Professional Documents
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Basic Quality Control Tools
Basic Quality Control Tools
Dr. Rathanraj K J
Professor, BMSCE
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Im Co
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Procedures
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Plant &
Legal
Equipment
Reqts
Customer
People
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Technology
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R&D
Adapted from S.
Thomas Foster
Data
Collection
Check
Sheet
Data
Analysis
Problem
Identification
Prioritization
Histograms
Scatter
Plots
Control
Charts
Cause
Effect
Pareto
Analysis
Adapted from S.
Thomas Foster
Flowcharts
Graphic representation of system
or procedure flow
Can be used for both macro and
micro level processes
Promotes system understanding
and will identify gaps in procedural
logic
Flowcharting Steps
Agree on a standard set of
symbols
Clearly communicate purpose of
the flowchart
Observe the work; shadow the
workers
Develop flowchart of the process
Review with the employees and
adjust as necessary.
Flowcharts
Flowcharts
Graphical description of how work is
done.
Used to describe processes that are to
be improved.
Flow Diagrams
" Draw a flowchart for whatever you
do. Until you do, you do not know
what you are doing, you just have a
job.
-- Dr. W. Edwards Deming.
Flowchart
Activity
Decision
No
Yes
Flowchart
Flow Diagrams
Flow Diagrams
Check Sheets
Check Sheets
The format for recording all the
necessary information to execute
preventive plans and to enable
development of strategies for
improvement, commonly known
as Data Sheet, Log Book,
Inspection Record, Schedule of
Enquiry has been termed check
sheet in this context.
Total
Friday
Thursday
Wednesday
Tuesday
Problem Type
Monday
Setup routines
not standardized
Missing equipment
for setup
Failure to separate
internal and external
tasks
Extensive machine
resetting and paper
change
Other
Adapted from S.
Thomas Foster
Attribute Inspection
Variable Inspection
Packing Process
A typical check sheet for list of items to be packed and or dispatched
to a customer such as a standard list of spares accompanying a
machine tool as accessories
2k n
Histograms
Histograms bar chart graphical
representation of data, also used to
observe the shape of data
Rules for developing histograms:
Width of bars must be consistent
Classes must be mutually exclusive and
all-inclusive
Rule of thumb for the number of classes:
k log n / log 2
Histograms (cont.)
n = number of raw data values
k = number of classes
k log n / log 2
Using this formula, we find:
Number of Observations
Number of Classes
9 to 16
17 to 32
33 to 64
65 to 128
129 to 256
H
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Histogram Example
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Reference:
Lab 1, CIT 320
Spring 2004
Lindsay Howard
Cause-and-Effect Diagrams
Cause-and-Effect Diagrams used to
move to lower levels of abstraction in
solving problems
A.K.A.: Ishikawa Cause-and-Effect or
Fishbone or Ishikawa Diagram
Fish skeleton shape, the problem is the
head, major causes are the ribs, subcauses form smaller bones of the ribs
Cause-and-Effect (cont.)
Ref: http://courses.bus.ualberta.ca/orga432-reshef/fishbone.html
Pareto Principle
Vilfredo Pareto (1848-1923) Italian
economist
20% of the population has 80% of the
wealth
Pareto Charts
Pareto Charts used to identify
and prioritize problems to be
solved
Histograms aided by the 80/20
rule
SOME EXAMPLES
Table Showing Nature, Frequency and Rank of Nonconformity.
Organisation: ORG Product: PRO Month: MO/YR
Scatter Diagrams
N
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Reference:
Lab 3, CIT 320
Spring 2004
Lindsay Howard
Control Charts
Control Charts
Control Charts used to determine if a
process will produce a product or
service with consistent measurable
properties
X and R charts are used together, and
are calculated from the same raw data
d
Control Charts
Control charts
Control charts are powerful aids to
understanding the performance of
a process over time.
Output
Input
PROCESS
Whats causing variability?
Control Charts
Control Charts
Control Charts
Control chart
components
Centerline
shows where the process average is
centered or the central tendency of
the data
Control Charts
Control Charts
Control Charts
Other guidelines
The larger the subgroup size, the more
sensitive the chart becomes to small
variations.
This increases data collection costs.
Destructive testing may make large
subgroup sizes infeasible.
Subgroup sizes smaller than 4 arent
representative of the distribution averages.
Subgroups over 10 should use S chart.
Control Charts
Control Charts
X
Control Charts
X
i 1
UCL X 3
LCL X 3
standard deviation
Control Charts
R
i 1
UCL X A 2 R
LCL X A 2 R
Control Charts
Control Charts
Control Charts
Consequences of
misinterpreting the process
Blaming people for problems that they cannot
control
Spending time and money looking for
problems that do not exist
Spending time and money on unnecessary
process adjustments
Taking action where no action is warranted
Asking for worker-related improvements
when process improvements are needed first
Control Charts
Process variation
When a system is subject to only
chance causes of variation, 99.73% of
the measurements will fall within 3
standard deviations
If 1000 subgroups are measured, 997 will
fall within the six sigma limits.
Control Charts
Chart zones
Based on our knowledge of the normal curve, a
control chart exhibits a state of control when:
Two thirds of all points are near the center
value.
The points appear to float back and forth
across the centerline.
The points are balanced on both sides of the
centerline.
No points beyond the control limits.
No patterns or trends.
Control Charts
Identifying patterns
Trends
steady, progressive changes in level
Change, jump, or shift in level
Runs - 7 points above or below; six
increasing or decreasing, clusters
Recurring cycles
Two populations
Mistakes
Control Charts
Control Charts
Control Charts
Control Charts
Process Capability
Process Capability
Defining process
capability
Process capability refers to the
ability of the process to meet the
specifications set by the customer
or designer.
Process Capability
USL
-3
Target
Process Capability
+3
x
n
Process Capability
To simplify calculation
If the process can be assumed to be normal,
the population standard deviation can be
estimated from either the standard deviation
associated with the sample standard
deviation or the range:
or
2
Process Capability
Process Capability
Process Capability
Process Capability
Affinity Diagram
Creative
Logical
Tree Diagram/
System Flow
Prioritization
Matrices
Matrix
Diagram
Unknown
Process Decision
Program Chart
Known
Activity Network
Diagram
Affinity Diagrams
Affinity Diagrams creates a hierarchy
of ideas on a large surface
Useful to surface all issues related to a
problem
Helps groups converge on a set
number of themes or ideas
Ref:
http://www.infodesign.com.au/usab
ilityresources/general/affinitydi
agramming.asp
Ref:
http://mot.vuse.van
derbilt.edu/mt322/A
ffinity.htm
Interrelationship Diagrams
Interrelationship Diagrams show
relationships between different
issues
Helpful in identifying the most
important issue
Ref:
http://www.sm
artdraw.com/t
utorials/bpm/
bpm10.htm
Tree Diagrams
Ref:
www.smartdraw.com/resources/exa
mples/business/orgchart9.htm
Prioritization Grids
Ref:
http://www.smartdraw.
com/tutorials/bpm/bpm
13.htm
Matrix Diagrams
Matrix Diagrams brainstorming
tools used in a group to show
relationships between ideas or
issues
Can be used in two, three, or four
dimensions
Ref:
http://www.vanderbil
t.edu/Engineering/CI
S/Sloan/web/es130/qu
ality/newtool.htm#ma
trix
Ref:
http://www.flo
wbiz.com.au/fl
owbiz/products
/charter
Ref:
http://www.smartdraw.com/examples/p
ert/groupsculpture.htm