Engineering, Technology & Applied Science Research Vol. 9, No.

6, 2019, 5062-5065 5062

Controlling the Defects of Paint Shop using Seven

Quality Control Tools in an Automotive Factory

Imdad Ali Memon Ahmed Ali Munawar Ayaz Memon

Department of Mechanical Engineering Department of Electrical Engineering Department of Electrical Engineering
Quaid-e-Awam University of Sukkur IBA University Quaid-e-Awam University of
Engineering, Science & Technology Sukkur, Pakistan Engineering, Science & Technology
Nawabshah, Pakistan ahmed.shah@iba-suk.edu.pk Nawabshah, Pakistan
engineerimdad@yahoo.com engr.mam@gmail.com

Umair Ahmed Rajput Saeed Ahmed Khan Abro Ahsan Ali Memon
Department of Mechanical Engineering Department of Electrical Engineering Department of Mechanical Engineering
Quaid-e-Awam University of Sukkur IBA University Quaid-e-Awam University of
Engineering, Science & Technology Sukkur, Pakistan Engineering, Science & Technology
Nawabshah, Pakistan saeed.abro@iba-suk.edu.pk Nawabshah, Pakistan
engr.umair@quest.edu.pk 15el06@quest.edu.pk

Abstract—Seven quality control (7QC) tools are used for many industries [8]. Many studies focused on these tools which
reducing defects during manufacturing. These tools are highly were found very effective regarding problem solving in many
effective in productivity and quality improvement. In this case, industries. A comparative study was conducted between them
the study of the 7QC tools was applied in an automotive factory and the new 7QC tools [8]. It has been reported that there are
in order to reduce paint shop defects. Within four months the more than two SPC techniques, namely the Ishikawa diagram
production line was inspected, defects were categorized and the (cause and effect diagram) and the SPC control charts which
7QC tools were successfully applied, reducing the overall defect were also applied in automotive industry. The study in [9]
rate by 70%. Although every tool was important, the cause and focused on the defects in shocker seals of the automotive
effect diagram was responsible for finding the root causes of the industry. The rejection level was reduced from 9.1% to 5% and
defects.
95% process capability was achieved. The control chart alone
Keywords-defects reduction; productivity improvement; paint was applied to automotive components and monitored process
shop; 7QC tools capability. It was reported that the defect level has been
reduced using a data acquisition system. The automated
I. INTRODUCTION inspection method was adopted and offline SPC method was
The Seven Quality Control (7QC) tools are highly useful converted into the online method in [10]. In many companies,
for improving productivity, resolving problems in the quality more complex quality tools were used, but they were not highly
operational process and delivery [1, 2]. The 7QC tools are effective and also they were not able to examine defects at a
applied for improving the performance of the production proper level [11].
processes, solving problems at any stage [3, 4]. Solving In today’s challenging environment, every organization
problems by the 7QC tools reduces cost, while they cannot be should apply proper productivity improvement tools. This
replaced by any other complex decision-making support system paper presents a case study of the application of the 7QC tools
[5]. The level of defects or problems in the product is in an automotive factory. Initially, the factory used partially
associated with the process conditions. If the process is under some of the tools without getting fruitful results. A goal to
control limit then the product is useful, while when the process apply all the 7QC tools and understand their implementation
is out of control the product has demerits resulting to rejection, mechanism was set, focusing on the identification and
rework or scrap [6]. These problem solving tools are directly reduction of the defects occurring in the paint shop. An
beneficial for customers too, as quality products entail the vast inspection point of the paint shop was used in order to collect,
reduction of defects, while this process reduces cost. Improving assess and analyze data.
the quality of the product is very important for any company
and its endurance in the market. The 7QC tools can be used in II. RELATED WORK
the production processing line ensuring the reduction of defects The 7QC tools are applicable to any kind of industry
while suggesting improvements [7]. Statistical Process Control regardless of size and capacity [11, 12]. These techniques (flow
(SPC) tools used to hold the position of 7QC tools. These tools chart, Pareto diagram, check sheet, control chart, histogram,
have played an important role in the reduction of variations in
Corresponding author: Imdad Ali Memon
www.etasr.com Memon et al.: Controlling the Defects of Paint Shop using Seven Quality Control Tools in an …
 Engineering, Technology & Applied Science Research Vol. 9, No. 6, 2019, 5062-5065 5063

