2.QC Beginer For ITC For Trainee FY21 - Final

DENSO Monozukuri Workshop
Course: QC 7 Tools
DENSO Training Academy(Thailand)
Training Rules
• Pay attention on training
• Listen when trainer is speaking
• Keep mobile phone away
• If have a question, Send E-mail to trainer
• Open your mind & Knowledge sharing
QC 7 Tools for ITC – DENSO MONOZUKUI WORKSHOP Presented by Mr.Warupong Chatkaew 2/49
Purpose of training
 Understand basic QC 7 tools
 Create QC 7 tools to
• indicate trend and mean of data
• indicate priority cause of problem and find out major
and minor cause of problem
• set up countermeasures and so on
 Apply knowledge of “QC 7 tools” through case study
Overall
Product
Supplier
Car maker
Customer buy a car
If have a problem about quality, We have to solve the

problem on time and on point by using QC tools
How do you feel if you receive a defective product?
How do people feel if they receive a defective

product?
Although it is one of the many distributed products, it is

the only one for the person who received.
Necessary actions to ensure quality same as safety

Following rules.
Reporting unusual findings to one’s supervisor.
Why are we using QC 7 Tools?
QC 7 Tools
Manufacturing process
No. DATA（㎜）方向(度)

1 0.14 58
2 0.03 70
Product
3 0.16 39
4 0.09 154
5 0.07 48
6 0.07 118
7 0.12 4
8 0.07 344
Numerical data
QC 7 Tools  Tools for arrangement or change numerical data into graph or others
which using for analysis, finding root cause or relation, problem solving and
improvement
In manufacturing process, the factors which probably cause defect are “Man”
“Machine” “Material” “Method” “ Measurement” & “Environment” We have to
improve our work in order to reduce defect.
“QC 7 Tools” provides the basic concept of quality control.

Our objective is to improve working method for “Zero defect” By introducing
the basic rules & the basic tools of QC.
1) Basic rules of Defect prevention 2) QC 7 Tools
Basic Rules of Defect Prevention
The basic rules, which are need to be observed, are provided in order to prevent
a defective part which occurs during process at the production site or being
flow out to the next process.
Stratification indication
Do not interrupt
the operation.
Indication of OK/NG parts Stratification of parts Always finish one

cycle operation
Prevention of temporary Check when

the product Check after
placing operation.
comes.
Sequential check
completely
Operate
after check
QC 7 Tools
調調調
１月１１調
(台) ＮＮ７７
15
10 規
格
台
外
5 れ
数
0
20.0 .05 .10 .15 .20 .25 .30 .35 .40 .45
mm
Histogram Pareto Diagram Fishbone Diagram

-Understand at a glance the variation -Helps graphically display -Breaks problems down into bite-size
Exists in a process result of significant few problems pieces to find root cause
-Shape will show process behavior -Tell what to work on first -Understanding factor causing the
problem
1.2
1.1
無負荷電流(A) 0.9
0.8
0.7
0.6
0 0.1 0.2 0.3 0.4 0.5
軸方向の遊び（m m ）
Control chart Scatter Diagram Graph

-Early warning detection system -Show relationship between 2 variables -Easily compare 2, 3 data sets
-Predict process out of control -Best method to show non-linear pattern -Better clarify trends than do tables
Check sheet
-Simple and effective way to display data
-Determine source of problem
Check Sheet
• Control, follow up, analyze trends
• Gathering simple data and accurate
• Easy to understand & easy to use
• Understand the current situation
• Finding the problem to find the cause
• Confirm the result to prevent repeated problems
1.Defective item check sheet 2.Defective location check sheet
3.Production process distribution check sheet
Check Sheet
1. Defective item check sheet
• To show the type of defect at the required interval.
• To clearly show the defect points.
Injection molding : MC-1 Part : Tank cover
Topic Monday Tuesday Wednesday Thursday Friday Total
1. Short-molding lllll ll lllll lllll lllll llll lllll ll lllll ll

2. Flash llll lll lllll lllll lll
3. Sink marks lll ll l ll l
4. Burnt lllll ll lllll lll llll lllll lll
5. Voids/Bubbles lllll ll ll ll ll lll
6.Others ll l ll l ll
Total
1.What is the most defect? , How many? ____________________________________________________
2.What day has the most total defect? , How many? ________________________________________
Check Sheet
2.Defect location check sheet
• To clearly show the type of defect location in drawing or schematic.
• To show focusing point and clearly show the defect points.
Defect Symbol Total

∆ ∆
∆ Not completely
assembled x
∆
∆ ∆∆ O Greasy glue
O
O
O xx
O The stitches are
xx not completely ∆
OO sealed.
1. Where is the most defect location? : ____________________________________________________
2. What type of defect location? : __________________________________________________________
Check Sheet
• To show an overview of the distribution of the data relative to the specification.
• To show the average, trend, ability to control the process.
Frequency
5 10 15 20 25
3.4
3.3
3.2 X
3.1
3.0 X
2.9 X X X
2.8 X X X X Spec 2.7 mm
2.7 X X X X X X
2.6 X X X X X X X X
2.5 X X X X X X X X X X X X X
Thickness (mm) 2.4 X X X X X X X X X X
2.3 X X X X X X X X X X X X X X X X X X
2.2 X X X X X X X X X X X X X X X X X X X X X
2.1 X X X X X X X X X X X X X X
2.0 X X X X X X X X X X
1.9 X X X X X X
1.8 X X X X X
1.7 X X X X X X X Spec 1.7 mm
1.6 X X
1.5 X X X X
1.4 X
1.3 X X
1.2
1.1 X
1.0
1. How is the control of the production process? _____________________________________________
2. What is the average thickness of sample? ___________________________________________________
Check Sheet
Check sheet Type
:______________________________
Purpose
:_________________________________________
_________________________________________
Analysis
:_________________________________________
_________________________________________
_________________________________________
_________________________________________
_________________________________________
Check sheet Type

:______________________________
Purpose
:_________________________________________
_________________________________________
Analysis
:_________________________________________
O : Black dot
_________________________________________
□ : Tear _________________________________________
∆ : Scratch _________________________________________
_________________________________________
Graph
Graph is the statistical representation of the distribution. In an easy-to-understand
format, you can see the trend at a glance. Convenient for analysis and decision
• Plot data at different times • Plot proportional information

