ELENTEC INDIA

Training module
on 7 QC TOOLS

Duration : 04 Hours
 What is a “Problem “?
“Problem is an undesirable event”
or ..
Any Gap between what is expected and what is
obtained , can be called as a Problem, and any effort to
reduce this gap can be called as “Problem Solving”

Expected
(Gap ?) A Problem!

Obtained
 Types of Problems
Four types of Problems
Four types of Problems
7 QC Tools
 7QC Tools
History
7 QC Tools invented during Postwar in Japan.(End of Word
War II in 1945) Before & during the War, Japan was known
as an Empire but is now simply known as Japan.

It was possibly introduced by Kaoru Ishikawa.

It is given to Japanese Engineers & Scientists in 1950 at the

time Companies that had set about training their work force
in Statistical Quality Control
 7QC Tools
Definition

 7 QC Tools are using for Collecting data, Analyzing data, Finding

the Root Cause and Measuring the results.

 7 QC Tools ka]pyaaoga data kao ek~ krnaoMÊ

data ka ivaElaoYaNa krnaoÊ maUla karNa ka pta
krnao maoMÊ tqaa pirNaama kao jaacanaoM
maoM krto hOM.
 Details of 7QC Tools
 Cause & Effect Diagram

 Check Sheet

 Pareto Diagram

 Control Chart

 Histogram

 Scatter Diagram

 Stratification
 Tool No :-1

Cause & Effect

Diagram
 Cause & Effect Diagram
Definition
Cause & Effect Diagram is also known as Fishbone Diagram or
Ishikawa Diagram

 Cause & Effect Diagram is a tool to find out all provable to

possible causes which is create a specified defect in term of 4M.
(Man, Machine, Material & Method)

ek eosaa tool hOÊ ijasasao

 Cause & Effect Diagram
hma iksaI BaI samasyaa ko samBaaibat sao
samBaaibat saBaI maUla karNaaoM ka pta
lagaato hOMÊ jaaoik ek daoYa kao ]<apnna krnao
 Cause & Effect Diagram
Method, Usage & Results
Method Usage Results

1. Used when clarifying a 1. Can obtain a clear overall

Cause and Effect cause and effect relationship picture of causal relation.
Diagram
Machine Man

2. Used to develop 2. Can list up all causes to

identify important causes.
Effect

countermeasures
3. Can determine the direction
Material Method of action (countermeasure).
Cause (4M’s) Result
(Controlled State)
Cause & Effect Diagram
Example / Format
 Tool No :-2

Check Sheet
 Check Sheet
Definition

 Check Sheet is a tool which show the relation between present and
past data.

For Example :- OCS (Operation Check Sheet), PDIR (Pre Dispatch

Inspection report), Lay Out reports, Travel Cards, 100% Insp. check
sheet, etc.

 Check Sheet ek
eosaa tool hOÊ jaao hmaoM bat-
maana AaOr BaUtkala ko Aa^MkNaaoM maoM
sambanQa dSaa-ta hO.
 Check Sheet
Method, Usage & Results
Method Usage Results

1. Used to collect data. 1. Ensures collection of

required data.

Check Sheet 2. Used when performing a

Day thorough inspection 2. Allows a thorough inspection
Process of all check items.
Process 1

Process 2
Used during phases to
monitor the situation, 3. Can understand tendencies
Process 3
analyze causes, review and variations.
effectiveness of an action,
perform standardization,
and implement a selected 4. Can record required data.
control measure
 Check Sheet
Example
Date
S.No. Defects Total
1 2 3 4 5 6 7

1 Gauging NG

2 Paint NG

3 Welding NG

4 Dent

5 Scratches
 Tool No :-3

Pareto Diagram
 Pareto Diagram
Definition
Pareto Diagram is also known as 80-20 Rule

 Pareto is a tool to find out those 20% problems, By which solving

our product is 80% defect free.

 Pareto is a tool to find out the priority of things.

 Pareto diagram is a combination of bar and line graphs of

accumulated data, where data associated with a problem.

 Pareto ekeosaa tool hOÊ jaao hmaoM iksaI ]

%pad kI eosaI 20% samasyaaAaoM kao Kaoja kr
inakalata hOÊ ijasaka samaaQaana krnao pr
 Pareto Diagram
Method, Usage & Results
Method Usage Results

1. Used to identify and 1. Allows clarification of

prioritize a problem. important tasks.

