The effect of statistical process control training for production operators on product quality and productivity
Abstract
The primary purpose of this study was to examine the effect of Statistical Process Control (SPC) training for production operators on product quality and productivity. The SPC training program was developed and taught by the training department at the manufacturing facility of interest. The operators were required to attend the SPC training program which met one time each week for six weeks. The operators received their hourly pay for attending the SPC class as part of their work assignment. The operators that participated in the study were selected for participation in the study by the management and supervisory staff at the manufacturing facility of interest. The comparison group (N = 11) consisted of operators that had previously completed the SPC training program. The training group (N = 11) were the last operators to complete the SPC training program. The production data associated with product quality and productivity were collected from November 1986 through February 1987 for the training and comparison group. The data were analyzed during the training and post-training phase of the study. A major finding of the research was that there was a here-to-fore unknown difference in both quality and productivity based on production zone and part size. The training group contained a high percentage of workers from zones that produced large parts and the comparison group consisted of workers from zones that produced small production parts. Based on the results of the study, it was inferred that SPC training for production operators had no effect on product quality and productivity. However, a shift in production performance associated with both product quality and productivity for the training and comparison group was detected during January and February 1987. This shift was related to preventive maintenance, repairs to a major component of the production equipment, and replacement of worn machine parts that took place during the end of year shutdown. Therefore, it was inferred that production zone and maintenance had a greater impact on product quality and productivity than SPC training of the nature utilized in the study.
Degree
Ph.D.
Advisors
Suess, Purdue University.
Subject Area
Educational software|Inservice training|Industrial engineering
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