• Show historical data Total area 100%
• The X axis represents the period • Calculate the proportion of
• The Y axis represents the each topic in%
interested data • Show the overall aspect ratio,
• Plot graph compare with target main topic clearly
values
• Plot data at different times • Compare relationships with each topic

• The X axis represents the period. • Plot compare before after
• The Y axis represents the • Show the difference before & after
interested data or current with the target
• Plot compare target values • Evaluate result before and after the
• Show trends and forecast kaizen activity
Graph
Table show the historical percentage of defect: Jan – Jun 2019 of Product A
Month Jan Feb Mar Apr May Jun Avg

% 4 3 4 2 5 3
• The horizontal axis (x) represents the period, • Bars do not have to stick together.
day, month, year, etc. • Bar height shows how much of the data is.
• The vertical (Y) axis represent the data range.
Complete the bar graph
Analysis :______________________________________________________________________________________________________
_________________________________________________________________________________________________________________
Graph
show the amount of production against the target in Jan-Jun 2019.
Jan Feb Mar Apr May Jun Avg
Plan 1000 1200 1500 1000 1000 1300
Actual 950 1300 1500 900 900 1400
• The horizontal axis (x) represents the period, • Plot data points, draw lines, create line graphs.
day, month, year, etc. • Use different symbols, colors, or line styles.
Complete the line graph
Analysis :______________________________________________________________________________________________________
_________________________________________________________________________________________________________________
Graph
Show each defect type of Product A
Crack Burnt Black spot Dent Short Total
Quantity (Pieces) 10 20 50 10 10 100
% 10 20 50 10 10 100
Degree 36 72 180 36 36
• Calculate the proportion (%) of each topic. • Calculate area (degree) each topic ( __% x 360) / 100
• Enter information from much -> less clockwise. • Fill in data in small circles and explain the symbol
Complete the pie graph
Analysis :______________________________________________________________________________________________________
Graph
Show an estimation of the capabilities of the QCC group.
Finding Problem
QC Tools Join meeting Teamwork Avg
problem solving
Before 2 2 3 1 1
After 3 3 4 3 3
• Write the heading at each corner in order • Plot each point onto a line by heading and connect
• Write a scale based on the data from 0-5 or the each point.
highest scale on the first line. • The two lines have different colored symbols.
Complete the radar graph
explain
คําอธิ บthe
ายสัญsymbol
ลักษณ์
:
:
Analysis :______________________________________________________________________________________________________
_________________________________________________________________________________________________________________
Pareto Diagram
• Represented by bar graphs and line graphs

• Bar graph showing the data of interest, left-hand scale
• Line graph showing% accumulated, right-hand scale
• Show important problem topics from more to less
• Compare before and after confirm the improvement results
1. Create a table to analyze the data 2. Create Pareto Diagram
Amount Accumul Accumulat

Defect ％
(Pieces) ated ed ％
Crack 7 7 46.7 46.7
Chipped 3 10 20.0 66.7
Short 2 12 13.3 80.0
Others 3 15 20.0 100
Total 15 100
Crack
Pareto Diagram
Table show type of each defect
Crack Burnt Black spot Dent Scratch Short Chipped
Amount 20 40 70 10 2 1 1
(Pieces)
Create analysis table

② Sum remaining amount and
Amount ④ ⑤ ⑥ fill in others
Defect type Accumulated % %Accumulated
(Pieces)
① ③ Calculate total amount
More
④ Current amount + Previous

amount
⑤ (Amount / Total) x 100 %
Less
② ⑥ Current % + Previous %
③ Total
Pareto Diagram
Create Pareto diagram
① : Create the horizontal axis
and the 2 vertical axis
② : Divide the left-hand axis
scale from 0 to the total amount
③ : Divide the right-hand
axis scale from 0, 50, 100
④ : Divide the horizontal axis

by the subject in the table and
write a name.
⑤ : Take amount then
create a bar graph on the
left hand scale.
⑥ : Take the %accumulative
then create a line graph on the
right-hand scale starting from 0
⑦: Write down the values of
the bar graph, accumulative%
of line graph
⑧: Write the graph name, axis
name and unit
Analysis :____________________________________________________________________________________________
Pareto Diagram
Create Pareto diagram
① : Create the horizontal axis
Amount, pieces Pareto shows breakdowns by defect type %Acc, % and the 2 vertical axis
144 100 % ② : Divide the left-hand axis
97.2 % scale from 0 to the total amount
90.3 %
③ : Divide the right-hand
axis scale from 0, 50, 100
76.4 %
④ : Divide the horizontal axis
by the subject in the table and
72 70 50 % write a name.
48.6 % ⑤ : Take amount then
create a bar graph on the
left hand scale.
40
⑥ : Take the %accumulative
then create a line graph on the
20 right-hand scale starting from 0
10 ⑦: Write down the values of
4 the bar graph, accumulative%
0 0 of line graph
Black spot Burnt Crack Dent Others
⑧: Write the graph name, axis
Defect type name and unit
Analysis: Black spot is the highest defect, about 49% of all defects. should be countermeasure first
Control Chart
Follow up, control, verify the ability to control the production process & defect which was generate
Show data from Abnormality type
measurements UCL : Upper control limit
UCL CL : Central line
CL LCL : Lower control limit
Abnormality condition
LCL
• Control process
• X-R Chart (quality &
deviation)
• Collect data measure • Separate Process, shift • Compare with control line
plot graph
• Follow up abnormality in • Summarize process capability
graph
Show data from counting
UCL
• Control defect in process

