Seven Quality Control Tools ( 7QC)

Seven QC tools are fundamental instruments to improve the

quality of the product. They are used to analyze the production
process, identify the major problems, control fluctuations of
product quality, and provide solutions to avoid future defects.
Statistical literacy is necessary to effectively use the seven QC
tools. These tools use statistical techniques and knowledge to
accumulate data and analyze them.

Seven QC tools are utilized to organize the collected data in a

way that is easy to understand and analyze. Moreover, from
using the seven QC tools, any specific problems in a process are
identified.
Seven Quality Control Tools

• Check sheet
• Cause Effect Diagram
• Graphs & Charts
• Histogram
• Pareto Chart
• Scatter Diagram
• Stratification.

These 7 QC tools also known as ISHIKAWA’S 7QC tools which

revolutionized the Japane & the World in Sixties & Seventies
Check
Check Sheet
Sheet
Description
A check sheet is structured, prepared form for collecting and analyzing
data. It can also be used to confirm and record that steps of the process
were done.

When to Use
1. When collecting data on the frequency or patterns of events, problems,
defects, defect location, defect causes and so forth.
2. When collecting data from production process
3. When data can be observed and collected repeatedly by the same
person or at the same location.
4. Data collection can occur at any step of the project.

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Check Sheet – Example

Part Name : S/Abs Assy

TIME PERIOD: 22 Feb to 27 Feb 1998

PA S/Abs ASSY
Spatter ||||
Mixup |||| |||| |||| |||| |||| ||
Caulking Crack ||
Damage ||||
No Oil
Piston Rev Assy |
Cause-and-Effect
Cause-and-Effect Diagrams
Diagrams
Description
The Cause and effect diagram relates causes and effects. It can be used to structure a brain
storming session. It immediately sorts ideas into useful categories

The cause and Effect diagram is also called as

 Ishikawa diagram
 Fish Bone Diagram
 4 M Diagram

When to use

 For organizing a problem in an understandable manner

 When broad thinking about possible causes is desired.
 When the team’s thinking tend to fall in to us.

Procedure
 Agree on a problem statement (effect)
 Brainstorming the major categories of causes of the problem. If there is difficulty
here use generic headings, method, machines (equipment), people (Manpower),
Materials, Measurement, Environment.

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Cause
Cause and
and Effect
Effect “Skeleton”
“Skeleton”

Materials Machine

Quality
Problem

Man Method
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Fishbone Diagram
Measurement Man Machines

Faulty testing equipment Poor supervision Out of adjustment

Incorrect specifications Lack of concentration Tooling problems

Improper methods Inadequate training Old / worn

Quality
Inaccurate Problem
temperature Poor process
control Defective from vendor
design
Ineffective quality
Not to specifications management
Dust and
Dirt Material- Deficiencies
handling problems in product
design
Environment Materials Process
Cause and effect diagrams
 Advantages
• making the diagram is educational in itself
• diagram demonstrates knowledge of problem solving
team
• diagram results in active searches for causes
• diagram is a guide for data collection
 Cause Validation
 All identified causes needs to be validated
Cause and effect diagrams

To construct the skeleton, remember:

 For manufacturing - the 4 M’s

 man, method, machine, material

 For service applications

 equipment, policies, procedures, people

Graphs & Charts
Description.
A graph is a visual display of numerical data to achieve deeper or quicker
understanding of the meaning the numbers.
When to Use
When analyzing the data
When presenting the data
Basic Principle
 Collect or assemble the data to be shown on your graph. Decide what you want to
study or to show with the graph.
 Decide what form the graph should take. See the variance section for different
formats
 Determine the range (Lowest number) you need to show on the graph for each set
of data. Choose the scale for each set of data to be as or slightly larger than the
range.
 Analyze the graph, What does it teach? What additional graphing, analysis,
investigation ot data collection does suggest?.
Run Charts
Description
A run chart is a graph shows a measurement (on the vertical axis) against time (on the
horizontal axis) with a reference line to show the average of the data. It is similar to control
chart but has no limits.
When to Use
 During data collection before enough points have been collected to draw a chart.
 To look for trend or changes in the average.
 To look for cycles, auto correlation or other patters.

Procedure
 Decide on the vertical scale based on the range of measurements you expect to
see. Decide on the horizontal time scale based on the frequency of measurements.
Mark and label the scale.
 Plot each measurements in the time order it occurs. Connect points with straight
lines.
 Lock for patters in the data using tests for out of control situations.
Control Chart
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
Histogram
Description
A Histogram is bar graph that shows the distribution of assets of data: how often the different values
occur., individual data values cannot be seen. A variation the stem and leaf display, preserves the
individual values also it describes the pattern of variation.
When to use
 To gain an impression of measured value distribution
 To analyze quickly whether a process can meet the customer’s requirements.
 To see whether a change has occurred from one time period to another
 To determine whether the output of a process is distributed approximately normally.
 To communicate the distribution quickly and easily to others.
Procedure
 Collective at least 50 consecutive data points from a process. If you don’t have that
much data. Use a point graph, described under graph section.
 From the data collected find out the minimum & maximum numbers
 Record all the observed data in the frequency distribution following the method of check
sheet. (min is the start of the class and maximum in the end)
 The class interval is discretionary. However closer interval gives accuracy for
interpretation.
 Draw X & Y axes on the graph paper and label the y axis for counting data values. Mark
the x axis with class values to draw bars of the histogram. 7 Quality Tools
Histogram
25

