8 Rules Of

SPC
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 Rejected Zone B is the zone
from one sigma to two
UCL sigma above the
+3σ
Zone A average. Again, there
is a corresponding
Zone B below the
+2σ Zone B average.

Zone C is the zone

closest to the
+1σ Zone C average. It represents
X-Bar the area from the
(Mean) average to one sigma
above the
-1σ Zone C average. There is a
-2σ corresponding zone C
below the average.

Zone B
Zone A is the zone
from two sigma to
-3σ Zone A three sigma above
LCL the average – as well

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Rejected as below the
average.
 Rule Rule Pattern
Name
1 Beyond One or more points beyond the control limits
Limits
2 Zone A 2 out of 3 consecutive points in Zone A or beyond
3 Zone B 4 out of 5 consecutive points in Zone B or beyond
4 Zone C 6 or more consecutive points on one side of the average (in
Zone C or beyond)
5 Trend 6 or more consecutive points trending up or trending down
6 Mixture 6 or more consecutive points with no points in Zone C
7 Stratification 15 consecutive points in Zone C
8 Over- 14 consecutive points alternating up and down
control

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8 Critical Patterns in SPC
Rule -1
Rule -3
Rule -7 Rule -8

Rule -5

Rule -4 Rule -6

Rule -2
 Rule 1 – One point beyond the 3 σ control limit

If one point beyond the 3 σ control limits, seeks to identify points

that are random or outliers, as shown here in red. When random or
outlier points are identified, the following are potential special
causes to consider:
Equipment, Machines, and Tooling
improper start-up
improper setup
sudden support system failure (cooling, heating, compressed air, vacuum,
steam, etc.)
tool failure/breakage
equipment or machine failure
improper equipment, machine, and tooling maintenance
utility interruption
Environment
temperature suddenly too low/high
humidity suddenly too low/high
 Rule 1 – One point beyond the 3 σ control limit
Process
equipment has not stabilized (warmed-up)
inadequate work instructions
missed process step
new process
Inspection
inspection, measuring, and testing equipment not properly calibrated
damaged inspection, measuring, and testing equipment
Materials
change in raw materials
change in components
handling damage
expired materials
Operator
new operators
inadequate training
operator interrupted or distracted
operator overcompensating when making process adjustments
 Rule 2 – Two out of three points in zone A

If two out of three points in zone A, is considered a large shift.

(the shift can be on either side of the centerline). The points
circled in red are considered large shifts. When a large shift is
identified, the following are potential special causes to consider:

Equipment, Machines, and Tooling

improper setup

support system failure (cooling, heating, compressed air, vacuum, steam, etc.)

improper equipment, machine, and tooling maintenance

Environment
temperature suddenly too low/high
humidity suddenly too low/high
 Rule 2 – Two out of three points in zone A
Process
new process parameters
incorrect process parameters
process has degraded
Inspection
inspection, measuring, and testing equipment not properly calibrated
inspection, measuring, and testing equipment not adequate for the
intended use
damaged inspection, measuring, and testing equipment
Materials
mixed raw materials
mixed components
Operator
new operators
inadequate training
operator interrupted or distracted
shift change
 Rule 3 – Four out of five points in zone B or beyond

Rule 3, four out of five points in zone B or beyond, is considered a

small shift (the shift can be on either side of the centerline). The
points circled in red are considered small shifts. When a small shift is
identified, the following are potential special causes to consider:

Equipment, Machines, and Tooling

improper setup
intermittent support system failure (cooling, heating, compressed air,
vacuum, steam, etc.)
improper equipment, machine, and tooling maintenance

Environment
temperature suddenly too low/high
humidity suddenly too low/high
 Rule 3 – Four out of five points in zone B or beyond

Process
new process parameters
incorrect process parameters
process has improved
process has degraded
Inspection
inspection, measuring, and testing equipment not properly calibrated
inspection, measuring, and testing equipment not adequate for the intended use
damaged inspection, measuring, and testing equipment
Materials
mixed raw materials
mixed components
Operator
new operators
inadequate training
operator interrupted or distracted
shift change
 Rule 4 – Six or more points on one side of the centerline without crossing
If six or more points on one side of the centerline without crossing, is
considered a prominent shift (the shift can be on either side of the
centerline). The points circled in red are considered a prominent shift.
When a prominent shift is identified, the following are potential special
causes to consider:

Equipment, Machines, and Tooling

improper setup
improper equipment, machine, and tooling maintenance
damaged tooling
tool wear
Environment

temperature shifted too low/high

humidity shifted too low/high

 Rule 4 – Six or more points on one side of the centerline without crossing
Process
new process parameters
incorrect process parameters
process has improved
process has degraded
Inspection
inspection, measuring, and testing equipment not properly calibrated
damaged inspection, measuring, and testing equipment
Materials
change in raw materials
change in components
expired materials
Operator
new operators
inadequate training
operator interrupted or distracted
shift change
 Rule 5 – Six points or more in a row steadily increasing or decreasing