• P Chart (defect ratio:
defect / total production amount)
• Control not over UCL Summary of defect types
defect characteristic,
control limit or P for the whole month
amount
Sort of more  less
Criteria for judging abnormality condition
from the control chart
Six abnormality conditions
Control Chart
make a circle around the abnormality points and specify numbered and described.
42
40
UCL
38
36
34
CL
32
30
28
LCL
26
24
D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
M 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
1 33 35 34 38 33 36 34 36 31 35 33 33 33 31 33
2 35 33 35 33 31 34 35 39 34 33 31 37 26 32 30
3 34 31 36 35 35 35 32 37 33 32 33 35 30 30 28
4 36 33 37 34 37 33 37 39 36 34 32 34 32 31 32
1.____________________________________________________________________________________________________________________________________________
2.____________________________________________________________________________________________________________________________________________
3._____________________________________________________________________________________________________________________________________________
4._____________________________________________________________________________________________________________________________________________
Fish Bone Diagram
• Brainstorm and share opinions.
• Investigate the cause of the problem with the 5M1E.
• Create small bones (large, medium, small) by category.
• Ask for the reason with the word how to find out the cause.
• Listen to other opinions is not contrary.
• The small bone represents the minor cause. To go to analyze or find
out measures.
Fish Bone Diagram : Cause and Effect, CE diagram, Ishikawa

* The factor in the 5M1E does not effect. It's not about the problem. Do not analyze. Cause category
Do 3 Gen to determine Root cause of problem
the cause. Sub-cause of problem
Method Machine Man Why
• Write something wrong, select a sub-cause
Machine
Drill not
sharp X
Effect Sway drill
75
Problem ✓ Not
sharpen
loosen
(chronic) Select to solve
Why • Cause and effect

Why
Effect
Environment Measurement Material Problem Cause
select a sub-cause
Effect
Fish Bone Diagram

Problem Cause Analysis Sample : Unripe Rice Unripe again !!!
Skip step
Method Rice Cooker Man Don’t understand step
Not fix Heat system error

Wire worn Not press Don’t
quantity Plug loose
out Cook S/W
Rice q’ty is Coil burnt complain
more than No power No plug
Temp. not match me only !!
water supply in
with standard.
volume. Thermostat S/W Cannot
Not fix water Didn’t
damage damage use
level. check
Water Control system Not reach
Volume is error Water vapor std. time No training
less than leak
Timer damage
rice q’ty Uncompleted close
Unripe
Bad store
Power
drain Spoiled
Rice more
than water
Rice
Electric wheat
interruption Not fix amount
Mix from shop
Power Ratio rice & water
failure Have sticky
rice mixed not std. Why
Mis scoop Not fix level
Problem Cause
Environment Material Water less than Don’t
rice
forget !!! Effect
Fish Bone Diagram
Problem Cause Analysis Sample : Unripe Rice Unripe again !!!
Skip step
Method Rice Cooker Man Don’t understand
step
Not fix Heat system error
Wire worn Not press Don’t
quantity Plug loose
out Cook S/W
Rice q’ty is Coil burnt complain
more than No power No plug
Temp. not match me only !!
water supply in
with standard.
volume. Thermostat S/W Cannot
Not fix water Didn’t
damage damage use
level. check
Water Control system Not reach
Volume is error Water vapor std. time No training
less than leak
Timer damage
rice q’ty Uncompleted close
Unripe
Bad store
Power
drain Spoiled
Rice more
than water
Rice
Electric wheat
interruption Not fix amount
Mix from shop
Power Ratio rice & water
failure Have sticky
rice mixed not std.
Mis scoop Not fix level Do 3 Gen from
fact to
determine the
Environment Material Water less than Don’t sub-cause.
rice
forget !!!
Scatter Diagram
• Plot X-axis value (initial variable, precedence, cause)
• Plot Y-axis value (dependent variable, occurring after, result)
• Show the type of relationship (concurrent, opposite, unrelated)
• Show confirming cause relationship And the problem of the fishbone
(Positive) (Negative) (No relation) • Show correlation tendencies of 2 variables
X↑ Y↑ X↑ Y↓ X Not relate Y
Case study of relation between % carbon and Tensile strength of Plastic

No Carbon (%) Tensile Strength (kg/mm2) No Carbon (%) Tensile Strength (kg/mm2) ………………………………………………………………
1 2 43 16 2.7 47
2 2.4 46 17 2.1 42
3 2.2 45 18 2.6 48
4 2.3 44 19 2.4 45
5 2.5 45 20 2.1 43
6 2.8 48 21 2.3 45
7 2.2 43 22 2.2 43
8 2.7 47 23 2.3 46
9 2.4 44 24 2.4 47
10 2.3 45 25 2.3 44
11 2 42 26 2.4 45
12 2.2 44 27 2.6 46
13 2.6 47 28 2.5 44
14 2.1 44 29 2.6 46
15 2.5 46 30 2.4 46
• No. of data  30
• Plot in order of point until
• Scale not start from 0
all point.
• Schematic shape close to square
• Repeat position no plot.
• The no. column is only the order in the plot
• No dash line show the line
• Plot the point at the intersection of the X- and
of sight.
Y-axis values
• Write the title, axis and unit.
Analysis : ________________________________________________________________________________
Histogram
• Bar graph of data ranges show the distribution of the variance data.
• Show data in graph instantly grasp the state quickly.
• When compared to the spec, it makes sense of the quality of the data.
• Show mean the trend of information can be roughly visualized.
• Can demonstrate the ability of an introductory process
LSL USL
Appropriate control
LSL USL
Should reduce the
dispersion
LSL USL
Poo controlled,
• Amount of data > 50 • Compared with the spec, will know if there is out of there is defect
• The X-axis represents a range of data. spec or not.
• Graphs are contiguous and have the same width • Can estimate the average from the eyes.
• Y-axis displays the amount of information. In the data • Can tell trend of data (Closer, away from spec)
range • The graph base is wide, the data is scattered, very
• Bar height Is the amount of information in each period. volatile.
• Graph patterns are used to guide control.
Histogram
How to create Histogram
measure by Micrometer 1. Graph 10 Bar
Ø 7.25 ± 0.15 0.01 mm 2. Max value = _______________
Amount 100 data 3. Min value = ________________
No 1 2 3 4 5 6 7 8 9 10 4. Range = Max – Min = ______________
0 7.25 7.23 7.28 7.28 7.31 7.26 7.27 7.33 7.31 7.36 5. Range / Bar amount = _____________
10 7.35 7.36 7.4 7.33 7.36 7.33 7.34 7.35 7.38 7.4 6. Graph width = Cut decimal (5.) = ________
20 7.4 7.37 7.4 7.41 7.37 7.38 7.38 7.4 7.4 7.47 7. Upper limit = Max + (Graduation/2)
30 7.46 7.39 7.37 7.19 7.2 7.27 7.25 7.29 7.33 7.29 =________________________________
40 7.29 7.35 7.28 7.24 7.32 7.31 7.32 7.31 7.29 7.29 8. Lower limit 1 = Upper limit – Graph width
50 7.31 7.3 7.38 7.32 7.33 7.35 7.33 7.37 7.36 7.37 =________________________________
60 7.38 7.38 7.4 7.43 7.42 7.42 7.37 7.36 7.44 7.15 9. Lower limit 2 = Lower limit 1 – Graph width
70 7.14 7.17 7.16 7.16 7.23 7.2 7.22 7.21 7.21 7.15 =_________________________________
80 7.17 7.28 7.16 7.18 7.2 7.19 7.23 7.23 7.25 7.24 10. Repeat calculate until less than min value
90 7.27 7.33 7.29 7.27 7.32 7.32 7.36 7.33 7.34 7.35 (________)
11. Fill data of upper limit in the 1st Limit Frequency Total
column
12. Fill data lower limit until completed
13. Compare data with upper limit &
lower limit then mark into frequency
column (I) lthough same data.
14. Fill total in each limit into total
column
15. Fix scale then create graph
(Horizontal)
16. Draw spec line
17. Shade the part out of spec
Analysis:_____________________________________________________________________
Case Study 1
Select problem by Pareto Diagram
Many rework parts effect to high cost, loss time to manage → Checking and specify problem
1. Grasp the problem
Part No
Amount
2. Create table to analyze problem 3. Create Pareto Diagram
Cumulative Cumulative
Part No Amount %
amount %
Analysis : _____________________________________________________________________
QC 7 Tools
調調調
１月１１調
(台) ＮＮ７７
15
10 規
格
台
外
5 れ
数
0
20.0 .05 .10 .15 .20 .25 .30 .35 .40 .45
mm