20

15
Frequency

10

Category

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Histogram belongs to the same family and helps us to keep track of
the variations.
 35

30 142
FREQUENCY

144
25
146
20 148
150
15 152
154
10
156
5 158

0
WEIGHT (gms)

When a process is like this we call it "normal distribution"

(bell Shaped) and consider the process is under control.
Pareto Principle
Description
A pareto chart is a bar graph. The length of the bar represents the frequency of occurrence or cost
(money, time). Therefore the chart visually shows which situations are more significant .
When to use
 For selecting problems, based on priority
 When analyzing data by groups, to reveal unnoticed patterns.
 When trying to focus on the most significant problem or cause.
 When communicating with others about your data.
 When relating cause and effect, by comparing a Pareto chart classified by causes with one
classified by effects.
 When evaluating improvements, by comparing before & after data.
Procedure
 Decide what categories you will use to group items.
 Decide what period of time the chart will include.
 Decide what measurement to use - frequency, percent, cost time, quantity.
 Collect the data.
 Determine the appropriate number scale for your chart. Mark the scale on your chart.
 Write down data in descending order.
 Construct and label bars for each category. Place the tallest at the top or far left, then next tallest
band so on. If there are many categories with small measurement, they can be grouped as “ others”
 Calculate the percentage for each category: the total for that category divided bt the total for all
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categories. Label each bar with its percentage, or a right vertical axis and label it with percentage.
Data for Pareto Analysis

PA -- Head Assy
Period : 01.11.2008 to 15.11.2008
Problem Qty % Rej Cumm %
eye eccentricity problem 23 25.8 25.8
spatter problem 20 22.5 48.3
extra material 19 21.3 69.7
weld check error 13 14.6 84.3
head cap rust 5 5.6 89.9
incomplete welding 5 5.6 95.5
Gap problem 3 3.4 98.9
Damage 1 1.1 100.0

Total 89
Pareto Diagram
Pareto Analysis -- PA HEAD ASSY

25 100.0
23
90.0
20
20 19 80.0

70.0

15 60.0

Cumm % Rej
13
Qty

50.0

10 40.0

30.0
5 5
5 20.0
3
10.0
1

0 0.0
eye spatter extra material weld check head cap rust incomplete Gap problem Damage
eccentricity problem error welding
problem
Scatter diagram ( Correlation diagram)
Description
The scatter diagram helps identify relationships between two
variables.
When to use
 When trying to identify potential root causes of problems.
 After brainstorming causes and effects using fishbone diagram, to
determine objective whether a particular cause and effect are related.
 When determining whether two effects that appear to be related both
occur with the same cause.
Procedure
 Collect paired data for variables where a relationship is suspected.
 Plot all the variable pairs on a graph, with one variable on the horizontal axis
and the other variable on the vertical axis.

Formula to calculate the co-efficient of Correlation 7 Quality Tools

Positive Correlation

.
Negative Correlation
No Correlation
Stratification
Description
Stratification is a technique used in combination of with other data analysis
tools.
When data from variety of sources or categories had been lumped together,
the meaning of the data can be impossible to see. The technique separates
the data so that patterns can be seen.
When to use
 When using check sheet, scatter diagram, control chart, histogram, or similar data
collection or analysis tool.
 When data come from several sources such as several shifts, days of the week, lots,
suppliers, pieces of equipments and so on.
Procedure
 Before collecting data, consider what information about the sources of the data has an
effect on the results. Setup the data collection so that you collect that information
also. The following list gives examples of typical information that requires data to be
stratified.
i.e Machines, Materials, day of week, equipment, shift, products workers, time of day
suppliers. Etc

Group the data for analysis based on the requirements.

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 Right tool for the Job

Understand problem

Check the effects of

Establish control
Analysis Causes

improvement
The 7 QC tools for Problem solving

Fish Bone Assuring Awareness of possible causes,

Diagram Logical arrangement of causes
Pareto Chart Selecting major problem out of many
Graph Visual representation of data for quick
understanding
Check sheet Quick data collection and prevention of
mistakes
Control Chart Checking stability of process
Histogram Viewing the shape of dispersion or
comparing with spec
Very Effective Used Often
Scatter Seeing the relationships of pairs of
Diagram variable
 Problem Solving Technique
S.No Steps 7 QC tools
1. Problem
2 Observation Check sheet

3 Analysis Cause Effect Diagram , Graphs &

Charts , Histogram , Pareto Chart
Scatter Diagram
4 Action Cause Validation,
5 Check Check sheet

6 Standardization Graphs & Charts , Histogram

7 Conclusion Check sheet