Series A

TQM Training Module on

Check Sheet
Doc. No. A-06.00.20150220
Revision 00; 2nd Feb 2015
Authors: Prakash Kashetti

For further clarifications, write to prakash.kashetti@jsw.in © Total Quality Management, JSW Group
 TQM Training Series: 6 series with 66 training modules
This training module: Check Sheets (A-06)
Series-A Series-C Series-D Series-F
Basic Problem Solving Tools Quality Management Basics Productivity & Efficiency Tools Advanced Statistical Tools
A-01 Flow Charts C-01 Quality Mgmt. Basics D-01 Value Stream Mapping (VSM) F-01 Sampling & Distribution
A-02 Cause & Effects Diagram C-02 Basic Statistics D-02 Time & Motion Study F-02 Hypothesis Testing
A-03 Stratification C-03 Statistical Process Control D-03 SMED F-03 Regression
A-04 Scatter Diagram C-04 KPI Drill Down D-04 Wrench Time Analysis F-04 Basics of DoE
A-05 Control Charts C-05 KPI Benchmarking D-05 Queuing Theory F-05 Factorial DoE
A-06 Check Sheets C-06 Strategic Analysis Tools D-06 Inventory Management F-06 Principal Component Analysis
A-07 Histogram C-07 Policy Management D-07 Linear Programming Problem F-07 Cluster Analysis
C-08 Policy Diagnosis F-08 Conjoint Analysis
A-08 Pareto Charts D-08 Game Theory
C-09 Daily Management F-09 Discriminant Analysis
A-09 Graphs D-09 OEE
C-10 Daily Mgmt. in Maintenance F-10 Factor Analysis
D-10 PERT & CPM
C-11 Cross Functional Mgmt.
Series-B F-11 Response Surface Method
C-12 Quality Assurance Basics
Basic Management Tools F-12 Taguchi DoE
C-13 MSA
B-01 Brainstorming F-13 Weibull Analysis
C-14 PFD, FMEA, Control Plan Series-E
B-02 Affinity Diagram Decision-making Tools
C-15 Cost of Poor Quality (COPQ)
B-03 Arrow Diagram C-16 Improvement Fundamentals E-01 Quality Function Deployment
B-04 Tree Diagram C-17 4i Methodology E-02 Fault Tree Analysis
B-05 PDPC C-18 5S E-03 AHP & Paired Analysis
B-06 Matrix Diagram C-19 Quality Circles E-04 Pugh Matrix
B-07 Matrix Data Analysis C-20 QC Story Approach E-05 Time Series Analysis
B-08 Relation Diagram C-21 Kaizen, OPL, Poka Yoke
AGENDA

 What is Check-sheet ?
1 Introduction to Check-
Sheets
 History
 Types of Check-sheets

2 Steps of Construction

3 Examples from our Plant

CHECK-SHEET: INTRODUCTION

What It is?
 It is a tool for manual data gathering
 Used for gathering facts, rather than Purpose & applicability of
opinion about a process the tool:
 Is used to collect data in real time at the
 When observing a process and
source of data generation.
recording information over time.
 Provides an easy, structured and
 When measuring and visualising
standardized way of recording data.
the effect of a problem on a
 The data captured may be quantitative or process.
qualitative.
 When checking a solution to see
 Usually involves making tally-marks / the improvement.
check-marks on a sheet to count the
number of times something happens as it
happens.
TYPES OF CHECK-SHEETS

1. Defective item check sheet

 To investigate total number
of different types of defects
occurring.
 Can give clue to where
improvements needed
 Incorporate stratification
into check sheet design, e.g.
morning shift, evening shift,
lines, machine etc
 Must understand how to
record defects. Can have
two or more defects in one
defective part.
TYPES OF CHECK-SHEETS

2. Defect cause Check Sheet

 Need Stratification of
data to find possible
causes of defects
 Understand type of
defects and possible
causes
− Which machine?
− Which worker?
− Shift, time, day of
week?
 Can take
countermeasures
immediately
TYPES OF CHECK-SHEETS

3. Production Process distribution Check Sheet

 To find the variations of Example: variation in diameter of rubber hose
measured item.
 Similar to a histogram
 Simple way to classify
data exactly at the time
of collection.
 Prepared in advance.
Symbols (e.g. X) placed
in the box each time
measurement made
 When stratification
required on single sheet-
use different colour or
symbol/mark
TYPES OF CHECK-SHEETS

4. Defect Location check Sheet

 Need to know location

occurrence
 Defect location – sketch
or expanded view of
product.
 Mark location to find
pattern of defect
occurrence
 Once location known-
finding causes of defects
is easier. e.g. casting
blowhole positions, paint
chipping, dents, etc
AGENDA

1 Introduction to Check-
Sheets

2
 The 5-step process
Steps of Construction
 Illustrative example

3 Examples from our Plant

Steps of Check-sheet Construction

1 Decide what event or problem will be observed.

2 Decide Data Collection Plan - time-period and frequency

3 Design the check-sheet template,

4 Trial run of the check-sheet

5 Record data on the check Sheet.

10
 DECIDE WHAT IS TO BE OBSERVED

Step 1 Let us understand the process of Problem : operation failure of Mud

constructing Check Sheet with the help of gun machine
an Example Causes:
ILLUSTRATIVE
EXAMPLE
 Select the problem for investigation. 1. Radio & control desk
 Collect various causes for the Problem 2. Mechanical
To Improve the availability of cast house 3. Electrical MCC panel
equipment (Mudgun machine), managers in the 4. Hydraulics
Cast House decided to collect the Problems in the 5. Human error
Mud Gun failure

Step 2 Decide data-collection Plan

 Frequency: every Mudgun due to various causes above mentioned.
 Data collected from Jan-December 2013, during the Cast House Operation
 DESIGN THE CHECK-SHEET TEMPLATE

Step 3 Design the form, Set it up so that data can be recorded simply by making check
marks or Xs or similar symbols

ILLUSTRATIVE
EXAMPLE
AGENDA

1 Introduction to Check-
Sheets

2 Steps of Construction

 HM Silicon Variation
3 Examples from our Plant  Problems in RM Supply
 Example 1: Check Sheet for Si Deviation

EXAMPLE FROM
OUR PLANT Check Sheet For Si Deviation
Name of Data
Harish M
Recorder:
Location: Steel Making
Data Collection Date: 12-10-2014

Frequenc
Causes for Si deviation Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
y
Variation in Coke
5
Quality
Variation in the Sinter
4
Quality
Furnace Interruptions 9
Variation in Fuel rate 3
Slow Casting Speed 2
Variation in O2 blow 7
Variation In Humidity 4
Single trough
3
Operation
Frequency 5 3 3 4 2 4 2 4 1 3 2 3
 EXAMPLE 2: CHECK-SHEET FOR PROBLEMS IN
RAW MATL. SUPPLY

EXAMPLE FROM
OUR PLANT
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