1.

EXISTING GOOD PRACTICES 2.

QUALITY PRACTICES LIKE TQM 3. WORLD CLASS - BENCH MARKING ? 1. - PEOPLE 2. - PRODUCT 3. - PROCESS 4. - PROFIT 5. - PROGRESS 6. - PROSPERITY 7. - PRIDE

7 QC TOOLS
:

1. 7QC TOOLS
2. 3. ( TOOLS )

4. 7QC TOOLS
5. TOOL 6. QC TOOL .

BRAIN STORMING
/ , , BRAIN STORMING , . , , .

BRAIN STORMING (GUIDE LINES)

1. OBJECTIVE: , . 2. ,
. 3. , .

4. , .
5. , , , .

6.
.

BRAIN STORMING
7. , . 8. . 9. ? ? ? ? ? ? ? ?...

.
10. , BRAIN STORMING .

11.BRAIN STORMING
CREATIVE .

BRAIN STORMING
12. , , , , .

HISTOGRAM- .
1. . 2. , . 3. . 4. .

SCATTER DIAGRAM - .
1. .

STRATIFICATION - .
1. .

2. .

7QC TOOLS
1. CHECK SHEET. 2. PARETO DIAGRAM 3. CAUSE AND EFFECT DIAGRAM.

4. HISTOGRAM
5. SCATTER DIAGRAM 6. STRATIFICATION. 7. GRAPHS & CONTROL CHART.

DATA COLLECTION
TYPES OF DATA
1. INDISCRETE VALUES ( MEASURABLE)

EXAMPLE: Height, Weight, Length, Time, Temperature, etc., 2. DISCRETE VALUES ( QUANTIFIABLE )

EXAMPLE: ONE, TWO ..

3. PRIORITY DATA EXAMPLE: YES / NO TYPE 4. ORDERED DATA EXAMPLE: 1ST, 2ND, 3RD 5. POINT SCALE DATA EXAMPLE: 1 POINT, 2 POINT. Check sheet is one of the ways of preparing a relatively simple and easy method of data collection. There is no definite rule for preparing check sheet. Any form will do as long as it is easy to fill and understand.

2. PARETO DIAGRAM
This concept was developed by Mr.. V. PARETO, an Italian Economist in the year 1894.
Dr.. Juran used this concept and effectively converted it as a QC Tool. This Tool is used for prioritising the problems ( based on numerical value, impact, occurrence, etc..,) VITAL FEW FROM TRIVIAL MANY

2. PARETO DIAGRAM
Stratify problem points according to purpose and represent them Data should preferably be expressed in monetary values, quantity, counts

numerically. (By causes, phenomena, equipment, etc.,)

or percentage.

Select a data period.

chart

Arrange the stratified data in descending order of value and draw a bar Draw a line showing the cumulative % above the bar, starting from the At the RHS, a straight vertical line is drawn to indicate 0 to 100 % greatest value.

PARETO DIAGRAM
The Pareto shows the distribution of items and arranges them from the most frequent to the least frequent with the final bar indicating miscellaneous items ( that cannot be grouped under others items ). The tool is named after Vilfredo Pareto, the Italian economist who studied the distribution of wealth amongst the population. This tool is a graphical representation of the most frequent causes of a particular problem and shows the direction. i.e. point where one has to put initial effort and reap benefits.

WHAT IS A CAUSE & EFFECT DIAGRAM?

This tool, also named as Fish Bone Diagram because it looks like a fishbone OR Dr. Ishikawa Diagram , is an effective way to relate the Effect (results) with that of the Causes (reasons). This is an effective tool that bring out the divergent knowledge /ideas of the members in a group.

CHECK SHEET FOR DRIVER / CONDUCTOR OF A TRANSPORT CORPORATION

DRIVER NAME : CONDUCTOR NAME :
SL NO 1 2 3 4 5 6 7 8 9 10

ROUTE NO: BUS REGN NO:

OK NOT OK

DESCRIPTION AIR PRESSURE OF WHEEL FUEL STEPHNEY BRAKE BATTERY WATER WIPER LIGHT FIRST AID BOX HORN

DATA COLLECTION
DIMENSION - 5.00+- 0.08 (4.92 - 5.08) SAMPLE SIZE - 50 NOS.