problem
1.2
1.1
1
無負荷電流(A)
0.9
0.8
0.7
0.6
0 0.1 0.2 0.3 0.4 0.5

Check sheet
Case Study 2
Specify position direction of problem and find out measures
Spec: Eccentric ≤0.20mm
Ø 4.0mm
Record 60 data of eccentric value from “drilling process”
USL
UCL
CL
Cp = 0.90 Cpk = 0.81 Judge = X
Analysis : ____________________________________________________________________
Case Study 2
Understand variance, dispersion, and trend of information.
Eccentric Measure by Dial gauge 1. Create graph 10 Bar
≤ 0.2 mm Graduation 0.01 mm 2. Max Value = ________________
amount 60 data (Produce 15 days) 3. Min Value = ________________
4. Range = Max – Min = _____________
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 5. Range / No. of bar = _____________
6. Graph width = Cut decimal (5.) = _____
9:00 0.09 0.07 0.11 0.10 0.08 0.03 0.11 0.04 0.08 0.05 0.16 0.17 0.07 0.05 0.08 7. Upper limit = Max + (Graduation/2)
=_______________________
11:00 0.10 0.08 0.10 0.13 0.13 0.06 0.06 0.14 0.20 0.03 0.03 0.13 0.05 0.07 0.07 8. Lower limit 1 = Upper limit – Graph width
=_______________________
14:00 0.05 0.08 0.07 0.10 0.02 0.15 0.03 0.07 0.08 0.09 0.14 0.17 0.06 0.05 0.11 9. Lower limit 2 = LSL 1 – Graph width
=_______________________
16:00 0.06 0.09 0.11 0.16 0.15 0.05 0.12 0.13 0.14 0.04 0.09 0.09 0.04 0.11 0.06 10. Repeat calculate until less than min value
(________)
11. Fill data of upper limit in the 1st Limit Frequency Total
column
12. Fill data lower limit until
completed
13. Compare data with upper limit &
lower limit then mark (l) into
frequency column and mark (l)
although same data.
column
15. Draw spec line
วิเคราะห ์ :
____________________________________________________________________________
Case Study 2
Understand the direction of the problem more clearly
DATA DATA
No. （㎜） Degree No. （㎜） Degree Data
1 0.14 58 26 0.06 236
2 0.03 70 27 0.13 4 Degree
3 0.16 39 28 0.05 68
4 0.09 154 29 0.06 359
5 0.07 48 30 0.07 290
6 0.07 118 31 0.13 28
7 0.12 4 32 0.06 343
8 0.07 344 33 0.15 25
9 0.18 29 34 0.03 346
10 0.01 200 35 0.19 17
11 0.13 59 36 0.09 226
12 0.02 210 37 0.11 29
13 0.09 2 38 0.06 276
14 0.04 240 39 0.12 50
0.02
15 0.11 10 40 0.03 0
16 0.08 269 41 0.09 47 0.04
17 0.05 41 42 0.05 160 0.06
18 0.08 195 43 0.09 85 0.08

19 0.18 15 44 0.11 170 0.10
20 0.07 24 45 0.15 49 0.12
21 0.09 5 46 0.06 252
0.14
22 0.09 138 47 0.14 10
0.16
23 0.10 40 48 0.07 160
0.18
24 0.06 86 49 0.09 61
25 0.11 41 50 0.06 310 0.20
0.22
Analysis : ________________________________________________________________
Case Study 2
Understand the process, related information to analyze the cause of the problem and preventive solution
Automation Manual
Production Inspection
supplier
MT: check clamp Insp : Master check 1/w
• Diameter force 1/w Dial gauge calibrate
• Length 1/Y
• Strength
• Chamfer
Loadin Put workpiece on Jig,

PE : Set program g Measure by dial gauge
: Speed 500 rpm Insp : Rotate constant
MT : PM, set up speed
(Tool life JP : 500 pcs) Cleaning jig 1/d
Incoming PD : Cleaning jig 1/D
• Lot size 200 pcs Drilling Rotate by hand