scatter plot, cause-and-effect diagram) aim to control quality • Histograms (QC tool 3): Histograms were created using
parameters such as methods, machine, equipment, and Excel. The histograms display variation levels and process
products. Hence, these tools reduce the loss and give more capability. Occurrence frequency of each defect was
profit [13]. In [7], the 7QC tools were used for reducing the displayed in a monthly histogram between November 2015
rejection of shift fork. The total rejection was reduced from to February 2016, as shown in Figure 1.
16.66% to 0.65%, saving Rs 303.000 per year. In [14] the cost
impact of the application of real time SPC in hardwood
sawmills was investigated. In [15], some of the basic statistical
tools were selected, such as Pareto diagram, control chart and
histogram, studying their impact on the overall process
performance, cost and product quality. In [16], the importance
of the 7QC tools was examined, showing a continuous quality
improvement process in an automotive industry, while in [17]
those tools were used for productivity improvement. Many
companies adopted SPC tools and continued the
implementation of process control in manufacturing industries.
These techniques fulfill the customer requirements for high-
quality products at low price. Manufacturing firms use SPC to
analyze their impact, isolate problems, monitor the outcome
and process parameters for achieving quality goals [18, 19].
Moreover, the SPC process can enhance problem solving and Fig. 1. Histogram for paint shop defects
performance [9, 20].
• Pareto diagrams (QC tool 4): A Pareto diagram shows the
Paint is a dispersion of pigments. It is used as filler in a defects in descending order of occurrences. The Pareto
fluid vehicle. The fluid vehicle includes a liquid binder that diagram is also monitoring the defects cumulative
was solidified during cure. It has the capability to serve as a frequency level occurrences on its secondary axis. The red
liquid carrier, viscosity reducing aid, and also provide healthy trend line shows the defect cumulative percentage level.
application distinctive [21]. Drying oil, volatile thinner, and Defects occurring at a high level should be given priority.
paint have been developed by mixing, grinding, thinning, The Pareto diagrams are displayed in Figure 2.
straining operations [22]
III. MATERIALS AND METHODS
Data collection started from the assessment of the
automotive factory, through frequent visits. After visual
inspection, defects were categorized in four types: dust,
floatation, scratch, and improper paint. Then, defects having a
direct impact on the car body were focused. Therefore, a check
sheet was developed for finding the root cause of paint defects,
applying the cause and effect diagram technique. This
technique is very useful for the reduction of body section
defects [23, 24]. Data were collected through the check sheet
for four months, using the same pattern. These data can be
simulated, as reported in [25].
IV. RESULTS ΑND DISCUSSION
A. Application of the 7QC Tools
• Flow chart (QC Tool 1): It was developed for collecting
data from the paint shop. The defects observed at paint shop
Fig. 2. Pareto charts of paint shop defects for (a) Nov-15, (b) Dec-15,
are of four types: scratch, dust, improper paint and (c) Jan-16 and (d) Feb-16
floatation.
• Check sheets (QC tool 2): After identifying the defects, the • Cause and effect diagram (QC Tool 5): The cause and
next step is data collection. The check sheets were effect diagram helps in discovering the root causes of the
developed for collecting defect data for further analysis, problem. This tool can point out the defects and their
and were designed focusing on attributted data, providing reasons. The preliminary data collected through check
simple checkmarks, where check inspectors marked defect sheets showed a high frequency of defects in November and
occurences. The check sheets mentioned different types of December 2015. Cause and effect diagrams were developed
defects in the paint shop. Data were collected from and applied in the paint shop. Using check sheets the data
November 2015 to February 2016. were collected for January 2016 and February 2016,

www.etasr.com Memon et al.: Controlling the Defects of Paint Shop using Seven Quality Control Tools in an …
 Engineering, Technology & Applied Science Research Vol. 9, No. 6, 2019, 5062-5065 5064

showing considerable reduction in paint defects, due to paint shop. 122 defects occurred during the first month and 155
control on root causes as pointed out in Figure 3. occurred during the second. After using the 7QC tools the
defects were reduced to 83 during the third month and to 47
• Scatter diagram (QC tool 6): This tool was used for the during the fourth.
study and evaluation of the impact of each parameter to
another. Fig. 4 shows the scatter diagram of the paint shop.
This diagram shows time in weeks and the number of
defective bodies. In the first eight weeks, the defect rate
was too high, while after finding the root cause of defects
through cause and effect diagram, it was observed that the
occurrence rate of defective bodies was reduced.

