MMZG 522 Total Quality

Management
Rajiv Gupta
BITS Pilani
August 2014
Lecture 9

Session Outline
Module 1

Traditional and New Tools

Cause and Effect Diagram
Check Sheet
Histograms

Module 2

Scatter Diagrams
Stratification
Pareto Diagram
Control Charts

Module 3
Seven New Tools

Module 4
Summary
2

Session 9
Begin Module 1
Traditional and New Tools
Cause and Effect Diagram
Check Sheet
Histograms

Tool Grouping
1. Seven Traditional or Basic Quality Tools (e.g.
C-E diagrams, Stratification, Histogram, Pareto
Chart, Control Charts)
2. Seven New Quality Tools (e.g. Relations
Diagram, Affinity Diagram, Tree Diagram,
Matrix Diagram, Arrow Chart, Process Decision
Program Chart)
3. Other: Product/Process Development Tools
(e.g. Benchmarking, QFD, FMEA, Faulty Tree
Analysis, Reliability Analyses, Experiment
Design, CAD, FEA, Prototyping, CAM, etc.)
4

Traditional Tools
Used primarily in reactive mode to improve
quality
Mostly quantitative --They handle
Quantitative data
Their format allows visualization of quality
issues/problems
Used primarily on the shop floor
Any of the tools can be used with any
other tools.
5

Seven Traditional or Basic Quality

Tools
1.
2.
3.
4.
5.
6.
7.

C-E (Cause-Effect) Diagram

Stratification Analysis
Check Sheet
Histogram
Scatter Diagram
Pareto Chart
Control Charts
6

New Quality Tools

Mainly used in proactive manner (to create
quality).
Used primarily for planning and by management
(for brainstorming)
Qualitative in nature
More effective when used by multi-functional
teams
Visual in nature help visualize problems,
issues, relationships, etc.
Any of the tools can be used with any other
tools.
7

Seven New Quality Tools

1.
2.
3.
4.
5.
6.
7.

Relations Diagram
Affinity Diagram
Systematic Diagram
Matrix Diagram
Matrix Data Analysis
Process Decision Program Chart (PDPC)
Arrow Diagram

Cause and Effect Diagram

Also called Ishikawa or Fishbone Diagram
Drawn to investigate only one Bad or good
effect
Causes broken down into major and minor
causes
Excellent for brainstorming and in teams
Team members can vote to obtain most likely
causes for problem solving
Two types of C-E Diagrams: Traditional and
Process
9

C-E Diagram (Fish Diagram)

10

C-E Process Chart

11

Check Sheet
Data should be collected accurately and
quickly to allow visualization and analysis
Tabular and Pictorial (Graphical) Formats
Creativity plays a major role in the design
of a check sheet.

12

Check Sheet - Tabular

13

Check Sheet - Graphic

14

Histogram
Quantitative data consisting of values of a
variable from a sample are plotted to obtain
distribution
It is a bar chart but each bar represents
frequency of occurrences within an interval
represented by the bar.
Not all bar charts are histograms (Note: Bar
charts of categorical data are not histograms).
Sufficient sample size or observations (>30) and
number of intervals (5-15) needed for useful
analysis/interpretation
15

Histogram

16

Histograms with Stratified Data

Outputs from
three (1,2,3)
machines
combined

17

Session 9
End of module 1

18

Session 9
Begin Module 2
Traditional Tools contd.
Scatter Diagrams
Stratification
Pareto Chart
Control Charts

19

Scatter Diagram

20

Scatter Diagram Stratified Data

21

Stratification
Can be used with other tools
Data separated (identified) by categories
for visualization and analyses
Stratification by source (machine,
operator/user, supplier, location, time of
the day, day, season, etc.)

22

Pareto Chart
Bar chart of categorical data arranged from
largest to smallest occurrence frequency
Cumulative percentage of occurrence provides
Vital few and useful many
Powerful quality improvement tool. (Great for
continuous improvement keep solving
problems that have largest impact to quality).

23

Pareto Chart

24

Control Charts
Visual plot of process output along with
control limits
Variables Charts (X-bar and R, X-bar and
S) and Attributes Charts (P, NP, U, C).
Variables based on successive values of
a parameter
Attribute based on defectives and defects

25

Control Chart X-Bar Chart

26

Control Chart-- R- Chart

27

Control Chart P-Chart

28

Session 9
End of module 2

29

Session 9
Begin Module 3
Seven New Tools
Relations Diagram
Affinity Diagram
Event Tree
Systematic Diagram
Matrix Diagram
Process Chart
Arrow Diagram
30

Relations Diagram

31

Affinity
Diagram

32

Affinity Diagram

33

Event Tree

34

Systematic Diagram

35

Matrix Diagram

36

Matrix Data
Level of or quantitative information about
relationships in terms of direction
(increase/decrease), strength/importance,
priority

37

Process Chart
Provides information on a process
- Description of Steps
- Sequence/Flow of steps
- Time Required to complete
- Distance Traveled
- Decisions Made
- People Involved
- Material, Information, Tools, etc.
38

Process Chart

39

Arrow Diagram

40

Tools More effective when used

as a system for improvement

41

Session 9
End of module 3

42

Session 9
Begin Module 4
Summary

43

Summary of Session 9
Quality and Management tools have been
developed over the years to help analyze and
solve problems on the shop floor and elsewhere
The traditional tools tend to be more quantitative
and are used in a reactive mode
The seven new tools are more qualitative and
can be used in a proactive mode
Ideally, the tools ought to be used in conjunction
with other tools so that their usefulness is
enhanced
44

Session 9
End of module 4

45