Seven Quality Control Tools

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 1. Pareto analysis
 2. Flowcharts
 3. Check sheets
 4. Histograms
 5. Scatter diagrams
 6. Control charts
 7. Fishbone diagram

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 Vilfredo Pareto was an Italian
economist who noted that
approximately 80% of wealth was
owned by only 20% of the population.
This was true in almost all the
societies he studied.

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1. Pareto analysis
 Choosing the Most Important Changes to Make
 Pareto analysis is a very simple technique that helps you to
choose the most effective changes to make.
 It uses the Pareto principle - the idea that by doing 20% of
work you can generate 80% of the advantage of doing the
entire job.
 Pareto analysis is a formal technique for finding the changes
that will give the biggest benefits.
 It is useful where many possible courses of action are
competing for your attention.

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 It is a statistical technique in decision
making that is used for selection of a
limited number of tasks that produce
significant overall effect.
 It uses the Pareto principle - the idea that
by doing 20% of work you can generate
80% of the advantage of doing the entire
job.
 Or in terms of quality improvement, a large
majority of problems (80%) are produced by a few
key causes (20%).
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 Pareto analysis is a formal technique useful
where many possible courses of action are
competing for your attention.
 Basically, it consists of estimating the
benefit delivered by each action with
subsequent selection of a number of the
most effective actions that deliver the total
benefit reasonably close to the maximum
possible one.

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 Write out a list of the changes you could
make. If you have a long list, group it into
related changes.
 Then score the items or groups. The
scoring method you use depends on the
sort of problem you are trying to solve.

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 For example, if you are trying to improve
profitability, you would score options on the
basis of the profit each group might
generate.
 If you are trying to improve customer
satisfaction, you might score on the basis
of the number of complaints eliminated by
each change.

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 The first change to tackle is the one that
has the highest score. This one will give
you the biggest benefit if you solve it.
 The options with the lowest scores will
probably not even be worth bothering with -
solving these problems may cost you more
than the solutions are worth.

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Case Study

Implementation of Pareto analysis.

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A failing service center
 Phones are only answered after
many rings.
 Staff seem distracted and under
pressure.
 Engineers do not appear to be well
organized. They need second visits
to bring extra parts. This means that
customers have to take more holiday
to be there a second time.

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 They do not know what time they will
arrive. This means that customers may
have to be in all day for an engineer to
visit.
 Staff members do not always seem to know
what they are doing.
 Sometimes when staff members arrive, the
customer finds that the problem could have
been solved over the phone

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Grouping & Scoring the problems.
 Lack of staff training: items 5 and 6: 51
complaints
 Too few staff: items 1, 2 and 4: 21
complaints
 Poor organization and preparation: item 3: 2
complaints
 By doing the Pareto analysis above, the
manager can better see that the vast
majority of problems (69%) can be solved by
improving staff skills.

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 Once this is done, it may be worth looking
at increasing the number of staff members.
 Alternatively, as staff members become
more able to solve problems over the
phone, maybe the need for new staff
members may decline.
 It looks as if comments on poor
organization and preparation may be rare,
and could be caused by problems beyond
the manager's control.

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 By carrying out a Pareto Analysis, the
manager is able to focus on training
as an issue, rather than spreading
effort over training, taking on new
staff members, and possibly installing
a new computer system.

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 2. Flowcharts
 Flow charts are easy-to-understand
diagrams showing how steps in a process
fit together.
 This makes them useful tools for
communicating how processes work, and
for clearly documenting how a particular
job is done.
 Furthermore, the act of mapping a process
out in flow chart format helps you clarify
your understanding of the process, and
helps you think about where the process
can be improved.

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 A flow chart is used to

 Define and analyze processes;

 Build a step-by-step picture of the
process for analysis, discussion, or
communication; and
 Define, standardize or find areas for
improvement in a process

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How to make a flow chart
 Most flow charts are made up of three
main types of symbol:
 Elongated circles, which signify the
start or end of a process;

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 Rectangles, which show instructions
or actions; and

 Diamonds, which show decisions that

must be made

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 Within each symbol, write down what
the symbol represents.
 This could be the start or finish of the
process, the action to be taken, or
the decision to be made.
 Symbols are connected one to the
other by arrows, showing the flow of
the process.