Pareto Diagram 2. Allows identification of a

(No. of Occurrences)
2. Used to review the effects starting point (which task to
of an action taken. start with)

3. Allows projection of the

effects of a measure to be
Used to prioritize actions. taken.
(Used during phases to
monitor the situation,
analyze causes, and review
effectiveness of an action.)
 Pareto Diagram
Example
120 Qty.
Cum%
100
100
91
80

71
60
45
34
40
41
22
20
10

0
Paint NG Dent Gauging NG Welding NG
 Tool No :-4

Control Chart
 Control Chart
Definition
 Control Chart is a tool for Controlling, Measuring & Improving
the process by eliminating the special cause of variation.

 We can say that the process is statistical control if it contain

common cause of variation.

 Causes are three types :- 1. Common Cause

2. Special Cause
3. Natural Cause

 Control Chart ek
eosaa tool hOÊ jaao iksaI
p`ik`yaa ka inayaM~Na krta hOÊ p`ik`yaa kao
maapta hO tqaa ]sao sauQaarta hOÊ ]sa p`ik`yaa
 Control Chart
Method, Usage & Results
Method Usage Results

Can identify a change

Used to observe a
caused by elapse of time.
change caused by
Control Chart elapse of time. Can judge the process if it is
in its normal state or there
are some anomalies by
examining the dots plotted
[Used during phases to on the chart.
monitor the situation,
analyze causes, review
In the example “x bar ” -R
x-R Control Chart effectiveness of an control chart, “X bar”
action, perform represents the central value,
standardization, and while “R” indicates the range.
implement a selected
control measure]
Control Chart
Example
 Tool No :-5

Stratification
 Stratification
Definition
 The “common and basic principle” of quality control is
stratification, i.e., to think a matter out by breaking it into smaller
portions. Stratification has a number of useful purposes.

 StratificationÊ Quality inayaM~Na

ka saamaanya
AaOr maUla isawaMt hO.hma ApnaI saaoca va
ja$rt ko Anausaar Aa^MkDaoM kao CaoTo
BaagaaoM maoM taoDto hO.
 Stratification
Method, Usage & Results
Method Usage Results
•Used to observe
Grouping by day, time, variations among strata.
place, worker, or process •Allows observation of
•Used to identify the
variations among strata.
relationship between •By performing a cause
Number of Units
cause and effect. analysis using the stratified
•Used to identify a
X ★★★★★★★
data.
purpose and means to
Y △△△△
serve the purpose.
Z ○○○
 Tool No :-6

Scatter Diagram
 Scatter Diagram
Definition
 A scatter diagram is used to “examine the relationship between
the two, paired, interrelated data types, ” such as “height and weight
of a person.”

 Scatter diagram is a tool which show the relation between two

interrelated paired data.

Example :

 The age and value of a car

 The height and shoe size of a person

 The marks that a person gained in two separate tests.

 Scatter Diagram
Method, Usage & Results
Method Usage Results
•Used to identify a
relationship between •Can identify cause and
two matters. effect relation.
Scatter Diagram •Used to identify a •Can understand the
ｙ Axis
relationship between relationship between two
two matters and results.
Abrasion

establish
countermeasures based
x Axis
on their cause and effect
Number of relation.
Rotations
 Scatter Diagram
When to use a Scatter Diagram

 When you have paired numerical data.

 When your dependent variable may have multiple values for each value of your
independent variable.

 When trying to determine whether the two variables are related, such as…
1.When trying to identify potential root causes of problems.

2. After brainstorming causes and effects using a fishbone

diagram, to determine objectively whether a particular cause and effect are
related.

3. When determining whether two effects that appear to be related both occur
with the same cause.

4. When testing for autocorrelation before constructing a control chart.

 Scatter Diagram
Correlation on a Scatter Diagram

strong correlation weak correlation no correlation

Notice how the crosses are grouped close together along an

imagined line.

