Seven QC Tools

Problem Solving

Quality Improvement: Problem Solving

7 QC tools

1. Check sheet: A structured form for collecting and analyzing data A

powerful data recording tool.

2. Histogram: It is a graphical representation of frequency distributions.

2.1 Stratification : A technique to present data in different groups or
categories

3. Pareto chart: Pareto diagram is a technique of arranging data according

to priority or importance and using into a problem solving framework
This helps to identify vital few and useful many.

4. Cause-and-effect diagram (Ishikawa/Fishbone diagram): To

find out relationship between the causes & effect
4.1 Brainstorming : A group technique for generating new & useful ideas

7 QC tools & Uses.

5. Scatter diagram: Graphical representation of relationship between
two variables. It can be between cause & effect and two causes

6. Graphs and Chart : Pictorial presentation of DATA. It helps to

represent large amount of information comprehensively but in a compact
manner
6.1 Flow Chart : Graphical or pictorial way to depict a process. Process
sequence can be represented in a systematic manner.

7. Control charts: Graphs used to study how a process changes over

time.

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Quality Improvement: Problem Solving

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: Problem Solving

Pareto chart
Pareto Chart - Defects.
120%

60
50

91%

97%

99%

100%
100%

80%
40

No. of Cases.

30

80%

67%

60%

52 42%

20

40%
31

10

16

20%
13

1
0%

Punching

Drilling

Shearing

Excess
Ovality

Material
Short

Punch
Break

Marking

52

31

16

13

42%

25%

13%

11%

6%

2%

1%

Cum %

42%

67%

80%

91%

97%

99%

100%

No. of Cases

7 Quality Tools
Quality Improvement: Problem Solving

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 contributors 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: Problem Solving

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Quality Improvement: Problem Solving

Flowcharts
Flowcharts

Graphical description of how work is done.

Used to describe processes that are to be improved.

7 Quality Tools

Quality Improvement: Problem Solving

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: Problem Solving

Process Chart Symbols

Operations
Inspection

Transportation
Delay
Storage

Flowchart
Activity

Yes

Decision

No

7 Quality Tools

Quality Improvement: Problem Solving

Flowchart

Quality Improvement: Problem Solving

Flow Diagrams

Quality Improvement: Problem Solving

Analyst: TLR

Process: Apple Sauce

Description
of
process

Time
(min)

Operation
Transport
Inspect
Delay
Storage

Location: Graves Mountain

Step

Date: 9-30-00

Unload apples from truck

Move to inspection station

Weigh, inspect, sort

Move to storage

Wait until needed

Move to peeler

Apples peeled and cored

15

Soak in water until needed

20

Place in conveyor

10

Move to mixing area

11

Weigh, inspect, sort

Page 1 0f 3

Distance
(feet)

Process Chart

20
100 ft
30
50 ft
360
20 ft

20 ft
30
Total

480

Quality Improvement: Problem Solving

190 ft

Quality Improvement: Problem Solving

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Quality Improvement: Problem Solving

Cause--andCause
and-Effect Diagrams
Show the relationships between a problem and its possible
causes.
Developed by Kaoru Ishikawa (1953)
Also known as F

Fishbone diagrams
Ishikawa diagrams

7 Quality Tools

Quality Improvement: Problem Solving

Cause and Effect Skeleton

Materials

Procedures

Quality
Problem

People

Equipment
7 Quality Tools

Quality Improvement: Problem Solving

Fishbone Diagram
Measurement

Human

Lack of concentration

Incorrect specifications
Improper methods

Inaccurate
temperature
control

Out of adjustment

Poor supervision

Faulty testing equipment

Machines

Tooling problems
Old / worn

Inadequate training

Quality
Problem
Defective from vendor

Poor process design

Ineffective quality
management

Not to specifications
Dust and Dirt
Materialhandling problems

Environment

Deficiencies
in product design

Materials

Process

Quality Improvement: Problem Solving

Cause and effect diagrams

To construct the skeleton, remember:
For manufacturing - the 4 Ms & E
man, method, machine, material, environment.

For service applications

equipment, policies, procedures, people

Quality Improvement: Problem Solving

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: Problem Solving

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Quality Improvement: Problem Solving

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: Problem Solving

Check Sheet

Defect Type

Shifts

7 Quality Tools

Quality Improvement: Problem Solving

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: Problem Solving

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Check sheet

Histogram

Cause and Effect Diagram

Control chart

Scatter diagram

Quality Improvement: Problem Solving

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: Problem Solving

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: Problem Solving

10
9
9
8
8
7
Frequency

7
6
5
5

5
4

4
3
2
2
1
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

Diameter

Quality Improvement: Problem Solving

Frequency

Dot diagrams

Integrated Circuit Response Time (ps)

4
Plant B

6
Plant A

Quality Improvement: Problem Solving

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: Problem Solving

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Quality Improvement: Problem Solving

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: Problem Solving

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: Problem Solving

Control Charts

Quality Improvement: Problem Solving

Control Chart
27
24
UCL = 23.35

Number
umber of de
defects

21
c = 12.67

18

15
12
9

6
LCL = 1.99

10

Sample number
Quality Improvement: Problem Solving

12

14

16

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Quality Improvement: Problem Solving

Scatter Diagram

Quality Improvement: Problem Solving

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: Problem Solving

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: Problem Solving

The graphic nature of the scatter diagram helps a team to see

the relationship between the variables.
ItThe
canpatterns
be statistically
described- as Pearsons Correlation Coefficient
of Correlation

A) Linear

( It can be strong or Weak correlation)

Positive Correlation

Negative correlation

B) Non Linear

C)

No Correlation

Quality Improvement: Problem Solving

Thank You

Quality Improvement: Problem Solving