Process Control for Engineers



The first goal of every process is stability: a consistent and predictable outcome. When we can make every casting the same, every dimension and every characteristic the same we can truly say we can control the process. If we can control it, we can improve it. But how are processes controlled? What are the factors of influence on processes that must be managed? This introductory course is designed to help process and quality engineers to answer these questions and to develop a methodology of process control. Attendees will leave with a set of tools and perspectives on process control that will provide a framework for attacking production and quality problems.

Ted Schorn, Enkei America Inc.

Ted Schorn is currently responsible for quality and technology for Enkei America’s North American operations as Vice President. He has worked in the field of quality over 35 years, spanning automotive, aerospace and medical markets. Ted also operates his own consulting firm, Schorn Consulting, LLC which provides training, management consulting and expert witness services. Ted’s areas of special expertise include quality management, wheel design and engineering, foundry safety and visual inspection. He has degrees in Physics and Mathematics and is the author of two books: Understanding the Wheel Fastening System on Trailers (RVIA/NATM) and Improving the Effectiveness of Visual Inspection (AFS). Ted is frequently called on to speak on both technical and management topics and has authored over 40 technical articles. Ted was awarded the Scientific Merit Award by AFS, was the 2005 Hoyt Memorial Lecturer and has been the recipient of the Ray Witt Management Paper Award three times. He served on the AFS board of directors 2011 – 2015, chaired the Division Council and the Engineering Division, serving on the Quality Systems committee over 25 years. Ted serves as President of the Lean Network, Inc. an association of Honda suppliers.

Course Length

2.0 days

CEU Units

Course outline

The Role of a Process or Quality Engineer
    1. The definition of quality
    2. The job description
    3. The qualifications
    4. The nature of the job
The Goal of Process Control
    1. The definition of stability
      1. Mean
      2. Standard deviation
    2. The definition of capability
      1. Formal variable and attribute capability
      2. Capability as conformity
    3. The approach to assignable causes
    4. The approach to common cause contributors
The Big Picture of Process Success
    1. The turtle diagram
    2. The process in the box
    3. Metrics for engineers
That Which Must be Controlled
    1. Man
    2. Machine
    3. Materials
    4. Method
    5. Measurement
    6. Environment
Documenting Process Design
    1. Process control plans
    2. Process maps
Assessing Process Design
    1. Process validation
    2. Process failure modes and effects analysis
Returning to the Picture of Process Success
    1. Effectiveness
    2. Efficiency
    3. Continual improvement