The simplest reliable way of achieving this is by Control Charts.

It is neither necessary, nor beneficial to control every input with this rigour.

I can help with the selection of the most important – and also which should be monitored ‘in case of the unexpected’.

The figure below shows a basic Control Chart (also known as an “I-Chart”).

The most frequent – and possibly important – “Special cause” is shown.  Although these are “one-offs” they need investigation and understanding.

There are several other definable Special Causes which can help us to stop a problem before it occurs by identifying the trend that is leading towards non-conformance.

Once the Key Process Variables have been identified and charted, Reaction Plans can be created to ensure the correct action is taken for every Special Cause encountered.

This all fits into the Control Plan (see Process Design), and also feeds the continual up-dating of the PFMEA.

Electroplating-assiastance.co.uk can help establish all of these documents and procedures