Fig. 5. NP control chart

Fig. 3. Cause and effect diagram for paint shop of: (a) improper paint,
(b) floatation, (c) scratch, and (d) dust

Fig. 6. Reduction of defects after the application of the 7QC tools

V. CONCLUSION
This research investigated the application of the 7QC tools for
the reduction of defects it an automotive factory. The initial
flow chart was developed and check sheets were designed for
data collection on inspection points. It was observed that the
highest frequency defects were seen in November and
December, 2015. After using the cause and effect diagram, the
defects reduced substantially. During the fourth month
(February 2016) total defects reduced by 70%, comparing to
the first month, from 155 to 47. Every tool played an important
Fig. 4. Scatter diagram role in the defect reduction, but the cause and effect diagram
was very useful for finding the cause and its effect. The main
• p-chart (QC tool 7): The p-chart was based on the number contribution of this study is to highlight all the possible defects
of paint defect occurrences using binominal distribution. or errors affecting production in manufacturing industries.
The process, running either in statistical control or not, can
be pointed by the P-chart. It also pointed out that the REFERENCES
changes occurred in the defective items when process [1] J. C. Benneyan, “The design, selection, and performance of statistical
measurement took place. control charts for healthcare process improvement”. International
Journal of Six Sigma and Competitive Advantage, Vol. 4, No. 3, p. 209-
B. Overall Defect Reduction 239, 2008
Figure 5 shows the NP control chart for the paint shop, [2] P. Kuendee, “Application of 7 quality control (7 QC) tools for quality
where the blue line shows the defect rate, the green line shows management: A case study of a liquid chemical warehousing”, 4th
the upper control limit, the red line shows the center and the International Conference on Industrial Engineering and Applications,
Nagoya, Japan, April 21-23, 2017
purple line shows the lower control limit. Nine weeks after the
[3] H. Hailu, H. Tabuchi, H. Ezawa, K. Jilcha, “Reduction of excessive
implementation of the 7QC tools, the defections were trimming and reject leather by integration of 7 QC tools and QC story
drastically reduced. Figure 6 shows the impact on the defect formula: The case report of Sheba Leather PLC”, Industrial Engineering
rate before and after the implementation of 7QC tools in the & Management, Vol. 6, No. 3, 2017

