TQM / 7 QC Tools

by

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Adding Value In Totality !!

Introduction

The 7 QC Tools are simple statistical tools used

for problem solving
Inspired after seven famous weapons of
Benkei. Viz
1. Masakari-Broad Axe
2. Kumade- Rake
3. Nagihama - Sickle weapon
4. hizuchi- Wooden mallet
5. Nokogiri- Saw
6. Tetsubo- iron staf
7. sasumata- Half moon spear
. It was possibly introduced by Kaoru Ishikawa
who in turn was influenced by a series of lectures
W. Edwards Deming had given to Japanese

Conti
The term 7 tools for QC is named after
the 7 tools of the famous warrior,Benkei.
Benkei owned 7 weapons, which he used to
win all his battles. Similarly, from my own
experience, you will find that you will be
able to solve 95% of the problems around
you if you wisely use the 7 tools of QC.
- ISHIKAWA KAORU, Professor Emeritus,
University of Tokyo
These tools have been the foundation of Japan's
astonishing industrial resurgence after the second
world war.

Basic QC Tools
The following are the 7 QC Tools :
1.Pareto Diagram
2.Cause & Efect Diagram
3.Histogram
4.Control Charts
5.Scatter Diagrams
6.Flowchart
7.Check Sheets

Pareto Diagram

1/2

Origin of the tool lies in the observation by an Italian

economist Vilfredo Pareto that a large portion of
wealth was in the hands of a few people.
Dr.Juran suggested the use of this principle to quality
control for separating the "vital few" problems from the
"useful many".
Also referred as 80/20 rule viz your 80% of problems
are due to 20% of cause.
It is used in the field of materials management for ABC
analysis. 20% of the items purchased by a company
account for 80% of the value. These constitute the A
items on which maximum attention is paid
It works on cumulative frequency and shows how
few items exert maximum influence

Pareto Diagram

2/2

For E.g
80 % of sales revenue is earned by 20% of firms
products
20 % of the items in a factory Store may account
for 80 % of the volume of items issued
80 % of defects are caused by 20% of the
possible defects type

Also used in conjunction with Brainstorming,

Cause and Efect Analysis and Cumulative Line
Chart. The Diagram displays, in decreasing order,
the relative contribution of each cause or problem
to the total

The relative contribution can be based on the

number of occurrences, the quality damage or

How to create a Pareto Diagram

1/2
Types of
Number of
Defects
Defects
A-Lever Tight
B-W/High
C-Less Torque
D-Pause Fail
E-Abnormal
noise
F-Auto Stop
Fail
G-Others

1
10
42
6
104
4
20
14

Types of
Number of
Defects
Defects
D-Pause Fail
B-W/High
F-Auto Stop
Fail
G-Others
A-Lever Tight
C-Less Torque
E-Abnormal
noise

4
Types of
Number of
Defects
Defects
D-Pause Fail
B-W/High
F-Auto Stop
Fail
G-Others
A-Lever Tight
C-Less Torque
E-Abnormal
noise

Types of
No.of
Defects
Defects
D-Pause Fail
B-W/High
F-Auto Stop
Fail
G-Others
A-Lever Tight
C-Less Torque
E-Abnormal
noise

104
42
20
14
10
6
4

% Cumulative
104
52
146
73

20
14
10
6

166
180
190
196

83
90
95
98

200

100

200

20
14
10
6

166
180
190
196

200

200

200

Cumulative Total
104
42

Cumulativ
e Total
104
104
42
146

How to create a Pareto Diagram

2/2
5
100
80
60
40
20
0

104
42

20

14

10

Number of
Defects

100
90
80
70
60
50
40
30
20
10
0

7
100

104

90

90

95

98 100100
90

83

80

80

73

70

70

60
50

60
52

42

40
30

20

20

50

Number of Defects

40

% Cumulative

30
14

10

10

20
6

10
0

104

42
20

14

Number of Defects
10

% Cumulative

Pareto Diagram
110

95

104

98

100

90

100

90

83
90

80

73

80

70

70

No. of
Defect
s

60

100

60
52
50

50

Number of Defects
% Cumulative

42

40

40

30

30
20

20

20
14

10

10

10
0

Types of
Defects

Cause & Effect Diagram

1/2

It is called Fish-Bone Diagram due to the shape of

the completed structure.
This was proposed by Kaoru Ishikawa in the
1960s,hence also referred as Ishikawa Diagram
The Ishikawa diagram shows the causes of a
certain event. A common use of the Ishikawa
diagram is in product design, to identify potential
factors causing an overall effect
It shows the relation between a quality
characteristics and factors
Causes in the diagram are often based on a certain
set of causes, such as the 5M+1E,8 P's or 4 S's
Cause-and-efect
diagrams
can
reveal
key
relationships among various variables, and the
possible causes provide additional insight into process
behaviour.

