Laboratories & science · Case study

A control chart is only useful when the observations are truly comparable.

Governed observation populations, limits and rules turned charts into traceable quality decisions.

Case study context

The project and the problem

The laboratory wanted statistical process control to distinguish routine variation from isolated quality events and gradual drift. Drawing a chart was not the difficult part: measurements sharing a parameter name could come from different processes, materials, instruments or methods and therefore be scientifically incomparable. Using only today's control limits would also reinterpret historical alerts whenever those limits changed.

How the process worked

The I-MR plan fixed the recipe, chamber, measurement method and approved baseline before evaluation. Every event retained its original limit set, rule set and engine version; reviewers could inspect the supporting observation and open an investigation without recalculating history.

SPC event review

Review the signal. Preserve the evidence.

SPC event review

SPC-017 v4 · ALD witness-coupon thickness

Individuals and moving range · approved plan

Action required · Rule 1EVAL-1048 · Evaluated
Official evaluation

Thickness control history

UCL
53.2
CL
50.1
LCL
47.0
EVT-1048 · Rule 1 · observation window OBS-0020OBS-0031
Individuals chart for EVT-1048 · Rule 1Twelve comparable ALD witness-coupon thickness observations in nanometres. Centre line 50.1, upper control limit 53.2 and lower control limit 47.0. Nelson Rule 1: One point beyond the upper control limit. Selected observation OBS-0031, 54.0 nanometres. An ALD-03 chamber clean is marked between RUN-2505 and RUN-2506.47505355UCLCLLCLALD-03 cleanRule 1 · 54.0 nm000102030405060708091011Thickness (nm)Run sequenceMoving range chart for EVT-1048 · Rule 1Moving ranges derived from consecutive included observations. Centre line 1.17 nanometres and upper control limit 3.81 nanometres.024UCLMRMR (nm)
Observation
OBS-0031
Run
RUN-2511
Witness
S-2197-D
Result
54.0 nm
Measured
Population
POP-017-04
Baseline
BL-2026-02
Limits
LS-04
Rules
NR-02
Engine
SPC-EVAL 2.3
Evaluation
EVAL-1048

Operating constraints

  • Comparable populations
  • Frozen evaluation versions
  • Control-limit provenance
  • Investigation evidence

What changed

  • Faster signal review
  • Reproducible evaluations
  • Point-to-source evidence
  • Quality decisions preserved

Evidence retained: Each signal retained its observation, population definition, control limits, rule set and evaluation version.

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