There are several widely used and effective tools that organizations

often employ for safety reporting.

Mobile Apps and Software Platforms:

Mobile applications and software platforms allow employees to easily submit

safety reports using smartphones or other devices. These tools often provide auser-friendly interface and can streamline the reporting process. A simple to use

and regulatory compliant software is SiteDocs.

Web-Based Reporting Systems:

Online reporting systems accessible through web browsers can be effective for

collecting safety reports. These systems often offer customizable forms and

automated workflows to manage the reporting and resolution process.

Incident Reporting Software:

Specialized incident reporting software is designed specifically for capturing and

managing safety incidents. These tools often include features such as real-time

reporting, trend analysis, and incident tracking. SiteDocs is a real-time reporting

tool.

Anonymous Reporting Systems:

Providing personnel with the option to submit reports anonymously can encourage

more open and honest reporting. Some tools allow for confidential reporting while

still enabling organizations to investigate and address safety concerns. Anonymous

reporting is available for submitting opinions, concerns and hazard observations.

Integration with Other Systems:

Integrating safety reporting tools with existing organizational systems, such as

Enterprise Resource Planning (ERP) or Human Resources (HR) software, can

enhance efficiency and data accuracy.

Email and Hotline Systems:

Traditional methods like email reporting and dedicated hotlines can still be

effective, especially for employees who may not have regular access to digital

tools.

QR Code-Based Reporting:

Some organizations use QR codes placed

in relevant locations (e.g., near

equipment or in work areas) that

employees can scan to access a reporting

system quickly. SiteDocs QR codes should

be placed on airside ID cards, airside

vehicles, aircraft, fueling locations, and

apron, taxiway, and runway hotspot

locations.

Continuous Improvement Tools:

Using continuous improvement tools and

methodologies, such as Six Sigma or Lean, and statistical process control (SPC) can

help organizations not only collect safety reports but also analyze data to identify

when root cause analyses are required and implement preventive measures.

Before selecting a tool, it is crucial to assess the unique requirements of the SMS

enterprise organization, including the size, airport or airline, specific safety

concerns, and safety critical areas and safety critical functions. Additionally, consider factors such as ease of use, reporting capabilities, analytics features, and the ability to integrate with other systems. Regularly reviewing and updating safety reporting processes and tools ensures that they remain effective and aligned with the evolving needs of your organization.

There are several good reasons to use SPC to manage the safety management

system. In summary, Statistical Process Control ensures quality service by providing

a systematic and data-driven approach to monitoring, analyzing, and improving

service delivery processes. It allows organizations to identify and address

variations, maintain consistency, and continuously enhance the quality of their

services.SPC relies on the collection of data from various stages of a process. In the context

of services, data may include customer feedback, response times, error rates, and

other relevant metrics. Analyzing this data helps identify patterns, trends, and

variations in the service delivery process.

SPC distinguishes between common cause variations (inherent to the process) and

special cause variations (resulting from external factors). Identifying the source of

variations allows organizations to address issues systematically.

SPC involves continuous monitoring of key process parameters. In a service setting,

this might mean monitoring service response times, customer satisfaction scores,

and other performance indicators.

SPC establishes control limits based on historical performance data. Control limits

help determine when a process is operating within normal variation or if there are

signs of unusual events that require attention.

SPC allows for the early detection of variations that may lead to service quality

issues. Timely identification of deviations from the norm enables proactive

corrective actions before they impact service quality significantly.

SPC fosters a culture of continuous improvement by encouraging organizations to

analyze data and make informed decisions. In the service industry, this means

using data-driven insights to optimize processes and enhance the quality of service

delivery over time.

By consistently monitoring and improving processes, SPC contributes to delivering

services that meet or exceed customer expectations. Customer satisfaction is a key

metric in service quality, and SPC helps organizations stay aligned with customer

needs.SPC helps identify areas where resources can be optimized without compromising

service quality. This efficiency contributes to cost-effectiveness and improved

overall service performance.

SPC encourages the documentation of processes and the establishment of

standards. Standardizing service delivery processes helps ensure a consistent level

of quality across different service interactions.

SPC4SMS is crucial for the integrity of the SMS, delivery of customer service, and to

capture process variations.

OffRoadPilots