Certification Course on

Quality Assurance and Statistical Quality Techniques

Course Level A Graphic Tools Code 1.04: Graphic Tools
Issue No.: 01
Effective Date: 15-04-2014

Graphs
Graphs represent data pictorially. A picture can see what 1000 words can not tell.

“Graph it as you collect it” is a good rule to remember. Properly used graphs are
indispensable tools for the management and improvement at the work place.

The computer tools that we have available today give us access to a wide array of
graphical techniques and tools that can be used for effective presentation of data.
However, we need to first understand what type of information we wish to present, since
the graphical tool that should be used for a set of data depends on the questions we
wish to answer and the type of data we are using to answer those questions.

Advantages of Graphs

 A graph attracts the attention of people more than numerical data analysis
 A graph makes people feel familiar with the subject as it is easier to interpret
 A graph is visual, which makes the information easier to remember.
 A graph helps the user pick out trends, patterns, and other characteristics more
vividly than numerical data presentations
 A graph can reveal hidden facts and relationship not previously known.

Graphs used in Quality applications

Most commonly used graphs in Quality applications are:

Bar Charts - A simple tool used to show the differences between different groups of
data.
.

Page1
Bar Charts or Bar graphs are parallel bars of identical width but differing length to
compare the size of different quantities/things as they appear in categories. The
categories could be type, grades, class, sizes or time periods such as shifts, days,
weeks, months, years.Fiure 1 shows an example of categorizing and depicting types of
complaints received in a time period.

Figure 1 : Bar Chart Example

Figure 2a and are examples of how we can combine two categorizations in a stacked or
clustered bar graph. The categories here are levels of employees in an organization and
the nature of work they engage in. The analysis presents how the division of time spent
at each level

Figure 2a : Stacked Bar Chart Example Figure 2b : Clustered Bar Chart Example

Page2
Line Chart
Line Charts or Line graphs display the overall trend in time series data by the
direction of their lines. The data for the line charts must be tabulated in the order in
which it occurs.Figure 3 displays the trend in machine breakdown over a 15 month
study period. A line chart distributes category data evenly along a horizontal (category)
axis , and distributes all numerical value data along a vertical (value) axis.

Figure 3 : Line Chart Example

Figure 4 shows a comparative analysis of 3 suppliers. It can be seen that Supplier C is
the best performing among the 3. However the line graph also contains trend lines for
each. If you notice carefully you will find that the performance of supplier A is not only
low, but also declining. Supplier C is better than others but in this case also there is a
small but perceptible declining trend. Supplier B has an average performance but shows
a promising upward improvement trend.
We also notice that there is a general correlation in months where performance in
general goes down. This may be a cuase of investigation. We may not have been able
to deduce so much information if we only had the data table.

Figure 4 : Mutliple Line Chart Example

Page3
Histogram
Histogram is a simple tool used to summarize and display process data in a graph. It is
particularly useful when there are a large number of observations. It is used in combination with
checksheet that records data in an organized manner. Figure 5 gives us a graphical breakup of
daily production of castings in a foundry. The figure shows us how the data is distributed, what
is the central tendency and what is the degree of spread. The Company may decide to adopt a
more consistent approach in production planning after seeing this visualization of variation in
production rates.In a histogram, the choice of the data band or class interval sometimes
becomes critical. Too wide bands may conceal smaller variations, while too narrow bands may
mislead that the variation is excessive, which may otherwise be natural. See figures 6a and 6 b
for the same data set, which may lead us to draw very different conclusions. The best way is to
experiment with different choices of width, and to choose a histogram according to how well it
communicates the shape of the distribution. In the Excel template on Histogram you can change
the class intervals as well as the starting and end values. Students are encouraged to
experiment with these and learn how the histogram communicates with each change.

Figure 5 : Histogram

Figure 6a : Too narrow band width Figure 6a : Too wide band width

Page4
Pie Chart
Pie charts are used to display the proportion of occurrence of data across various
categories. While bar charts also present data in reltative terms, the pie chart presents
data in proportions or percentages of the total of all categories put together. This makes
relative comparisons stand out more vividly. Figure 7 gives a cost break up of Quality
costs calculated by a company. The chart informs that a high proportion of the cost
breakup is towards internal failure and process scraps. The company may target to
change the cost mix to enhance the proportion of prevrntive costs, and reduce the
proportion of scrap and internal, external falure as an immediate step.

Figure 7 : Pie Chart

Radar Chart

Radar Chart is used to display relative ranking or grades, or maturity levels of

different categories on a common scale. Radar Chart is also used to measure progress
over a period of time. The visual display makes it easier to observe the trends as well
the balance between several items. The values of each category are plotted along a
separate axis that starts in the center of the chart and ends on the outer ring.

The radar chart is also known as a spider chart because of its appearance. A Spider
chart on status of implementation of 5 S in a company is shown in Figure 8

Page5
 Figure 8 : 5 S Implementation RADAR Chart

Scatter Chart
Scatter charts are commonly used for displaying and comparing numeric values, such
as scientific, statistical, and engineering data. These charts are useful to show the
relationships and plot two groups of numbers as one series of xy coordinates. Figure 9
is a Scatter chart showing relationship between harness in Steel and the carbon % as a
constituent of Steel. The closeness of the data points and the pattern in which they
progress shows the strength and nature of of the relationship

Figure 9 : Scatter Chart

Page6
 Gantt chart

A Gantt chart is a type of bar chart,that illustrates a project schedule. Gantt charts
illustrate the start and finish dates of the tasks of a project. Gantt charts can also be
used to show current schedule status using percent-complete shadings.

Gantt Charts makes it easy to understand the details of a plan and progress in its
implementation schedule.Figure 10 shows a Gantt Chart for a Quality Problem solving
project.

Figure 10 : Gantt Chart

Process Flow Chart

The Process Flow chart provides a visual representation of the steps in a process.
Flow charts are also referred to as Process Mapping or Flow Diagrams. Constructing a
flow chart is often one of the first activities of a process improvement effort, because of
the following benefits:
 Gives everyone a clear understanding of the process

 Helps to identify non-value-added operations

Page7
 Facilitates teamwork and communication

 Keeps everyone on the same page

There are many symbols used to construct a flow chart; the more common symbols are
shown below:

Flow Charting Symbols

 Drill Hole
Operation  Fill out form
 Design a part

Movement or  Move a part to next location

transportation  Deliver a document

Decision Point  Make or buy ?

 Send to operation A or operation B
?

Inspection  Part tested by QA

 Forms audited
 Buy off

 For signature
Delay  To be filled
 From supplier
 From stores

Storage  Filed documents

 In stores

Direction of flow  Document

 Product
 Process output
 Process input

Transmission Data transmission

Example

Page8
Flow charts with the functions or people that work within the process are in the left hand
side. Each operation is numbered to provide traceability throughout planning and
manufacturing process.

The process step number is a numerical progression in the process flow. In the example
below, “60” is the sixth manufacturing operation.

The next number is the operation number. This number is established for each unique
process, such as a lathe operation. In this example, the operation number is “12”. Each
operation that affects the key characteristic should be highlighted as a potential area to
measure the key characteristic.

Flow chart with Control Numbering System

Area 4 Inspect Inspect Store

35-80 85-80
90

Area 3 Chem etch

Heat treat
80-67
30.01

Area 2 Grind Straighten

Straighten Undercut
70-05
20-05 50-19

Area 1
Rough Cut to Cut groove
saw length and centres

10-26 40-07 60-12

Time Process step number in Identifies that this process

sequence per process flow affects a key characteristic
diagram

Operation number as set up in a

total company process database

Page9