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Points to note
 Flow charts are simple diagrams that map
out a process so that it can easily be
communicated to other people.
 To draw a flowchart, brainstorm the tasks
and decisions made during a process, and
write them down in order.
 Then map these out in flow chart format
using appropriate symbols for the start and
end of a process, for actions to be taken
and for decisions to be made.
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 Finally, challenge your flow chart to
make sure that it’s an accurate
representation of the process, and
that that it represents the most
efficient way of doing the job

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 3. Check sheets
 The intent and purpose of collecting data is
to either control the production process, to
see the relationship between cause-and-
effect, or for the continuous improvement
of those processes that produce any type of
defect or nonconforming product.
 A Check Sheet is used for the purpose of
collecting data to compile in such a way as
to be easily used, understood and analyzed
automatically.

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 The Check Sheet, as it is being
completed, actually becomes a
graphical representation of the data
you are collecting, thus you do NOT
need any computer software, or
spreadsheet to record the data.
 It can be simply done with pencil and
paper

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The main functions - Checks
 Production process distribution checks
- where the distribution lies.
 Defective item checks - to determine
what kind of defects exist in the
process.
 Defect location checks - to determine
where the common defects on a part
are located.

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 Defective cause checks - type of
defect and thus validate the cause
thereof.
 Check-up confirmation checks - final
phase of assembly to check the
finished product or work.

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 4. Histograms
 The common person believes that if a part
is made in mass production from a
machine, all of the parts will be exactly
alike.
 The truth is that even with the best of machines
and processes, no two parts are exactly the same.
 The product will have a main or "mean"
specification limit, with plus/minus tolerance that
states that as long as the part is produced within
this range, to that range, it is an acceptable part.

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 The object is to hit the target specification,
however, that is not always totally possible.
 The purpose of a Histogram is to take the
data that is collected from a process and
then display it graphically to view how the
distribution of the data, centers itself
around the mean, or main specification.

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The histogram will graphically show
 The center of the data.
 The spread of the data.
 Any data skewness (slant, bias or run
at an angle).
 The presence of outliers (product
outside the specification range).
 The presence of multiple modes (or
peaks) within the data.
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 5. Scatter diagrams
 The Scatter Diagram is another Quality Tool
that can be used to show the relationship
between "paired data", and can provide
more useful information about a production
process.
 What is meant by "paired data"?
 The term "cause-and-effect" relationship
between two kinds of data may also refer
to a relationship between one cause and
another, or between one cause and several
others.
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 For example, you could consider the
relationship between an ingredient and the
product hardness; between the cutting
speed of a blade and the variations
observed in length of parts; or the
relationship between the illumination levels
on the production floor and the mistakes
made in quality inspection of product
produced.

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 6. Control charts
 Control charts are generally used in a
production or manufacturing
environment and are used to control,
monitor and IMPROVE a process.
 Common causes are always present
and generally attributed to machines,
material and time vs. temperature.

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 This normally takes a minor adjustment to
the process to make the correction and
return the process to a normal output.
 However, when making a change to the process, it
should always be a MINOR change.
 If a plot is observed that shows a slight
deviation trend upward or downward, the
"tweaking" adjustment should be a slight
change, and then another observation
should be made.

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 Too often people will over-correct by
making too big of an adjustment
which then causes the process to
dramatically shift in the other
direction.
 For that reason, all changes to the
process should be SLIGHT and
GRADUAL!

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 Control Lines
 A control chart is a graph or chart
with limit lines, called control lines.
 There are basically three kinds of
control lines:
 the upper control limit (UCL),
 the central line (actual nominal size
of product),
 the lower control limit (LCL).
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 The Xbar & R Control Chart

 An Xbar & R Control Chart is one that

shows both the mean value ( X ), and
the range ( R ).
 The Xbar portion of the chart mainly
shows any changes in the mean value
of the process, while the R portion
shows any changes in the dispersion of
the process.
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 This chart is particularly useful in that
it shows changes in mean value and
dispersion of the process at the same
time, making it a very effective
method for checking abnormalities
within the process; and if charted while
in progress, also points out a problem
in the production flow in real time
mode.

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 7. Fishbone diagram
 Cause & Effect Diagrams
 Identifying the Likely Causes of
Problems
 Also called Fish or Fishbone Diagram
and Ishikawa Diagrams

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 Cause and Effect analysis helps you
to think through causes of a problem
thoroughly.
 Their major benefit is that they push
you to consider all possible causes of
the problem, rather than just the
ones that are most obvious

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Conclusion.

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