If six points or more in a row steadily increasing or decreasing, is

considered a trend (the trend can be rising or falling). The points
circled in red are considered a trend. When a trend is identified,
the following are potential special causes to consider:

Equipment, Machines, and Tooling

gradual support system failure (cooling, heating, compressed
air, vacuum, steam, etc.)
tool wear
Environment

temperature gradually drifting too low/high

humidity gradually drifting too low/high

 Rule 5 – Six points or more in a row steadily increasing or decreasing

Process
process is slowly degrading

Inspection
inspection, measuring, and testing equipment not adequate for
the intended use
damaged inspection, measuring, and testing equipment
Materials
variation in the raw materials
variation in the components

Operator
operator distracted
 Rule 6 – 6 or more consecutive points with no points in Zone C

The Statistical Process Control (SPC) rule you're referring to is

often associated with control charts and is related to the presence
of consecutive data points outside Zone C. This rule helps identify
potential patterns or trends in the data that may indicate special
cause variation in the process.

Interpretation:

Indicates a potential shift in the process mean.

The process is not fluctuating within a normal range.
The process is exhibiting a sustained shift rather than random variability.
The process has undergone a significant shift.
This could be due to changes in equipment, materials, operating procedures, or other
factors influencing the process.
 Rule 7 – 15 consecutive points in Zone C

When you observe fifteen consecutive points falling within Zone

C on a control chart, it suggests that the process is exhibiting
stability. Zone C is typically the region within the control chart
that is close to the center line and signifies that the process is in
statistical control.
Equipment, Machines, and Tooling:
Check if there have been any recent changes or maintenance activities related to
equipment, machines, or tooling.
Stability in Zone C may indicate that these elements are performing consistently.

Environment:
Assess whether any changes in the environment, such as temperature, humidity,
or other external factors, might be influencing the process.
 Rule 7 – 15 consecutive points in Zone C
Process:
Examine the overall process for changes or improvements.
If the process has been modified, it could explain the observed
stability in Zone C.
Inspection:
Review the inspection procedures and criteria.
Consistency in inspection methods may contribute to the stability observed in
the control chart.

Materials:
Analyze the materials used in the process.
Consistency in material quality and characteristics may contribute to the
stability of the process.

Operator:
Evaluate the role of operators in the process.
If there have been changes in personnel, training, or standard operating
procedures, it could impact process stability.
 Rule 8 – 14 points in a row alternating up and down

If 14 points in a row alternating up and down, is generally

considered to be over control. The points enclosed in red are
considered out of control. When this situation is identified, the
following are potential special causes to consider:

Equipment, Machines, and Tooling

improper setup
intermittent support system failure (cooling, heating, compressed air,
vacuum, steam, etc.)
improper equipment, machine, and tooling maintenance

Environment
temperature intermittently too low/high
humidity intermittently too low/high
 Rule 8 – 14 points in a row alternating up and down

Process
equipment has not stabilized (warmed-up)
new process parameters
incorrect process parameters
inadequate work instructions
missed process step
new process
Inspection
inspection, measuring, and testing equipment not adequate for the intended use
damaged inspection, measuring, and testing equipment
Materials
mixed raw materials
mixed components
Operator
new operators
inadequate training
operator overcompensating when making process adjustments
operator not waiting for the process to stabilize before making process
adjustments
 Pattern Description Rules
Large shifts from the average 1, 2
Small shifts from the average 3, 4
Trends 5
Mixtures 6
Stratifications 7
Over-control 8
 Rules Pattern Description Possible Causes

New person doing the job

Wrong setup
Measurement error
1 and 2 Large shifts from the average Process step skipped
Process step not completed
Power failure
Equipment breakdown

Raw material change

Change in work instruction
Different measurement device/calibration
3 and 4 Small shifts from the average
Different shift
Person gains greater skills in doing the job
Change in maintenance program
Change in setup procedure

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 Rules Pattern Description Possible Causes

Tooling wear
5 Trend
Temperature effects (cooling, heating)

More than one process present (such as.

6 Mixture
shifts, machines, raw material)

More than one process present (such as,

7 Stratification shifts, machines, raw materials)

8 Over control Tampering by operator

Alternating raw materials

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Implementation steps of
Statistical Process
Control
 Implementing Statistical Process Control
While SPC can help control processes and ensure consistent output, many of China’s factories seldom apply it.
To understand how this tool works, it is best to follow the logical steps in its implementation in a factory:

1. Select critical-to-quality (CTQ) product characteristics

2. Select critical processes

3. Determine if machines can calculate SPC by

themselves
4. Gather data and process knowledge of what impacts
the output of the process
5. Control independent variables that have a sizeable impact
on the process output

6. Look for ways to reduce variation

7. Keep it up in the long term

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