• Random check
appearance
5 pcs/lot
Eccentric ≤0.2mm
Unloading
If the eccentric value is different,
the dial gauge will move around.
Case Study 2
Check the actual working conditions with real process and analyze the causes for preventive solution
Production Inspection
Observe data from the actual process. Brainstorm and analyze the root cause of the problem.
And propose preventive solutions.
Method Machine Man Why
Counter
Reason PIC Due date
measure
Effect
75 degree Problem
(Chronic)
Why
Effect
Environment Measurement Material
Case Study 2 (Example analysis)
Man
It refers to the people involved in the
Method Machine production process, the work for this
case is automated and therefore is not
Drill bit taken into analysis.
oscillates
Load while
w/p drilling.
Hold the drill
Fix w/p not bit longer
Workpiece is not
center in the drilling
position
Drill bit
Drilling Table turn
misaligned
does not
Speed to Misposition rotate
high properly. Eccentric
to upper
left
Hardness
Dial gauge more than
Damage std.
Supplier sent
Not calibrate hard parts than
Inspector Diameter
usual.
Measure mistake smaller than
Unskilled
std.
Reading
mistake Insufficiency
Measurement Wrong Material checking
reading
Case Study 2 (Example analysis)

Man
It refers to the people involved in the
Method Machine production process, the work for this
case is automated and therefore is not
Drill bit taken into analysis.
oscillates Is there any other
Load while
w/p cause????
drilling.
Hold the drill
Fix w/p not bit longer
Workpiece is not
center in the drilling
position
Drill bit
Drilling Table turn
misaligned
does not
Speed to Misposition rotate
high properly. Eccentric
to upper
left
Hardness
Dial gauge more than
Damage std.
Supplier sent
Not calibrate hard parts than
Inspector Diameter
usual.
Measure mistake smaller than
Unskilled
std.
Reading
mistake Insufficiency
Measurement Wrong Material checking
reading
Case Study 2
From now on, let's look at the working of the “Holder". There are
two positions of the workpiece holder, let's explore the different
causes.
Holder 2
Holder 1 Table turn
The principle of operation is that the table turn rotates indefinitely and then
the holder 1 faces the drill. To hold the workpiece through drilling, then the
table turn will rotate to the holder 2 position.
Case Study 2
From random data of operation, let's try to create “Histogram" and

“Checklist" to analyze the data.
the odd data value is the penetration from the holder 1,
the even-data value is the penetration from the holder 2
Sampling DATA from Continuous process
No. DATA（㎜） Degree No. DATA（㎜） Degree
1 0.14 58 26 0.06 236
2 0.03 70 27 0.13 4
3 0.16 39 28 0.05 68
4 0.09 154 29 0.06 359
5 0.07 48 30 0.07 290
6 0.07 118 31 0.13 28
7 0.12 4 32 0.06 343
8 0.07 344 33 0.15 25
9 0.18 29 34 0.03 346
10 0.01 200 35 0.19 17
11 0.13 59 36 0.09 226
12 0.02 210 37 0.11 29
13 0.09 2 38 0.06 276
14 0.04 240 39 0.12 50
15 0.11 10 40 0.03 0
16 0.08 269 41 0.09 47
17 0.05 41 42 0.05 160
18 0.08 195 43 0.09 85
19 0.18 15 44 0.11 170
20 0.07 24 45 0.15 49
21 0.09 5 46 0.06 252
22 0.09 138 47 0.14 10
23 0.10 40 48 0.07 160
24 0.06 86 49 0.09 61
25 0.11 41 50 0.06 310
Case Study 2
When analyzed into 2 parts, it was found that the eccentricity variation of
the data in odd numbers value is high. We can clearly understand the
problem.
Odd-data value even-data value

from the holder 1 from the holder 2
Amount (pcs)
Eccentricity (mm) Amount (pcs) Eccentricity (mm)
Case Study 2
DATA DATA Data
No. （㎜） Degree No. （㎜） Degree
1 0.14 58 26 0.06 236 Degre
2 0.03 70 27 0.13 4
e
3 0.16 39 28 0.05 68
4 0.09 154 29 0.06 359
5 0.07 48 30 0.07 290
6 0.07 118 31 0.13 28
7 0.12 4 32 0.06 343
8 0.07 344 33 0.15 25
9 0.18 29 34 0.03 346
10 0.01 200 35 0.19 17
11 0.13 59 36 0.09 226
12 0.02 210 37 0.11 29
13 0.09 2 38 0.06 276
14 0.04 240 39 0.12 50 0.02
15 0.11 10 40 0.03 0 0.04
16 0.08 269 41 0.09 47
0.06
17 0.05 41 42 0.05 160
0.08
18 0.08 195 43 0.09 85
0.10
19 0.18 15 44 0.11 170
20 0.07 24 45 0.15 49 0.12
21 0.09 5 46 0.06 252 0.14
22 0.09 138 47 0.14 10 0.16

23 0.10 40 48 0.07 160 0.18
24 0.06 86 49 0.09 61 0.20
25 0.11 41 50 0.06 310
0.22
Analysis : ___________________________________________________________________
Case Study 2
Result from check sheet we found that the eccentric trend
of odd numbers value is on the left and upper
Odd number data:

Holder 1
Even number data:

Holder 2
After analyzed all data, the problem arising from the 1st holder
QC 7 Tools
調調調
１月１１調
(台) ＮＮ７７
15
10 規
格
台
外
5 れ
数
0
20.0 .05 .10 .15 .20 .25 .30 .35 .40 .45
mm

problem
1.2
1.1
1
無負荷電流(A)
0.9
0.8
0.7
0.6
0 0.1 0.2 0.3 0.4 0.5

Check sheet
Addition document:
Practice Answer
Check Sheet
1. Defective item check sheet
• To show the type of defect at the required interval
• To clearly show the defect points
Injection molding : MC-1 Part : Tank cover
Topic Monday Tuesday Wednesday Thursday Friday Total
1. Short-molding lllll ll lllll lllll lllll llll lllll ll lllll ll 40

2. Flash llll lll lllll lllll lll 20
3. Sink marks lll ll l ll l 9
4. Burnt lllll ll lllll lll llll lllll lll 27
5. Voids/Bubbles lllll ll ll ll ll lll 16
6.Others ll l ll l ll 8
Total 30 26 23 22 19 120
1. What is the most defect? , How many? : Short-molding (33.3%)

2. What day has the most total defect? , How many? : Monday 30 Pcs. (25%)
Check Sheet
2.Defect location check sheet
• To clearly show the type of defect location in drawing or schematic.
• To show focusing point and clearly show the defect points
Defect Symbol Total