Cause & Effect Diagram

2/2

Causes in a typical diagram are normally grouped

into categories, the main ones of which are:
The 5M+1E- recommended for the manufacturing
industry
Machine, Method, Materials, Measurement, Men
and Environment
The 8 P's - recommended for the administration and
service industries
Price, Promotion, People, Processes, Place / Plant,
Policies, Procedures, and Product (or Service)
The 4 S's - recommended for the service industry
Surroundings, Suppliers, Systems, Skills
Causes should be specific, measurable, and
controllable
derived
from
brainstorming
sessions. Then causes should be sorted through
affinity-grouping to collect similar ideas together.

Structure of Cause-andeffect Diagram

Procedure for making

C&E diagram
STEP 1:
Determine the Pain point/ characteristic
STEP 2:
Draw in the backbone from left to right, and enclose
the characteristic in a square
Next, write the primary causes which afect the
characteristics as big bones also enclosed by squares
STEP 3:
Write the causes (Secondary Causes) which afect
the big bones (Primary Causes) as medium sized
bones
Write the causes (Territory Causes) which affect the medium
sized bones as small bones.

Conti
STEP 4:
Assign an importance to each factor, and mark the
particularly important factors that seem to have a
significant efect on the quality characteristics.
STEP 5:
Record any necessary information

Example of C&E Analysis

Histogram

1/2

Histogram is a graphical technique to represent

dispersion of data
Ideally it will have symmetrical shape tapering
away on both sides from target value
For E.g
1. Production from same production line usually difers
slightly in dimensions, hardness, or others qualities
2. when we commute to work every day, the time
required varies from one day to other
Thus , Histogram can be used to
. To find out if the lot has acceptance dispersion
. To compare with target value and specification
limits to identify special causes of variation

Histogram

2/2

Histogram is a graph that represents the class

frequencies by vertical adjacent rectangles
in a frequency distribution.
In a histogram, the magnitude of the class
interval is plotted along the horizontal axis and
the frequency on the vertical axis
Since each class has lower and upper values,
hence two equal vertical lines represent the
frequency.
Upper ends of the two lines representing the class
interval are joined together. The height of
rectangle thus obtained are proportional to their
frequencies.

1
STUDE
NT
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z

Howdrawing
to
calculate
Methodology for
frequency in Excel
1. Select the cell
Histogram
2. Go to
2

%
47
45
78
82
89
45
55
65
58
68
52
57
89
35
65
58
50
52
73
62
59
65
68
84
82
80

STUDEN
T
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U

BIN
LIMITS

%
47
45
78
82
89
45
55
65
58
68
52
57
89
35
65
58
50
52
73
62
59

65

68

84

82

FREQUEN
CY
0
0
5
0
10
0
15
0
20
0
25
0
30
0
35
1
40
0
45
2
50
2
55
3
60
4
65
4
70
2
75
1
80
2
85
3
90
2
95
0
100
0

Formulas/More
Functions/
Statistical/
Frequency
3. Select the Data &
Bin limits
4. You will have the
frequency
5. Select the cell range
of
FREQ equal to BIN
LIMITS
6. Go to Formula Bar in
Excel
and press
ctrl+shift+enter
7. You will have FREQ
for
defined range

HISTOGRAM
3. Draw the Bar graph and set the limits. You will have
a histogram
Histogram- Student's Performance
4.5
4
3.5
3
2.5
Frequency

FREQUENCY

2
1.5
1
0.5
0

Bin limits

Almost a
TWIN PEAK
Case

Types of histograms

A. General
Type

E. Plateau
Type

B. Isolated-peak
Type

F. Twin-peak Type

C. Positively skew D. Left hand

Typeprecipice type

G. Comb Type

Control Charts

1/2

Variability is inherent in all manufacturing

processes. These variations may be due to two
causes :
i. Random / Chance causes (un-preventable)
ii. Assignable causes (preventable)
Control charts was developed by Dr. Walter A.
Shewhart during 1920's while he was with Bell
Telephone Laboratories.
These charts separate out assignable causes.
Control chart makes possible the diagnosis and
correction of many production troubles and brings
substantial improvements in the quality of the
products and reduction of spoilage and rework.
It tells us when to leave a process alone as well as
when to take action to correct trouble

Control Charts

2/2

Control
chart is a chart to examine whether a

process is in a stable condition.