www.etasr.com Memon et al.: Controlling the Defects of Paint Shop using Seven Quality Control Tools in an …
 Engineering, Technology & Applied Science Research Vol. 9, No. 6, 2019, 5062-5065 5065
[4] B. Neyestani, “Seven basic tools of quality control: The appropriate Technology and Applied Science Research, Vol. 9, No. 2, pp. 4044–
techniques for solving quality problems in the organizations”, SSRN, 4047, 2019
available at: https://zenodo.org/record/400832#.XdPBdJMzaUl, 2017 [25] M. L. Chew Hernandez, L. Viveros Rosas, R. F. Retes Mantilla, G.
[5] N. Visveshwar, V. Vishal, V. Venkatesh, R. V. Samsingh, P. Karthik, Espinosa Martínez, V. Velazquez Romero, “Supply chain cooperation
“Application of quality tools in a plastic based production industry to by agreed reduction of behavior variability: a simulation-based study”,
achieve the continuous improvement cycle”, Calitatea, Vol. 18, No. 157, Engineering, Technology and Applied Science Research, Vol. 7, No. 2,
pp. 61-64, 2017 pp. 1546–1551, 2016
[6] P. S. Parmar, T. N. Desai, “Reduction of rework cost in manufacturing
industry using statistical process control techniques: a case study”,
Industrial Engineering Journal, Vol. 10, No. 6, pp. 40-46, 2017
[7] A. Jaware, K. Bhandare, G. Sonawane, S. Bhagat, R. Ralebhat,
“Reduction of machining rejection of shift fork by using seven quality
tools”, International Journal of Engineering and Technology, Vol. 5, No.
4, pp. 4323-4334, 2018
[8] S. M. Ahmed, R. T. Aoieong, S. L. Tang, D. X. Zheng, “A comparison
of quality management systems in the construction industries of Hong
Kong and the USA”, International Journal of Quality & Reliability
Management, Vol. 22, No. 2, pp. 149–161, 2005
[9] D. R. Prajapati, “Implementation of SPC techniques in automotive
industry : a case study”, International Journal of Emerging Technology
and Advanced Engineering, Vol. 2, No. 3, pp. 227-241, 2012
[10] T. V. U. K. Kumar, “SPC tools in automobile component to analyze
inspection process”, Vol. 2, No. 1, pp. 624–630, 2013
[11] C. Fotopoulos, E. Psomas, “The use of quality management tools and
techniques in ISO 9001:2000 certified companies: The Greek case”,
International Journal of Productivity and Performance Management,
Vol. 58, No. 6, pp. 564–580, 2009
[12] R. H. Fouad, A. Mukattash, “Statistical process control tools : a practical
guide for Jordanian Industrial Organizations”, Vol. 4, No. 6, pp. 693–
700, 2010
[13] R. Srinivasu, G. S. Reddy, S. R. Rikkula, “Utility of quality control tools
and statistical process control to improve the productivity and quality in
an industry”, International Journal of Reviews in Computing, Vol. 5, pp.
15-20, 2011
[14] T. M. Young, B. H. Bond, J. Wiedenbeck, “Implementation of a real-
time statistical process control system in hardwood sawmills”, Forest
Products Journal, Vol. 57, No. 9, pp. 54–62, 2007
[15] N. Afzaal, A. Aftab, S. Khan, M. Najamuddin, “To analyze the use of
statistical tools for cost effectiveness and quality of products”, IOSR
Journal of Humanities and Social Science, Vol. 20, No. 1, pp. 47–57,
2015
[16] G. Paliska, D. Pavletic, M. Sokovic, “Quality tools: systematic use in
process industry”, Journal of Achievements in Materials and
Manufacturing Engineering, Vol. 25, No. 1, pp. 79–82, 2007
[17] M. Sokovic, J. Jovanovic, J. Krivokapic, A. Vujovic, “Basic quality
tools in continuous improvement process”, Journal of Mechanical
Engineering, Vol. 55, No. 5 pp. 333-341, 2009
[18] G. Patidar, D. D. S. Verma, “Implimantation of statistical process
control in small scale industries- a review”, International Journal of
Technologies and Engineering, Vol. 2, No. 7, pp. 121-124, 2015
[19] V. Parkash, D. Kumar, R. Rajoria, “Statistical process control”,
International Journal of Research in Engineering and Technology, Vol.
2, No. 8, pp. 70–72, 2013
[20] P. S. Parmar, V. A. Deshpande, “Implementation of statistical process
control techniques in industry : a review”, Journal of Emerging
Technologies and Innovative Research, Vol. 1, No. 6, pp. 583–587, 2014
[21] J. V. Koleske, “Mechanical properties of solid coatings”, in:
Encyclopedia of Analytical Chemistry: Applications, Theory and
Instrumentation, John Wiley and Sons, 2006
[22] A. E. Bryson, The control of quality in the manufacture of paint, PhD
Thesis, Masachusetts Institute of Technology, 1950
[23] P. Bhangale, R. Dhake, G. Gambhire, “Reduction in defects of car body
panel using 7QC tools approach”, National Conference on Modelling,
Optimization and Control, Pune, India, March 4-6, 2015
[24] I. A. Memon, Q. B. Jamali, A. S. Jamali, M. K. Abbasi, N. A. Jamali, Z.
H. Jamali, “Defect reduction with the use of seven quality control tools
for productivity improvement at an automobile company”, Engineering,

www.etasr.com Memon et al.: Controlling the Defects of Paint Shop using Seven Quality Control Tools in an …