SPC implementation for improving product quality

Process Quality is one of the key factors and early indicators that impacts outgoing duality and removal rates of the product (system or component). During the last five years, Lucent Technologies in Dallas (formerly AT&T Power Systems) has placed great emphasis on improving process quality by properly implementing Statistical Process Control (SPC). In 1990, AT&T Power Systems started their journey of implementing Total Quality Management (TQM) and challenging for the most prestigious duality award, the Deming Prize. A robust SPC program is a key requirement of the Deming Prize. As a result of the successful implementation of TQM and SPC, AT&T Power Systems was the first United States manufacturing company (and the second US company) to win the Deming Prize. During the examination process for the Deming Prize, an intense emphasis is placed on auditing the systems and processes in place to improve the product quality. Specifically, the effective implementation of SPC is a fundamental element of the examination process. SPC implementation included: a well structured and documented SPC plan; a comprehensive SPC training program for engineers, managers, and production employees; a team approach; and senior management involvement and reviews. The key elements of the SPC Plan are: product/process quality metrics, process control, process improvement, and capability indices improvement. This paper presents the details of this plan and resulting improvements in the product quality. The SPC implementation and product quality improvement exceeded the expectations of the JUSE (Japanese Union of Scientist and Engineers) examiners. Currently, Lucent Technologies (formerly AT&T Power Systems) is viewed as a world leader in quality and TQM.