Seven QC Tools


Problem Solving

Quality Improvement: Problem So

lving
Vision without action is merely a dream
Action without vision just passes time
Vision with action can change the world
J.A.Barker

Quality Improvement: Pro

Seven Quality Control Tools
• Pareto Chart
• Process flow diagram
• Cause and Effect Diagram
• Check sheet
• Histogram
• Control chart
• Scatter diagram
Quality Improvement: Pro
Pareto Principle

Vilfredo Pareto (1848-1923) Italian
economist
• 20% of the population has 80% of the
wealth

Juran used the term “vital few, trivial
many”. He noted that 20% of the quality
problems caused 80% of the dollar loss.

7 Quality Tools

Quality Improvement: Pro

Pareto chart
Pareto for Module X Problems
97% 99% 100%
91%
60 52 80% 100%
50 67% 80%
QTY (No.s)

40 31

Cum %
42% 60%
30
16 40%
20 13
7 20%
10 3 1
0 0%

No. of Cases Cum %

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Quality Improvement: Pro

 Grand total %
100 %

How to Construct a Pareto Diagram 80 %

Contributors

1. Total the data on effect of each contributor & sum these to determine grand total.
2. Re order the contributors from largest to the smallest
3. Determine the cumulative percent of total
4. Draw & label the left vertical axis.
5. Draw & label the horizontal axis.
6. Draw & label the right vertical axis.
7. Draw bars to represent the magnitude of each contributor’s effect.
8. Draw a line graph to represent the cumulative percent of total
9. Analyze the diagram
10. Title the chart, label the ‘ vital few’ and ‘useful many’ & show the cumulative
percent contribution of the vital few.

Quality Improvement: Pro

S.No Problem No. of Cases % Cum %
1 Diameter Oversize 52 42% 42%
2 Damages 31 25% 67%
3 Surface Roughness Poor 16 13% 80%
4 Excess Ovality 13 11% 91%
5 Excess Taper 7 6% 97%
6 NC Patch 3 2% 99%
7 Tool Mark 1 1% 100%
Total 123

Quality Improvement: Pro

Seven Quality Control Tools
• Pareto Chart
• Process flow diagram
• Cause and Effect Diagram
• Check sheet
• Histogram
• Control chart
• Scatter diagram
Quality Improvement: Pro
Flowcharts

Flowcharts
• Graphical description of how work is done.
• Used to describe processes that are to be
improved.

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Quality Improvement: Pro

Flow Diagrams
" Draw a flowchart for whatever you do.
Until you do, you do not know what you are
doing, you just have a job.”

-- Dr. W. Edwards Deming.

Quality Improvement: Pro

Flowchart
Flowchart
Activity

Yes
Decision

No

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Quality Improvement: Pro

Flowchart

Quality Improvement: Pro

Flow Diagrams

Quality Improvement: Pro

Process Chart Symbols
Operations
Inspection

Transportation

Delay

Storage

Quality Improvement: Pro

Process Chart
Date: 9-30-00 Location: Graves Mountain
Analyst: TLR Process: Apple Sauce

Distance
Operation
Transport Description

Storage
Inspect

(feet)
(min)
Time
Delay
Step

of
process

1 Unload apples from truck 20

2 Move to inspection station 100 ft
3 Weigh, inspect, sort 30
4 Move to storage 50 ft
5 Wait until needed 360
6 Move to peeler 20 ft
7 Apples peeled and cored 15
8 Soak in water until needed 20
9 Place in conveyor 5
10 Move to mixing area 20 ft
11 Weigh, inspect, sort 30
Page 1 0f 3 Total 480 190 ft

Quality Improvement: Pro

Quality Improvement: Pro
Seven Quality Control Tools
• Pareto Chart
• Process flow diagram
• Cause and Effect Diagram
• Check sheet
• Histogram
• Control chart
• Scatter diagram
Quality Improvement: Pro
Cause-and-Effect
Cause-and-Effect Diagrams
Diagrams

Show the relationships between a
problem and its possible causes.