∆ ∆
∆ Not completely
assembled x 12
∆
∆ ∆∆ O Greasy glue
O 6
O
O xx
O The stitches are
xx not completely ∆
OO
7
sealed.
1. Where is the most defect location? : Foxing

2. What type of defect location? : Not completely assembled
Check Sheet
• To show an overview of the distribution of the data relative to the specification.
• To show the average, trend, ability to control the process.
Frequency
5 10 15 20 25
3.4
3.3
3.2 X
3.1
3.0 X
2.9 X X X
2.8 X X X X Spec 2.7 mm
2.7 X X X X X X
2.6 X X X X X X X X
2.5 X X X X X X X X X X X X X
Thickness (mm) 2.3
2.2
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X X X
2.1 X X X X X X X X X X X X X X
1.9 X X X X X X
1.8 X X X X X
1.7 X X X X X X X Spec 1.7 mm
1.6 X X
1.5 X X X X
1.4 X
1.3 X X
1.2
1.1 X
1.0
1. How is the control of the production process? Process control is not good
because defect occur.
2. What is the average thickness of sample? Around 2.2 mm.
Check Sheet
Check sheet Type:
Defective item check sheet
Purpose:
To record and show the data about machine
and defect occur in the process compare
each associates
Analysis:
M/C 1 has more defect than M/C 2
- Mr. B produces more defect than Mr. A
- Mr. B produces a scratch at most surface
Check sheet Type:

Defect location check sheet
Purpose:
To show The defect location at front and
back of shirt
O : Black dot Analysis:

□ : Tear Sleeve, Front and back area found the
∆ : Scratch
most scratch defects
Graph
Table show the historical percentage of defect: Jan – Jun 2019 of Product A

% 4 3 4 2 5 3 3.5
• The horizontal axis (x) represents the period, • Bars do not have to stick together.
day, month, year, etc. • Bar height shows how much of the data is.
Complete the bar graph
Defect,% 6 Historical defect data of product A (Jan – Jun 2019)
0 Jan Avg
Feb Mar Apr May Jun
Analysis : Historical data Jan-Jun had 3.5% of the average defect, with May had the most 5%.
Graph
show the amount of production against the target in Jan-Jun 2019.
Plan 1000 1200 1500 1000 1000 1300 1167
Actual 950 1300 1500 900 900 1400 1158
• The horizontal axis (x) represents the period, • Plot data points, draw lines, create line graphs.
day, month, year, etc. • Use different symbols, colors, or line styles.
Complete the line graph
Graph show the amount of production against the target in Jan-Jun 2019.
Quantity, pieces
Avg
Analysis: The average production amount is 1158 pieces per month, 99.23% less than
the target of 9 pieces per month or about 0.77%.
Graph
Show each defect type of Product A
Crack Burnt Black spot Dent Short Total
Quantity (Pieces) 10 20 50 10 10 100
% 10 20 50 10 10 100
Degree 36 72 180 36 36
• Calculate the proportion (%) of each topic. • Calculate area (degree) each topic ( __% x 360) / 100
• Enter information from much -> less clockwise. • Fill in data in small circles and explain the symbol
Complete the pie graph
Analysis: Product A's largest defect is black spot, around 50% of all defects.
Graph
Show an estimation of the capabilities of the QCC group.
Finding Problem
QC Tools Join meeting Teamwork Avg
problem solving
Before 2 2 3 1 1 1.8
After 3 3 4 3 3 3.2
Write the heading at each corner in order

• • Plot each point onto a line by heading and connect
Write a scale based on the data from 0-5 or the
• each point.
highest scale on the first line. • The two lines have different colored symbols.
Complete the radar graph
estimation of the capabilities of the QCC group
QC Tools
Problem solving Join meeting
Finding problem Before

Teamwork
After
Analysis: The ability to do QCC activities increases with every topic. Overall 77% increase
Pareto Diagram
Table show type of each defect
Crack Burnt Black spot Dent Scratch Short Chipped
Amount
(Pieces)
20 40 70 10 2 1 1
Create analysis table

② Sum remaining amount and
Amount ④ ⑤ ⑥ fill in others 2 + 1 + 1 = 4
Defect type Accumulated % %Accumulated
(Pieces)
① ③ Calculate total amount
More Black spot 70 70 48.6 48.6 70 + 40 + 20 + 10 + 4 = 14
④ Current amount + Previous

Burnt 40 110 27.8 76.4 amount
70 + 0 = 70
40 + 70 = 110
Crack 20 130 13.9 90.3
⑤ (Amount / Total) x 100 %
Dent 10 140 6.9 97.2 (70 / 144) x 100 = 48.6 %

Less (40 / 144) x 100 = 27.8 %
Others 4 144 2.8 100
② ⑥ Current % + Previous %
Total 144 100 48.6 + 0 = 48.6 %

③ 27.8 + 48.6 = 76.4 %
Control Chart
make a circle around the abnormality points and specify numbered and described.
42
40
UCL
2
38
1
36
34 4 CL
32
30
28
LCL
26 3
24
D 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
M 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
1 33 35 34 38 33 36 34 36 31 35 33 33 33 31 33
2 35 33 35 33 31 34 35 39 34 33 31 37 26 32 30
3 34 31 36 35 35 35 32 37 33 32 33 35 30 30 28
4 36 33 37 34 37 33 37 39 36 34 32 34 32 31 32
1. Date 2-3, Run up ascending 7 points. 3. Date 13, is outside the LCL control limit.
2. Date 8, 2 points from 3 points near the 4. Date 13-15, 7 points continue below
UCL control limit. the CL line.
Scatter Diagram
• Plot X-axis value (initial variable, precedence, cause)
• Plot Y-axis value (dependent variable, occurring after, result)
• Show the type of relationship (concurrent, opposite, unrelated)
• Show confirming cause relationship And the problem of the fishbone
(Positive) (Negative) (No relation) • Show correlation tendencies of 2 variables
X↑ Y↑ X↑ Y↓ X Not relate Y
Case study of relation between % carbon and Tensile strength of Plastic

Scatter diagram between % carbon and Tensile strength
No Carbon (%) Tensile Strength (kg/mm2) No Carbon (%) Tensile Strength (kg/mm2)
1 2 43 16 2.7 47
2 2.4 46 17 2.1 42
3 2.2 45 18 2.6 48 48
4 2.3 44 19 2.4 45
5 2.5 45 20 2.1 43 47
Tensile strength (kg/mm2)

