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ProCalc Toolset Suite

Quality & process engineering tools

Practitioner-built workflows from problem definition through verification. Each tool includes step-by-step guidance — demo any tool free for 5 minutes, then license the full suite for your team.

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Problem Solving Toolbox

Master workflow from problem definition through measurement, confirmation, analysis, documentation, and verification — follow the stages in order for structured investigations.

1. Define the problem & quantify impact

Clearly define the problem and quantify its impact so resources are directed to the right project.

5W 2H / Quality Alert Builder

Define the problem with 5W2H fields, build a recommended description, and publish a printable quality alert with photos, training sign-off, and operator instructions.

COPQ Estimator

Helps quantify the impact of the problem and is instrumental in project selection — scrap, rework, warranty, and appraisal dollars.

Quality Issue Mapping And Convergence Plan

Map quality issues into main and sub-buckets, run Pareto at each level, and build a convergence roll-down plan.

2. Explore and narrow focus

Exploratory tools to narrow where the team should investigate — especially for transactional and spatial defects.

Exploration Cascade

Exploratory tool to narrow focus — cascade from error-state through measurement, process, and control splits.

Process Flow Builder

Critical for transactional issues — build process flow charts with drag-and-drop steps and export for team review.

Defect Location Map

Instrumental in determining where to focus within the process — zone defects on a part image and run Pareto by zone.

Fishbone Diagram

Build an Ishikawa 6M fishbone to brainstorm cause branches after the problem is scoped and focus is narrowed.

Stressor & Resistance Model

Overlap stressor and resistance distributions for breakage, leakers, or corrosion — shaded non-conformance tail plus accelerated test planning.

3×5 Why Builder

Critical to drive down to systemic root cause — Specific, Detection, and Systemic Why chains with export for 8D/A3.

3. Measurement system qualification

Confirm variable and attribute measurement systems before trusting the data.

Variable Gage R&R Study

Crossed or nested ANOVA gage study — repeatability, reproducibility, % study variation, tolerance, and ndc.

Attribute MSA Study

Go/no-go gage agreement study: repeatability, reproducibility, and effectiveness percentages with scorecard.

4. Process confirmation

Monitor process behavior with control charts before deeper analysis.

SPC Workbench

Upload CSV/Excel, control limits, and interactive process charts to confirm stable process behavior.

Attribute Control Charts

p, np, u, and c charts for defectives and defects — paste subgroup counts, get limits, and flag out-of-control points.

5. Distribution & failure analysis

Test distributions and model univariate failure or warranty behavior.

Chi-Square Test

Goodness-of-fit and test of independence — observed vs. expected counts with χ² contributions and contingency tables.

Univariate Warranty Prediction Tool

Univariate failure-time modeling by days or mileage — distribution fit, expected failure %, and probability plots.

6. Component isolation & screening

Isolate critical components and screen characteristics across conforming vs. non-conforming units.

Assembly Swap Study

Validate baseline performance delta, then isolate critical components with single pairwise exchanges.

Feature Screening

Screen characteristics for separation between extreme conforming and non-conforming units using Tukey end-count rules.

7. Regression, DOE & hypothesis testing

Model relationships, design experiments, and test hypotheses with structured statistical tools.

Simple Linear Regression

Analyze trends and relationships with scatter plots, fitted lines, R², and prediction intervals.

DOE Tool

Design and analyze experiments efficiently — factorial plans, effects, and optimization.

Multiple Regression Tool

Fit models with multiple predictors — coefficients, VIF, t-tests, and residual diagnostics.

Hypothesis Testing Tool

2-sample T, paired T, and 1-way ANOVA — compare groups with normality checks and automatic test selection.

Sample Size Calculator

Answer “how many parts?” for capability studies, t-tests, and proportion estimates with clear assumptions.

Monte Carlo Study

Simulate factor variation through a regression equation — project DPMO, out-of-spec rate, and output histogram with USL/LSL.

Statistical Chart Builder

Build probability plots, boxplots, histograms, interval plots, and dotplots from a table or CSV.

Scatter Plot with Groups

Plot every measurement across nested factor groups — CSV import, auto layout, and rotate factors for alternate views.

Multi-Vari Chart

Classic multi-vari study — all points, within-cell ranges, mean connectors, CSV template, and factor layout rotation.

8. Document learnings & sustain

Drive to systemic root cause, document learnings in FMEA and control plans, update audits, and close with 8D/A3.

PFMEA / DFMEA Lite

Document all learnings — RPN tables with severity/occurrence/detection scales and action tracking.

Control Plan Builder

Document all learnings — OEM-ready control plans from process steps, characteristics, and reaction plans.

LPA Builder

Add learnings to the audit template — layered process audits with scoring, NC tracking, and weekly workflow.

Special Process Review

Supplier self-assessment for welding, assembly, casting, and other special processes — best practices, checklists, health scoring, and action plans.

8D / A3 Report Builder

Document process and findings — build complete 8D and A3 reports; submit to the customer when needed.

9. Capability & containment verification

Confirm process capability and prove containment or sort effectiveness.

Process Capability Analysis

Capability study — Cp/Cpk/Ppk with histogram and plain-language interpretation from pasted data.

Containment Confirmation Tool

Confirm a sort or containment with exact binomial confidence, or size the sample to prove the reject rate beat a target.