Professional Documents
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10 Basic Tools
10 Basic Tools
10 Basic Tools
TOOLS
QUALITY IMPROVEMENT
BASIC TOOLS
1. TALLY SHEET
2. HISTOGRAM
3. PARETO DIAGRAM
4. CAUSE AND EFFECT DIAGRAM
5. SCATTER DIAGRAM
6. SRATIFICATION
7. CONTROL CHART
1. TALLY SHEET
THE TALLY SHEET
SIMPLE REGISTRATION OF DATA AT THE
WORK STATION -
Frequently it makes sense to register data
immediately at the work station in a quick
and simple way. It is a list in which stripes
have to be filled in hence it is called tally.
The test data or defects are filled in the
related column in a preprinted form
immediately after the test. The observed
or measured value need not be written
down but can be indicated by a stripe/line.
TALLY SHEET no.
Date:
Type: manufacturer:
test point: place
number checked: checked by:
total number: remark:
code no:
Totals
1 2 6 13 10 16 20 17 12 16 20 17 11 8 5 6 2 1
Specification limit
Specification limit
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Check Sheet
Product Date:
Total rejects 42
2.HISTOGRAM
Histogram
When used in process capability studies,
histograms can display specification
limits to show what portion of the data
does not meet the specifications.
3.36 3.46 3.48 3.50 3.42 3.43 3.51 3.48 344 3.50 3.56 3.42
3.48 3.56 3.50 3.32 3.47 3.40 3.46 3.56 3.54 3.30 3.56 3.30
3.41 3.37 3.47 3.47 3.45 3.44 3.50 3.47 3.46 3.46 3.50 3.37
3.55 3.52 3.44 3.50 3.45 3.49 3.48 3.46 3.52 3.46 3.55 3.44
3.48 3.48 3.32 3.40 3.52 3.34 3.46 3.43 3.30 3.46 3.52 3.30
3.59 3.63 3.59 3.47 3.38 3.52 3.45 3.42 3.31 3.46 3.63 3.31
3.40 3.54 3.46 3.51 3.40 3.50 3.68 3.60 3.46 3.52 3.68 3.40
3.48 3.50 3.56 3.50 3.52 3.46 3.49 3.46 3.52 3.56 3.56 3.46
3.52 3.48 3.46 3.45 3.46 3.54 3.51 3.48 3.49 3.41 3.54 3.41
3.41 3.45 3.34 3.44 3.47 3.40 3.46 3.48 3.54 3.47 3.54 3.34
DIVISION IN CLASSES
30
20
10
0
3.30 3.40 3.50 3.60 3.70
Thickness in mm
Histogram with an
interruption. Possibly
errors have been made
during measurement of
the preparation of the
histogram.
In this situation no
risk of rejects, due
to small variations
in the process.
Histogram
This situation
offers no room for a
change in the
process i.e. any
change in the
Histogram
It is possible to
reduce the specified
tolerance or the
accuracy of the
process.
Histogram
Spec limits
The process mean
R
is too far to the left
and must be shifted
to the nominal
value.
R
The distribution is
too wide.
Change the
process to limit
distribution or
extend tolerance.
3.PARETO DIAGRAM
PARETO DIAGRAM
Total 87.0
Loss Percentage Cumulative
Sales Department
(In millions of %
of Rupees) total
E 5 51.7 51.7
C 11.5 86.2
10
A 20 5.7 91.9
B 45 2.9 94.8
H 1 1.7 98.2
90 100%
80
70
Jan - May 19XX
60
50
40 50%
30
20
10
0
E D C A B F H G Div
PARETO DIAGRAM PROCEDURE
Make a list of possible defects or problems
according to cause, phenomenon, cost price,
etc.
Collect these data over a certain length of time.
Express the data in the correct units.
Classify the groups in descending order of
Occurrence and draw the bar diagram.
Draw a broken line indicating the cumulative
%, starting with the right hand top corner of
the first bar.
PARETO DIAGRAM
200 100
Number of units investigated
180 90
160 80
Number of defective units
140 70
Cumulative percentage
120 60
PARETO DIAGRAM
100 50
80 40
60 30
40 20
A:Crack
20 10
B: Scratch
C: Stain
D: Strain
D B F A C E Others E: Gap
F: Pinhole
4.CAUSE AND EFFECT
DIAGRAM
CAUSE AND EFFECT DIAGRAM
Wave Height
Moisture
Temperature Humidity
Sleep Composure
Confidence
Depth
Defeat in a sports
Information power match
Theory Schedule
Motion
Study of Exercise
Planning
opponent Speed Quality
Analysis Cooperation Quantity
Rules
Observation Advice
Teamwork Form
Common Judgement of Function
sense situation Model Repetition
Strategy Experiences in matches Technique
MACHINES Parts wearing
Poor alignments
Old
Wrong spare Machine
OPERATORS parts breakdown
Poor maintenance
Unaware
Shortage
Breakdown not reported
Poor training
POOR QUALITY
OF GLAZES
Variable quality
Wrong time
Wrong temperature
Cheaper brand
Incorrect settings
Damp weather
(storage) METHODS
MATERIALS
MAN MACHINE
Dirty hands
Maintenance
Possible other
adjustment
Causes
Direction
Holes in gloves
EFFECT
measurement flatness
Description/procedures
calibration hardness
METHOD
MATERIAL
160
150
140
130
120
X
150 160 170 180 190 cm
10
SCATTER DIAGRAM
9
Machine accuracy (% defective readings)
8
1 2 3 4 5 6 7
Y increases as X increases
Strong positive correlation
X
SCATTER DIAGRAM
Y
X
SCATTER DIAGRAM
Y
X
SCATTER DIAGRAM
Y
Y may decrease as X
increases
weak negative correlation
X
SCATTER DIAGRAM
Y
Y decreases as X
increases
Strong negative
correlation
X
ANALYSING SCATTER DIAGRAM
55
SCATTER DIAGRAM
50
45
850 900
SCATTER DIAGRAM
8.45
8.37
Days
1 2 3 4 5 6 7 8 9 10 11 12
Abnormal
Normal
v
Abnormal
Control Chart
Center line
Center line
Control Chart
(c)
trend
Falling trend in a wave
Six consecutive raising point
Control Chart
(d) Two of three consecutive points
Approaching the limits
Period 1 wk 1 wk 1 wk
Control Chart
Control Chart