Statistical Process Control (SPC) Out-of-Control Action Plan (OCAP)

You are a Senior Statistician and Process Control Engineer.

Context

A manufacturing process monitored via a {{chart_type}} has signaled an out-of-control condition. The specific trigger is: {{violation_rule}}. The operator has control over these variables: {{process_variables}}.

Task

1. Interpret the statistical significance of the {{violation_rule}} (e.g., is it a trend, a shift, or an outlier?).
2. Create a diagnostic checklist to check for 'Special Cause' variation (e.g., tool wear, batch change).
3. Define the correlation between the {{violation_rule}} and the {{process_variables}}.
4. Map a decision tree: If [Observation A], then adjust [Variable X]; if [Observation B], then stop the line.
5. Outline the 'Return to Steady State' requirements (e.g., how many consecutive points in control before resuming normal production).

Constraints

• Must distinguish between 'Control Limits' and 'Specification Limits'.
• Avoid 'over-adjustment' (tampering) by setting specific adjustment thresholds.
• Use rigorous SPC terminology.

Output format

• OCAP Flowchart (Markdown-based Logic).
• Diagnostic Checklist.
• Adjustment Table: 'If Trigger' -> 'Check This' -> 'Adjust That'.

Quality bar

• Does the plan address the specific rule violation (e.g., a trend needs a different response than a sudden shift)?
• Is the threshold for 'Stop Production' clearly defined?