6 2.8 48 21 2.3 45
7 2.2 43 22 2.2 43
46
8 2.7 47 23 2.3 46
9 2.4 44 24 2.4 47
10 2.3 45 25 2.3 44 45
11 2 42 26 2.4 45
12 2.2 44 27 2.6 46 44
13 2.6 47 28 2.5 44
14 2.1 44 29 2.6 46
30 2.4 46 43
15 2.5 46
• Amount of data  30
• Plot in order of point until 42
• Scale not start from 0
all point.
• Schematic shape close to square
• Repeat position no plot.
• The no. column is only the order in the 41
• No dash line show the line 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8
plot
of sight.
• Plot the point at the intersection of the
• Write the title, axis and unit. % carbon
X- and Y-axis values
Relation between % carbon and Tensile strength is positive. So, when %carbon has increase material will strength also.
Analysis : ________________________________________________________________________________
Histogram
How to create Histogram
measure by 1. Graph 10 Bar
Ø 7.25 ± Micrometer 0.01 mm 2. Max value = 7.47 mm
0.15 Amount 100 data 3. Min value = 7.14 mm
No 1 2 3 4 5 6 7 8 9 10 4. Range = Max – Min = 7.47 – 7.14=0.33 mm
0 7.25 7.23 7.28 7.28 7.31 7.26 7.27 7.33 7.31 7.36 5. Range / Bar amount = 0.33 / 10 = 0.033 mm
10 7.35 7.36 7.4 7.33 7.36 7.33 7.34 7.35 7.38 7.4 6. Graph width = Cut decimal (5.) = 0.03 mm
20 7.4 7.37 7.4 7.41 7.37 7.38 7.38 7.4 7.4 7.47 7. Upper limit = Max + (Graduation/2)
30 7.46 7.39 7.37 7.19 7.2 7.27 7.25 7.29 7.33 7.29 = 7.47 + (0.01/2) = 7.475 mm
40 7.29 7.35 7.28 7.24 7.32 7.31 7.32 7.31 7.29 7.29 8. Lower limit 1 = Upper limit – Graph width
50 7.31 7.3 7.38 7.32 7.33 7.35 7.33 7.37 7.36 7.37 = 7.475 – 0.03 = 7.445 mm
60 7.38 7.38 7.4 7.43 7.42 7.42 7.37 7.36 7.44 7.15 9. Lower limit 2 = LSL 1 – Graph width
70 7.14 7.17 7.16 7.16 7.23 7.2 7.22 7.21 7.21 7.15 = 7.445 – 0.03 = 7.415 mm
80 7.17 7.28 7.16 7.18 7.2 7.19 7.23 7.23 7.25 7.24 10. Repeat calculate until less than min value
90 7.27 7.33 7.29 7.27 7.32 7.32 7.36 7.33 7.34 7.35 (7.14 mm)
3 6 9
11. Fill data of upper limit in the 1st
12 15 18 21 24 27 30
Limit Frequency Total
column
12. Fill data lower limit until 7.475
completed 7.445 ll 2
13. Compare data with upper limit & 7.415 llll 4
lower limit then mark (l) into USL 7.4 mm
7.385 llll lll 8
frequency column and mark (l)
although same data. 7.355 llll llll llll llll 20
14. Fill total in each limit into total 7.325 llll llll llll 15
column
7.295 llll llll l 11
15. Fix scale then create graph
(Horizontal) 7.265 llll llll llll 14
16. Draw spec line 7.235 llll l 6
17. Shade the part out of spec 7.205 llll ll 7
7.175 llll 5
7.145 llll ll 7
7.115 l 1 LSL 7.1 mm
Analysis: Poor control for there is NG (out of USL spec) average 7.355-7.385 mm more than mean go to upper spec.
Addition document:
Case study Answer
Case Study 1
Select problem by Pareto Diagram
Many rework parts effect to high cost, loss time to manage → Checking and specify problem
1. Grasp the problem
Part No 9000 9010 9020 9031 9080
Amount 75 179 14 173 36
2. Create table to analyze problem 3. Create Pareto Diagram % Cumulative

(%)
Part Cumulative Cumulative Pareto show defect type of each Part No
Amount % Defect 477 100 %
No amount % (Pcs)
97%
9010 179 179 37 37
89%
9031 173 352 36 73

73%
9000 75 427 16 89
238.5 50 %
9080 36 463 8 97
179
37% 173
9020 14 477 3 100
Total 477 100

75
36
14
0 0
9010 9031 9000 9080 9020 Part No
Analysis: The most defect have to rework came from part no. 9010 is 37%
Case Study 1
Identify problem and specify by Pareto Diagram
Checking from Pareto and specify problem
1.Grasp the problem
Carbon Cannot Rotor Screw Repeat Rotation

Type of Center Climbing No No
brush press not Testing drop in checking not
Problem Eccentric screw washer output
noise bearing smooth workpiece torque smooth
Defect
25 33 103 9 1 1 2 1 2 1 1
amount
2. Create table to analyze problem 3. Create Pareto Diagram %

Cumulative
Defect Pareto show defect type of Part No 9010 (%)
Cumulative Cumulative 17 100
Problem Amount % (Pcs.)
amount % 9
95%
Center 90%
103 103 58 58
Eccentric
76%
Cannot
press 33 136 18 76 103
bearing 58%
Carbon 89.5 50
brush 25 161 14 90
noise
Climbing
9 170 5 95
screw
33
Others 9 179 5 100
25
Total 179 100 9 9