Developed by Kaoru Ishikawa (1953)


Also known as …
• Fishbone diagrams
• Ishikawa diagrams 7 Quality Tools

Quality Improvement: Pro

Cause
Cause and
and Effect
Effect
“Skeleton”
“Skeleton”
Materials Procedures

Quality
Problem

People Equipment
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Fishbone Diagram
Measurement Human Machines

Faulty testing equipment Poor supervision Out of adjustment

Incorrect specifications Lack of concentration Tooling problems

Improper methods Inadequate training Old / worn

Quality
Inaccurate Problem
temperature Poor process
control Defective from vendor
design
Ineffective quality
Not to specifications management
Dust and
Dirt Material- Deficiencies
handling problems in product
design
Environment Materials Process

Quality Improvement: Pro

Cause and effect diagrams
To construct the skeleton, remember:

For manufacturing - the 4 M’s & E
 man, method, machine, material,
environment.

For service applications
 equipment, policies, procedures, people

Quality Improvement: Pro

Cause and effect diagrams

Advantages
• Making the diagram is educational in itself
• Diagram demonstrates knowledge of
problem solving team
• Diagram results in active searches for
causes
• Diagram is a guide for data collection

Quality Improvement: Pro

Seven Quality Control Tools
• Pareto Chart
• Process flow diagram
• Cause and Effect Diagram
• Check sheet
• Histogram
• Control chart
• Scatter diagram
Quality Improvement: Pro
Planning for Data collection
• What question do we need to answer
• How we will recognize & communicate the answers to
the questions -Tells about required data
• What Data Analysis tools we need to use
• What type of data do we need in order to construct the
tool
• Where in the process can we get this data
• Who in the process can give this data
• How we can collect data from those people with
minimum efforts & chance of error.
• What additional information do we need to capture for
future analysis, reference & traceability

Quality Improvement: Pro

Check
Check Sheet
Sheet

Shifts

   

Defect Type

 

 

 

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Quality Improvement: Pro

Check Sheet
COMPONENTS REPLACED BY LAB
TIME PERIOD: 22 Feb to 27 Feb 1998
REPAIR TECHNICIAN: Bob

TV SET MODEL 1013

Integrated Circuits ||||
Capacitors |||| |||| |||| |||| |||| ||
Resistors ||
Transformers ||||
Commands
CRT |

Quality Improvement: Pro

Seven Quality Control Tools
• Pareto Chart
• Process flow diagram
• Check sheet
• Histogram
• Cause and Effect Diagram
• Control chart
• Scatter diagram
Quality Improvement: Pro
Histograms

A Histogram is a Graphic summary of variation in a set

of data. The pictorial nature of the Histogram enables us
to see patterns that are difficult to see in a simple table
of numbers.
This is a good tool to analyze data that contain variation.

It tells us about pattern of variation of the process.

The tool is most useful to work out Process Capability Index.

Hence this tool is used to compare before project &

after project process variation spread, pattern, improvement
in Cp.
Quality Improvement: Pro
 Steps for Constructing a Histogram
1. Collect the measurements / data.
2. Arrange / Group the data column wise in Table form
3. Find & mark the largest and smallest number / value in each
group.
4. Find the largest(Max) and smallest value(Min.) in whole set.
5. Calculate the range of measurements, i.e. Range = Max. - Min.
6. Determine the number of class intervals for the Frequency diagram
Guidelines :-
No of Readings No of Class intervals
< 50 5 to 7
50 to 100 6 to 10
> 100 7 to 12
7. Determine Intervals and Boundaries
Interval = Range / Class Interval
8. Determine the frequencies of each class interval with tallies.
9. Prepare the frequency Histogram
- mark & label the vertical scale (Frequency)
- Mark & label the horizontal scale ( Measurement value)
- Draw the columns according to the frequency tallies.
- Label the Histogram.
Quality Improvement: Pro
Data of 40 Diameter measurements
( Nominal value 25 mm)

23 22 24 25
27 25 26 24 Histogram
26 26 25 23
24 27 25 25 10
22 24 24 26 9
25 25 25 26 9
8
24 23 25 27 8
28 27 27 28 7
23 28 28 26 7
24 23 26 26

Frequency
6
5 5
Range= 28 - 22=6 5
No of Class interval = 6 4
4
Interval = Range/Class interval =1
The Boundries - Frequency 3
21.5 - 22.5 2 2
22.5 - 23.5 5
2
23.5 - 24.5 7 1
24.5 - 25.5 9
25.5 - 26.5 8 0 21.5 - 22.5 22.5 - 23.5 23.5 - 24.5 24.5 - 25.5 25.5 - 26.5 26.5 - 27.5 27.5 - 28.5

