Table of Contents
SPC Analytics
Pareto charts, compliance trend p-charts, XmR control charts, and numeric item deep dives -- all powered by your daily check data.
Open 5S SystemWhat Are 5S Analytics?
SPC (Statistical Process Control) analytics transform your daily operator checks into actionable visual insights. The analytics page applies proven statistical methods to your 5S checklist data.
- Three chart types: Pareto, p-chart (compliance trend), and XmR (score trend)
- Numeric items get their own XmR chart with spec limit overlay
- Powered by data from all operator submissions over time
- Helps identify patterns, prioritize improvements, and demonstrate 5S program impact
Before You Start
Analytics become more meaningful with more data. Here is what to expect:
- You need at least 2-4 weeks of daily submissions for meaningful trends
- Pareto analysis is useful even with 1 week of data
- Control chart limits (XmR) stabilize after approximately 20 data points
1 Access the Analytics Page
From the system dashboard, click "Analytics" to open the analytics page. The page shows all areas combined by default.
- Click "Analytics" in the system navigation to open the analytics dashboard
- Use the area filter to focus on a specific area or keep "All Areas" for a combined view
Click to view screenshot
2 Pareto Analysis (Which Items Fail Most?)
Pareto analysis shows which checklist items, areas, or pillars contribute the most failures. Use the toggle to switch between views.
- Item Failure Pareto
- Bar chart of checklist items sorted by failure count, with a cumulative percentage line. Shows which specific items fail most often.
- Area Failure Pareto
- Which areas in your plant have the most failures? Helps prioritize improvement efforts by location.
- Pillar Failure Pareto
- Which S-pillars (Sort, Set in Order, Shine, Standardize, Sustain) have the most failures across all areas?
The 80/20 rule applies: typically 20% of items cause 80% of failures. Focus on the tallest bars first.
Click to view screenshot
3 Compliance Trend (p-Chart)
The p-chart shows the non-compliance rate over time (daily or weekly grouping). Control limits are calculated automatically to indicate when performance deviates significantly from normal.
- The center line shows the average non-compliance rate
- Points above the upper control limit (UCL) indicate special causes worth investigating
- Toggle between daily and weekly grouping using the chart controls
Click to view screenshot
4 Area Score Trend (XmR Chart)
The XmR chart shows the overall 5S score over time for a selected area. It uses Individual and Moving Range calculations to establish natural process limits.
- Downward trends or points below the lower control limit signal degradation in 5S discipline
- A stable chart near 90% or above means your 5S discipline is strong
Click to view screenshot
5 Numeric Item Deep Dive
For items with a Numeric response type (temperature, pressure, dimensions), a dedicated XmR chart tracks individual measurements with spec limit overlay.
- Dedicated XmR chart for each numeric item's individual measurements
- Spec limit overlay (LSL/USL) from the item's configured min and max values
- AI coaching integration for out-of-control pattern detection
- Click any Numeric item from the analytics page to navigate to its deep dive
Click to view screenshot
How to Interpret the Charts
Understanding chart elements helps you take the right action from the data.
Pareto Charts
Bars show count or frequency of failures; the cumulative line shows the running total percentage. Focus on items that contribute to the first 80% of failures for maximum impact.
p-Chart (Compliance Trend)
The center line is the average non-compliance rate. UCL and LCL represent the expected range of variation. Points outside these limits indicate special causes worth investigating. Trends of 7 or more consecutive rising or falling points signal systematic change.
XmR Chart (Score Trend)
The center line is the average score. Upper and lower natural process limits show what the process is actually doing. Trends of 7 or more consecutive points in one direction signal systematic change requiring investigation.
Spec Limits vs. Control Limits
Spec limits (for Numeric items) define what the process SHOULD be. Control limits define what the process IS DOING. A process can be within spec but out of control (capable but unstable), or in control but out of spec (stable but not capable). Both dimensions matter for improvement.
Tips & Best Practices
- Check analytics weekly as part of your Quality Manager routine.
- Use Pareto to prioritize improvement projects -- fix the top failing items first.
- Share p-chart trends with plant management to demonstrate 5S program impact over time.
- Compare areas: if one area scores 95% and another 65%, investigate the gap.
- Use AI coaching on numeric items for automatic out-of-control pattern detection.