0 0
Center Cannot Carbon Climbing Others
Eccentric press brush noise screw
bearing
Defect type
Analysis : The most defect type of part no 9010 is Center eccentric = 58 % of
Case Study 2
Specify position direction of problem and find out measures
Spec: Eccentric ≤0.20mm
Ø 4.0mm
Record 60 data of eccentric value from “drilling process”
USL
UCL
CL
Cp = 0.90 Cpk = 0.81 Judge = X
Analysis : Day 1-2 has run up continue 7 point, Day 9 eccentric more than UCL , Day 12 has 2 from 3 point
near UCL, Day 13-14 has run 7 point continue below CL line.
Case Study 2
Understand variance, dispersion, and trend of information.
Eccentric Measure by Dial gauge 1. Create graph 10 Bar
≤ 0.2 mm Graduation 0.01 mm 2. Max Value = 0.20 mm
amount 60 data (Produce 15 days) 3. Min Value = 0.02 mm
4. Range = Max – Min = 0.20 – 0.02 = 0.18
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 5. Range / No. of bar = 0.18 / 10
6. Graph width = Cut decimal (5.) = 0.02 mm
9:00 0.09 0.07 0.11 0.10 0.08 0.03 0.11 0.04 0.08 0.05 0.16 0.17 0.07 0.05 0.08 7. Upper limit = Max + (Graduation/2)
= 0.20 + (0.01/2) = 0.205 mm
11:00 0.10 0.08 0.10 0.13 0.13 0.06 0.06 0.14 0.20 0.03 0.03 0.13 0.05 0.07 0.07 8. Lower limit 1 = Upper limit – Graph width
= 0.205 – 0.02 = 0.185 mm
14:00 0.05 0.08 0.07 0.10 0.02 0.15 0.03 0.07 0.08 0.09 0.14 0.17 0.06 0.05 0.11 9. Lower limit 2 = LSL 1 – Graph width
= 0.185 – 0.02 = 0.165 mm
16:00 0.06 0.09 0.11 0.16 0.15 0.05 0.12 0.13 0.14 0.04 0.09 0.09 0.04 0.11 0.06 10. Repeat calculate until less than min value
(0.02 mm)
11. Fill data of upper limit in the 1st Limit
ขอบเขต Frequency
ความถี
( ขีด) Total
รวม 2 4 6 8 10 12 14
column Spec.< 0.2mm
0.205
12. Fill data lower limit until
completed 0.185 l 1
13. Compare data with upper limit & 0.165 ll 2
lower limit then mark (l) into
frequency column and mark (l) 0.145 llll 4
although same data. 0.125 llll ll 7
column 0.105 llll l 6
15. Draw spec line 0.085 llll llll 9
0.065 llll llll ll 12
0.045 llll llll l 11
0.025 llll ll 7
0.005 l 1
Analysis : Even though data not over USL But the distribution tends to be greater than USL,
the eccentric 0.065-0.085mm
Case Study 2
DATA DATA
No. （㎜） Degree No. （㎜） Degree Data
1 0.14 58 26 0.06 236
2 0.03 70 27 0.13 4 Degree
3 0.16 39 28 0.05 68
4 0.09 154 29 0.06 359
5 0.07 48 30 0.07 290
6 0.07 118 31 0.13 28
7 0.12 4 32 0.06 343
8 0.07 344 33 0.15 25
9 0.18 29 34 0.03 346
10 0.01 200 35 0.19 17
11 0.13 59 36 0.09 226
12 0.02 210 37 0.11 29
13 0.09 2 38 0.06 276
14 0.04 240 39 0.12 50
0.02
15 0.11 10 40 0.03 0
0.04
16 0.08 269 41 0.09 47
0.06
17 0.05 41 42 0.05 160
18 0.08 195 43 0.09 85 0.08
19 0.18 15 44 0.11 170 0.10
20 0.07 24 45 0.15 49 0.12

21 0.09 5 46 0.06 252 0.14
22 0.09 138 47 0.14 10 0.16
23 0.10 40 48 0.07 160
0.18
24 0.06 86 49 0.09 61
0.20
25 0.11 41 50 0.06 310
0.22
Analysis : Misalignment trend to the upper left

2.QC Beginer For ITC For Trainee FY21 - Final

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DENSO Monozukuri Workshop

DENSO Training Academy(Thailand)

 Understand basic QC 7 tools

If have a problem about quality, We have to solve the

How do people feel if they receive a defective

Although it is one of the many distributed products, it is

Necessary actions to ensure quality same as safety

Why are we using QC 7 Tools?

No. DATA（㎜） 方向(度)

“QC 7 Tools” provides the basic concept of quality control.

1) Basic rules of Defect prevention 2) QC 7 Tools

Basic Rules of Defect Prevention

Indication of OK/NG parts Stratification of parts Always finish one

Prevention of temporary Check when

Histogram Pareto Diagram Fishbone Diagram

Control chart Scatter Diagram Graph

3.Production process distribution check sheet

Topic Monday Tuesday Wednesday Thursday Friday Total

1. Short-molding lllll ll lllll lllll lllll llll lllll ll lllll ll

1.What is the most defect? , How many? ____________________________________________________

Defect Symbol Total

1. Where is the most defect location? : ____________________________________________________

2. What type of defect location? : __________________________________________________________

1. How is the control of the production process? _____________________________________________

2. What is the average thickness of sample? ___________________________________________________

Check sheet Type

• Plot data at different times • Plot proportional information

• Plot data at different times • Compare relationships with each topic

Month Jan Feb Mar Apr May Jun Avg

• Represented by bar graphs and line graphs

1. Create a table to analyze the data 2. Create Pareto Diagram

Amount Accumul Accumulat

Crack 7 7 46.7 46.7

Chipped 3 10 20.0 66.7

Short 2 12 13.3 80.0

Others 3 15 20.0 100

Create analysis table

④ Current amount + Previous

⑤ (Amount / Total) x 100 %

④ : Divide the horizontal axis

UCL CL : Central line

CL LCL : Lower control limit

• Control defect in process

Fish Bone Diagram : Cause and Effect, CE diagram, Ishikawa

Why • Cause and effect

Fish Bone Diagram

Not fix Heat system error

Case study of relation between % carbon and Tensile strength of Plastic

2. Create table to analyze problem 3. Create Pareto Diagram

Histogram Pareto Diagram Fishbone Diagram

Control chart Scatter Diagram Graph

Record 60 data of eccentric value from “drilling process”

Cp = 0.90 Cpk = 0.81 Judge = X

17 0.05 41 42 0.05 160 0.06

18 0.08 195 43 0.09 85 0.08

Loadin Put workpiece on Jig,

• Lot size 200 pcs Drilling Rotate by hand

Method Machine Man Why

Case Study 2 (Example analysis)

Holder 1 Table turn

From random data of operation, let's try to create “Histogram" and

Odd-data value even-data value

No. DATA（㎜）方向(度)