The control limits are drawn for the process
characteristics to be controlled.
Data is of two types :
1. Variable - measured and expressed
quantitatively
2. Attribute - qualitative
. The elements of a control chart
- Mean is the average of a sub-group
R - Range is the diference between the minimum
and maximum in a sub-group
1. CL - Center line: This is the expected mean of
the process
2. UCL - Upper Control Limit and
3. LCL - Lower Control Limit

Control Chart

Sample Statistics

Upper control line

Upper warning line
Target
Lower warning line
Lower control line

2
3
4
Sample Number

Lower control line

Interpreting Control Chart

One point outside
control limit
UCL

Statistics

UWL

LWL
LCL

3
4
5
Sample Number

8
24

Interpreting Control Chart

Two points out of three consecutive points
between warning limit and corresponding
control limit
UCL

Statistics

UWL

LWL
LCL

Sample Number
25

Interpreting Control Chart

Two consecutive points between warning limit and
corresponding control limit
UCL

Statistics

UWL

LWL
LCL

Sample Number
26

Interpreting Control Chart

Seven consecutive points on one
side of the centre line
UCL

Statistics

UWL

LWL
LCL

Sample Number
27

Interpreting Control Chart

Seven consecutive points having
upward trend
UCL

Statistics

UWL

LWL
LCL

Sample Number
28

Interpreting Control Chart

Seven consecutive points having
downward trend
UCL

Statistics

UWL

LWL
LCL

Sample Number

29

Scatter Diagram

1/2

A relationship may or may not exist between two

variables
If a relationship exists, it may be positive or
negative, it may be strong or weak and may be
simple or complex
A tool to study the relationship between two
variables is known as Scatter Diagram
Examples:
The relationship between moisture content in threads
and elongation.
The relationship between an Ingredient and Product
Hardness.
The relationship between cutting speed and variations in
the length of parts.

Scatter Diagram

2/2

The method consists of plotting the two series on a

graph and fitting a Line of Best Fit free hand

The direction of line shows the extent of

correlation. If the line goes upward from left to
right, it means the correlation is positive.

If the line goes downward from left to right, it

means the correlation is negative.

If the points on the plot are scattered largely, it

shows little or no correlation.

Although Scatter Diagrams are very convenient tools

for asserting two-way relationships, they dont
provide formal measures of these relationships.

Scatter Diagrams also dont provide any means of

establishing whether any apparent associations are
actually due to chance or not.

How to draw scatter diagram

2

1
Year
1987
1988
1989
1990
1991
1992
1993
1993
1994
1995
1996
1997
1998
1999
2000

Average
Sales (Lac)
168
182
192
235
304
304
333
343
423
484
553
548
589
639
661

Profits
(Lac)
66
70
76
92
117
132
147
151
159
170
188
186
204
223
234

1. Select the Sales

& Profit column
and
insert
a
Scatter chart
2. Add the axis
label & Trend
line
3
Strong
Sales vs. profit
Positive
250
correlatio
200
n
150

Profits (Lac)

Profits (Lacs) 100

Linear (

50
0
0 200400600800
Avg. Sales (Lacs)

Profits (Lac))

Various plot patterns of scatter diagrams

X
Positive
correlation may
be present

X
Positive
correlation

Y
X

Negative
correlation

X
No
correlation

Y
X
Strong
Curvilinear

X
Negative
correlation

Flow chart

1/2

Purpose:
Visual illustration of the sequence of operations required to
complete a task
To develop understanding of how a process is done
To study a process for improvement
To communicate to others how a process is done
When better communication is needed between people
involved with the same process
To document a process
When planning a project
Benefits:
Identify process improvements
Understand the process
Shows duplicated efort and other non-value-added
steps
Clarify working relationships between people and
organizations

Flow chart

Benefits

Show what actually

happens at each step in
the process
Show what happens when
non-standard events occur
Graphically display
processes to identify
redundancies and other
wasted efort

How is it done?
Write the process step
inside each symbol
Connect the Symbols with
arrows showing the
direction of flow

1/2

Toolbox

Check sheet
WHAT IS A CHECK SHEET ?
A Check Sheet is a method for collecting the right
data in a simple manner.
Classification of check sheets according to
functions:
1. Recording check sheet
(A) Defective Item Check Sheet
(B) Defective Cause Check Sheet
(C) Production process distribution Check
Sheet
2. Inspection Check sheet
(A) Check up Confirmation Check Sheet
(B) Evaluation item inspection Check Sheet

How to make check sheet

1. Clearly indicate the purpose of the data
collection
2. Decide on how to collect data
3. Estimate the total quantum of data
4. Decide on the Check Sheet form
5. Enter the data and draw up the Check Sheet.
6. Check if it meet the objectives. Is it easy to
record? If there are any improvement points,
freely amend it.
Reading and using the check sheet:
A) Read the whole picture
B) To see the time series of time, day and
month

Recording check sheet

1/2
1. Defective Item Check Sheet for a motor

Recording check sheet

2/2

. Defective Cause Check Sheet

3. Production
process
distribution
Check Sheet

INSPECTION CHECK SHEET

1. Check up Confirmation
Check Sheet

2. Evaluation item inspection Check Sh

To sum up 7 QC tools ,
they are used to
Tools

Result

Pareto Diagram
To Identify the major cause/issue
Cause and Efect To identify the cause and efect
Diagram
relationship
Histogram
Control Charts

To see the distribution of data

To find out abnormalities and
identify the current status

Scatter
Diagrams
Flow chart

To identify the relationship between

two things
illustration of the sequence of
operations required to complete a
task
To record data collection

Check Sheets

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