The crosses are less closely grouped in the example of weak

correlation.
 Scatter Diagram
Correlation can also be described and positive or negative,
Depending on the slope (gradient) of the graph

positive correlation Negative correlation No correlation

Positive correlation means that as one item increases, so does

the other increases e.g. as a person’s height increases so does their arm span
Negative correlation means that as one item increases, so does
the other decreases e.g. as a car gets older its value decreases
No correlation means that as one item increases, so does
the other some time increase or decreases e.g. Daily use item sale
 Scatter Diagram
Example
Strength
16
14
12
10
f(x) = 0.0233333333333333 x + 5.95555555555556
Strength

8 R² = 0.0456521739130431 Strength
Linear (Strength)
6
4
2
0
90 100 110 120 130 140 150 160 170 180 190
Current
 Amount
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
2015.5 2016 2016.5 2017 2017.5 2018 2018.5
Amount
 Tool No :-7

Histogram
 Histogram
Definition
 Histogram is a tool which indicate the distribution of the data
centers it self around the mean.

Usage
 A histogram is mainly used to analyze a process by examining the
location of the mean value in the graph or degree of variations, to
find a problem point that needs to be improved. Its other
applications are listed in the table below.

 Histogram ek
eosaa TUla hO jaao hmaoM dSaa-ta
hO ik Aa^MkDaoM ka ivatrNa maIna pr iktnaa
koind`t hO.
 Histogram
Method, Usage & Results
Method Usage Results
•Used to assess the
actual conditions. •Can identify the location of
•Used to analyze a
the mean (central) value or
Histogram process to identify a degree of variations.
Standard
Range
problem point that •Can find out the scope of a
needs to be improved by defect by inserting standard
finding the location of values.
the mean value or •Can identify the condition
degree of variations in of distribution (e.g.,
X Axis (Values
the graph. whether there is an
Range of
Actually
•Used to examine that
Variations
Measured)
isolated, extreme value).
the target quality is
maintained throughout
the process.
•Others
 Histogram
How to do this
To show you how to do this, we will be using the data set below. I went ahead and put the
numbers in order which will make everything much easier.
To make a histogram by hand, we must first find the frequency distribution.
The idea behind a frequency distribution is to break the data into groups (called classes or
bins) so that we can better see patterns.
It is sort of like the difference between asking you your age and asking you if you are
between 20 and 25. In the second question,
I am grouping up the ages. This way if I have a HUGE data set (like many are) I can see
the patterns (like are most people older or younger).
Sample
1 2 3 4 5 6
12 18 27 31 40 42
14 20 27 32 40 51
14 20 27 32 40 56
14 21 29 34 40 60
16 23 31 36 40 65
 Histogram
Step :-1

1.Calculate the range of the data set.

The range is the difference between the largest value and the smallest value.
We need this to figure out how much “space” we need to divide into groups. In
this example:

Range=Max-Min Range=65-12=53

Note :-
Divide the range by the number of groups you want and then round up. Often, a
good number of groups is 5 or 6 although there are some rules that people use to
decide this.
 Histogram
Step :-2
2. Calculate the Class Width

The number we just found is commonly called the class width. We will round this up to 9
just because it is easier to work with that way. A computer would probably keep the 8.8
so be aware that sometimes you will see this number as a decimal. NOTE: In general,
people who are doing this by hand always round up even if it was 8.1!

Class Width = Range / No. of Sample Group Class Width = 53/6 = 8.8

Classes Frequency
12 – 21
21 – 30
30 – 39
39 – 48
48 – 57
57 – 66
 Histogram
Step :-3
3. Find the frequency of each group
We are going to count how many points are in each group. Let’s start with our first group:
12 – 21. We want to count how many points are between 12 and 21 NOT INCLUDING
21. You see the overlap between the groups right? That’s to account for decimals and we
keep it even when we don’t have any. The right hand endpoint of any group isn’t included
in that group. It goes in the next group. That means 21 would be in the second group and
any 30 we have would be counted in the third group.

Classes Frequency
Sample
12 – 21 8
1 2 3 4 5 6
12 18 27 31 40 42 21 – 30 6

14 20 27 32 40 51 30 – 39 6

14 20 27 32 40 56 39 – 48 6
14 21 29 34 40 60 48 – 57 2
16 23 31 36 40 65 57 – 66 2
 Histogram
Step :-4

Classes Frequency 9
8
8
12 – 21 8 7
6 6 6
21 – 30 6 6
5
30 – 39 6 4

39 – 48 6 3
2 2
2
48 – 57 2 1

57 – 66 2 0
12 – 21 21 – 30 30 – 39 39 – 48 48 – 57 57 – 66