KNC4293

QUALITY CONTROL AND RELIABILITY

Seven Quality Tools
Assoc. Prof. Dr. Rubiyah Baini
Department of Chemical Engineering & Energy Sustainability
Ground Floor, Chemical Engineering Building , UNIMAS
Email: ruby@feng.unimas.my
 Outcomes
Students are able to use the Basic 7 of Quality Tools
and analyse quality problem using these tools.
1. Fishbone cause and Effect Diagrams
2. Histograms
3. Pareto Analysis
4. Flowcharts
5. Check sheets
6. Scatter Plots
7. Control Charts
 Six Problem Solving Steps
• Identify
– recognize the symptoms
• Define
– Agree on the problem and set boundaries
• Investigate
– Collect data
• Analyze
– Use quality tools for data analysis
• Solve
– Develop the solution and implement
• Follow up
– Follow up to ensure that the solution is effective
 TOOL 1
Cause-and-Effect
Diagrams
 Cause-and-Effect Diagrams
• It is also known as a Fishbone Diagram or Ishikawa Diagram,
invented by Dr. Kaoru Ishikawa in 1960s, who founded quality
management processes in Kawasaki shipyards.
• It is an analysis tool that provides a systematic way of looking
at effects and the causes that contribute to those defects in
products’ quality. The design of the diagram looks much like
the skeleton of a fish. Therefore, it is often referred to as the
fishbone diagram.
 Cause-and-Effect Diagrams
The diagram can be used when there is the need to,
• determine the root causes for a problem/issue.
• visualize the important relationships between the
identified causes in relation to the effects in
studied.
• study all the possible reasons for the difficulties,
problems, or breakdowns occurred.
• identify areas for data collection.
• study why a process is not performing properly or
producing the desired results.
Steps:
• Draw the diagram
• Identify the problem/issue/effect to be studied, which becomes the "head
of the fish".
• Identify the major contributors/causes to the problem, such as Methods,
Machines, Materials, Manpower, Place, Procedure, People, Policies,
Surroundings, Suppliers, Systems, Skills, which becomes the bone of the
fish.
• Identify the factors within each category that may cause the
problem/issue to occur by having brainstorm session with team members.
• Analyze the results of the fishbone to make conclusion or to make priority
order on the 'most likely causes“ to the problem.
 Methods Materials
Cause
Cause
Cause
Cause
Cause Cause
Environment
Effect
Cause Cause

Cause Cause
Cause Cause

People Equipment
 An example done by a team in a
manufacturing factory to
understand the source of periodic
iron contamination.
 TOOL 2
Histogram
 Histogram

• A histogram is a of a bar chart representing the

frequency of an entire data grouped into evenly
spaced category. It can be viewed as a graph of
frequency versus class.
• It used to determine the spread or variation of a
set of data points in a graphical form.
 Frequency Distribution
Below are the data for the demand in weeks for
the last 30 orders of computers.

15 6 21 15 12
9 18 6 9 9
18 6 12 15 3
21 6 18 12 9
15 9 6 18 12
12 6 18 12 12 n = 30
 Frequency Distribution
The frequency distribution, a table that provides classes and
frequency (number of occurrences in the class) can be
developed as follow,

No. Class Frequency

1 1-4 1
2 5-8 6
3 9-12 12
4 13-16 4
5 17-20 5
6 21-24 2
 The graph of class versus frequency called
Histogram

Frequency

1-4 5-8 9-12 13-16 17-20 21-24

Range
 Stable process, exhibiting bell
shape
The shape of the
histogram will show
process behavior
 TOOL 3
Pareto Charts
 Pareto Charts
• It is named after the Italian economist, Vilfredo Pareto.
• It is also known as 80-20 rule, meaning about 80% of
problems come from the 20% causes.
• It is a graphical method to prioritize problems and to show
the significant problems.