26.5 - 27.5 5
Diameter
27.5 - 28.5 4
Total 40

Quality Improvement: Pro

“Stem and leaf” displays
Data
Integrated Circuit Response Time (ps)

4.6 4.0 3.7 4.1 4.1 5.6 4.5 6.0 6.0 3.4
3.4 4.6 3.7 4.2 4.6 4.7 4.1 3.7 3.4 3.3
3.7 4.1 4.5 4.6 4.4 4.8 4.3 4.4 5.1 3.9

Quality Improvement: Pro

“Stem and leaf” displays

Integrated Circuit Response Time (ps)

3 7 4 4 7 7 4 3 7 9

4 6 0 1 5 6 2 6 7 1 1 5 6 4 8 3 4

5 6 1

6 0 0

Quality Improvement: Pro

Dot diagrams

Integrated Circuit Response Time (ps)

3 4 5 6
Plant A

Plant B

Quality Improvement: Pro

 What is Graph ?

Graph is a diagram which explains connections or

inter relations amongst 2 or more things. These connections
are represented by a number of distinctive dots, lines, bars,
columns.

Common type of graphs -

• Line Graph
• Column / Bar Graph
• Pie Graph

Quality Improvement: Pro

Seven Quality Control Tools
• Pareto Chart
• Process flow diagram
• Cause and Effect Diagram
• Check sheet
• Histogram
• Control chart
• Scatter diagram
Quality Improvement: Pro
 Definition of Control Chart

A Control Chart is a special type of trend chart used to

detect the special causes of variation in the process.

Types of Control Charts -

• For Variables , i.e. For the characteristics that can be
measured - X - R Chart

• For Attributes - For characteristics that can be judges as

pass or fail, go or no-go, defective or non-defective etc.
- np chart, p chart, c chart, u chart

Quality Improvement: Pro

 Advantages of using control charts -

• It is a effective tool to control the process statistically (SPC)

•It helps to detect changes in the process over a period of time

and take corrective action.

• It differentiates chance cause variation & assignable cause

variation in the process.

• It is an effective tool which helps to reduce variations in the

process

• It provides information about process capability.

Quality Improvement: Pro

Control Charts

Quality Improvement: Pro

Control Chart 27

24
UCL = 23.35
21
Number of defects

18 c = 12.67

15

12

6
LCL = 1.99
3

2 4 6 8 10 12 14 16
Sample number
Quality Improvement: Pro
Seven Quality Control Tools
• Pareto Chart
• Process flow diagram
• Cause and Effect Diagram
• Check sheet
• Histogram
• Control chart
• Scatter diagram
Quality Improvement: Pro
Scatter Diagram

Quality Improvement: Pro

 Scatter Diagram
A Scatter diagram is a graphic presentation of the relationship
between two variables. In quality improvement, scatter diagrams
are usually used to explore cause - effect relationships in the
diagnostic journey.

It establishes correlation

A example - A Hydraulic system was tripping for indication

of overload. The tripping mechanism is provided as safety.
The electronic control circuitry was executing safety
shut down of the hydraulic system, with Voltage as a signal.
The complaint was more in Summer months from areas that
were close to large bodies of Water.
Quality Improvement: Pro
 One of the Probable cause was “ The higher Relative
Humidity causes stickiness in the system, leading to
increased load and subsequent tripping.”
The diagram clearly shows that as Relative Humidity
increases the sensor reads higher voltage. This causes
circuitry to believe that the hydraulic system had exceeded it
limits & trips.
Effect
•
• • •
• • • •
• • •
•
Voltage • •
•
Cause
Relative
Humidity
Quality Improvement: Pro
The graphic nature of the scatter diagram helps a team to see
the relationship between the variables.
It can be statistically described as Pearson’s Correlation Coefficient

The patterns of Correlation -

A) Linear ( It can be strong or Weak correlation)

Positive Correlation Negative correlation

B) Non Linear

C) No Correlation

Quality Improvement: Pro

Thank You

EICHERQuality
MOTORS
lving
Improvement: Problem So
LTD (COMMERCIAL VEHICLE DIVISION)