About the Book
Many businesses use Statistical Process Control (SPC) techniques. Yet few actually benefit from it. Ineffective programs create frustration, excessive alarms, endless adjustments, and ultimately deliver little more than "SPC for Show." Beyond Compliance explains why this happens - and more importantly, how to fix it. Steven F. Bergeron presents a practical, proven roadmap for transforming SPC into a powerful engine that will improve business performance. This is not another textbook on SPC theory. It is a field-tested guide for implementing, qualifying, auditing, and sustaining SPC systems that actually work in real production environments.
What makes this book different? Most SPC failures are not caused by bad statistics - they are caused by how SPC is setup in manufacturing. This book addresses the root causes others ignore, including:
- Incorrect control limits based on correlated sample data
- Control charts that monitor production lots instead of process runs
- Competing priorities between product control and process control
- Ineffective OCAPs that rely on adjustments instead of investigations
- And more...
You will learn how to:
- Correctly set up control limits using the innovative Effective Sample Size method
- Separate Product CTQs from Process CTQs to eliminate competing priorities
- Define OCAPs that drive root-cause removal-not yield-killing adjustments
- Combine equivalent equipment on common control charts
- And more...
Throughout the book, real-world case studies illustrate how organizations moved from unstable, compliance-driven SPC programs to measurable improvements in yield, reliability, cost, and customer satisfaction.
Who this book is for
- Process, Quality, and Manufacturing Engineers
- SPC Chart Owners and Implementors
- Quality Assurance, Control, Auditors and Supplier Quality Engineers
- Operations and Plant Managers
- Leaders responsible for ISO 9001, IATF 16949, AS9100, and customer compliance
- Organizations serious about operational excellence-not just passing audits
The promise of Effective SPC are stable processes that reduce scrap, rework, firefighting, and warranty exposure. When SPC is implemented correctly, it becomes a competitive advantage-not a burden. Beyond Compliance provides the tools, mindset, and proven methods to make that transformation real - and lasting.
If you are ready to move from SPC for Show to SPC for Improvement, this book will show you how.
About the Author :
Steven F. Bergeron has more than 45 years of experience advancing quality, reliability, and operational excellence across a wide range of industries. He began his career at IBM Corporation and Motorola, Inc., where he pioneered the application of advanced experimental design and Statistical Process Control (SPC) as a Process Engineer and Process Engineering Manager. His ability to translate complex technical concepts into practical, results-oriented solutions led him into senior leadership roles throughout his career.Mr. Bergeron served as a Quality Executive, holding Director, Vice President, and Senior Vice President positions, at organizations including Digital Equipment Corporation, Unitrode Corporation, Semtech Corporation, Conexant Systems, Inc., STEC, Inc., Pall Corporation, and Cree, Inc. As the Chief Quality Officer, he held enterprise-wide responsibility for Quality Assurance, Quality Control, Reliability Assurance, Supplier Quality Management, Failure Analysis, Customer Complaint Management, and Chemical Compliance Management.Driven by scientific curiosity and disciplined problem-solving, Mr. Bergeron's professional approach is rooted in a strong academic foundation. He holds a Bachelor of Science in Chemistry from Georgetown University and a Master's degree in Chemistry from the University of California, Santa Barbara. He further strengthened his executive leadership capabilities through the AEA Stanford Executive Institute.During his career, the American Society for Quality (ASQ) certified Mr. Bergeron as both a Quality Engineer and later as a Quality Manager. OMNEX recognized his proficiency in key automotive disciplines, including APQP, PPAP, DMEA, DVP&R, and VDA6.3 process auditing. Reliasoft certified his expertise in Accelerated Life Testing Analysis and Reliability Engineering & Life Data Analysis. Motorola University awarded him a Six Sigma Black Belt, while Pall Corporation qualified him as a Lead Facilitator in Lean Manufacturing. Additionally, he held auditor certifications for leading QMS standards such as ISO 9001, IATF 16949, and AS 9100 from multiple organizations. His contributions have been recognized by Who's Who in Quality, and he served as an editorial advisor for selected articles in The Quality Observer. He was also twice appointed by the U.S. Department of Commerce as a Malcolm Baldrige National Quality Award Examiner.After more than three decades as a Quality and Reliability Assurance Executive, Mr. Bergeron founded QLRFocus, LLC (Quality, Lean, and Reliability Focus) to support startups, small enterprises, and global corporations in achieving sustainable operational excellence. His consulting work spans multiple sectors and emphasizes effective standards compliance, process improvement, quality management systems, supplier management, customer complaint management, and data-driven reliability engineering and, of course, SPC implementation.Widely regarded by colleagues as an expert in the assessment, design, and application of Statistical Process Control, Mr. Bergeron is known for his direct, pragmatic approach to implementation, mentorship, and organizational transformation. His extensive experience leading successful SPC initiatives across diverse industries ultimately motivated him to author this book-sharing not only how to implement SPC correctly, but how to embed it as a lasting system that drives measurable business results.