Steps
• Create a preliminary list of problem classifications.
• Tally the occurrences in each problem classification.
• Arrange each classification in order from highest to lowest
• Construct the bar chart
Pareto Charts
 Pareto Charts
120

100

80
Quantity

60

40

20

0
Dent Scratch Hole Others Crack Stain Gap
Defects 104 42 20 14 10 6 4
 Pareto Charts
Weighted Pareto charts use
the quantity of defects
multiplied by their cost to 900

determine the order. 800

700

Weighted 600
Defect Total Cost cost
Weighted Cost 500
Gap 4 200 800
Dent 104 2 208
400
Hole 20 5 100
Crack 10 8 80 300
Scratch 42 1 42
Others 14 1 14 200

Stain 6 1 6
100

0
Gap Dent Hole Crack Scratch Others Stain
Weighted cost 800 208 100 80 42 14 6
 TOOL 4
Flow Charts
 Flow Charts
•Visual illustration of operations sequence.
•Charts are constructed using symbols, and these symbols are
connected to give a better understanding of the systems
involved.
•The charts help to
 Identify process improvements
 Understand the process
 Shows duplicated effort and other non-value-added steps
 Clarify working relationships between people and organizations
 Target specific steps in the process for improvement.
Process Chart Symbols
Flow Diagrams
 Process Chart
Date: 9-30-00 Location: Graves Mountain
Analyst: TLR Process: Apple Sauce

Distance
Operation
Transport Description

(min)
Time
Storage
Inspect

(feet)
of
Delay
Step

process

1 Unload apples from truck 20

2 Move to inspection station 100 ft
3 Weigh, inspect, sort 30
4 Move to storage 50 ft
5 Wait until needed 360
6 Move to peeler 20 ft
7 Apples peeled and cored 15
8 Soak in water until needed 20
9 Place in conveyor 5
10 Move to mixing area 20 ft
11 Weigh, inspect, sort 30
Page 1 0f 3 Total 480 190 ft
 TOOL 5
Scatter Diagram
 Scatter Diagrams
• It is a graphical method to identify the correlations between two
variables. These variables could be quality characteristic and the
factor/cause affecting the quality characteristics.
• Dots representing data points are scattered on the diagram. The
extent to which the dots cluster together in a line across the diagram
shows the strength with which the two factors are related.
• If the variables are
correlated, meaning the Scatter Diagrams
change in one variable
affecting the other variable.
• Dots, which form a line are
strongly correlated.
• Stratifying the data into two
or more groups based on
some difference such as the
equipment used, the time of
day, some variation in
materials or differences in the
people involved, may lead to
significant results
 Scatter Diagrams
• You may occasionally get scatter
diagrams that look boomerang- or
banana-shaped.
To analyze the strength of the
correlation, divide the scatter plot
into two sections.
Treat each half separately in your
analysis
• Analysis may helps in identifying and
testing probable causes.
• By knowing which elements of your
process are related and how they are
related, you will know what to control
or what to vary for quality
improvement.
 TOOL 6
Check Sheets
 Checksheets
• It is a tool for organizing
measured data over a specified
period of time or within a
certain batch of product.

• It is a tool collect data in a

systematic and organized
manner, to determine source of
problem and to facilitate
classification of data.
 TOOL 7
Control Charts
 Control Chart
The data must have a normal distribution (bell curve).
27

24
UCL = 23.35
21
Number of defects

18 c = 12.67

15

12

6
LCL = 1.99
3

2 4 6 8 10 12 14 16
Sample number
Control charts can tell us when a process changes
FURTHER DETAIL ON CONTROL CHARTS
WILL BE DISCUSSED IN A SEPARATE TOPIC,
STATISTICAL PROCESS CONTROL.

THANK YOU FOR YOUR ATTENTION

 Quotes for the day

"No one can make you feel inferior without your consent." --Eleanor Roosevelt

"When you stop chasing the wrong things, you give the right things a chance
to catch you." --Lolly Daskal

"Great minds discuss ideas; average minds discuss events; small minds
discuss people." --Eleanor Roosevelt

"Success is walking from failure to failure with no loss of enthusiasm."

--Winston Churchill

"Much of the stress that people feel doesn't come from having too
much to do. It comes from not finishing what they've started." David
Allen