5.01 4.95 4.99 4.96 4.98 4.92 5.04 5.01 4.99 5.00 4.97 5.02 5.04 4.97 4.96 4.95 5.03 5.01 4.99 5.01 5.03 4.94 4.99 4.98 4.93 4.99 5.02 5.01 5.02 5.03 5.01 4.92 5.05 4.98 4.99 4.97 5.02 5.00 5.02 5.00 5.01 4.98 5.00 4.98 5.00 4.99 5.03 5.08 5.07 5.00

CHECK SHEET
SL NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 SIZE 4.92 4.93 4.94 4.95 4.96 4.97 4.98 4.99 5.00 5.01 5.02 5.03 5.04 5.05 5.06 5.07 5.08 FREQUENCY QTY

Code No. _______ Lot No._________

CHECK SHEET FOR METAL PLATING Date: __________ Supervisor: ______ Operator: ________ Check point Water repellent Evenness of acid cleaning Contamination Stain Adequency of jigs Distance of clamps Location of hooks Wire connection Current density Temperature and level of bath Sedimentation Time Specific gravity of solution Surface of plated material Cleanliness of washing bath Adequency of finishing method Cleanliness of rinse AM PM

Finishing

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Remarks

Plating

Preparation

DATA COLLECTION
PRODUCT NAME : PRODUCT NO. :
SL NO DESCRIPTION

PERIOD : SOURCE :
NO OF TIMES 23 15 9 7 3 %

1 2 3 4 5

DEFECT DEFECT DEFECT DEFECT DEFECT

1 2 3 4 5

40.3% 26.3% 15.73% 12.4% 5.27%

DAILY LATE ARRIVAL OF A TRAIN IN MINUTES.

1 23 19 26 11 20 11 17 16 14 16 19 22 20 7X 10 15 14 7X 9 18 2 16 17 14 17 17 24 20 16 27 15 14 21 14 20 16 15 9 8X 16 14 3 14 17 9 13 20 21 8 14 19 9 8 80 X 6 9 10 14 16 13 19 18 4 20 16 11 19 16 27 16 22 16 17 19 9 11 13 19 13 8 5X 14 13 5 27 17 14 17 16 5 17 13 26 8 27 3X 12 20 13 25 16 13 29 L 10

CAUSE & EFFECT DIAGRAM - ABSENTEEISM

EDUCATION
EXAMINATIONS PAYMENT OF FEES ATTENDING CONTACT PROGRAMMES COLLECTION OF HALL TICKETS PREPERATION MENTAL TENSION FOR EXAMS OPERATION

SICKNESS
TIREDNESS

PERSONAL WORK
CHANGE IN WEATHER PILGRIMAGE SHOPPING ENTERTAINMENT VISITING NATIVE PLACE COURT DISPUTE

ACCIDENT

E.B. BILL PAYMENT

RELATIVES MARRIAGE
SELF MARRIAGE RELIGIOUS FUNCTIONS DEATH CEREMONY NAMAKARNAM EAR BORING CEREMONY BIRTHDAY

CHILDREN SICK

WIFE SICK

A B S E N T E E IS M

SCHOOL ADMISSION FOR CHILDREN

PARTITION OF FAMILY PROPERTY

FAMILY FUNCTIONS

FAMILY PROBLEMS

CAUSE AND EFFECT DIAGRAM

MAN
TRAINING EXPERIENCE OPERATION KNOWLEDGE CARELESSNESS SKILL

MACHINE
MACHINE CAPACITY CONDITION MAINTENANCE

HYDRAULIC
TYPE MECHANICAL

ACCIDENTS
PUNCH AND DIE ALIGNMENT PUNCH AND DIE CLEARANCE WORKING HEIGHT LOADING STRIP GUIDE COMPONENT

GUARD MATERIAL

TOOL

METHOD

MATERIAL

5.0 STRATIFICATION
1. TELEPHONE DIRECTORY 2. BOOKS LIBRARY.

3. TEXTILE SHOW ROOM

4. AUTOMOBILE SHOP 5. SUPER MARKET, etc.,

HISTOGRAM
Histogram is a bar chart showing a distribution of variables. e.g. Distribution of marks scored by students in a class.

Normally students would have scored marks from a lowest to higher scale
and there would be a cluster of students who have scored around the average of the scores. Hence the phrase normal distribution. This tool helps identify the cause of problems in a process by the shape of the distribution as well as the width of the distribution.

4. HISTOGRAM
Histogram is a powerful Tool used for finding out variation. To achieve ZERO DEFECT , we have to control variation.. How to draw a Histogram ? 1) Minimum 50 entries / 100 or more is desirable

2) Obtain largest value (L), smallest value (S). It is recommended to

bifurcate the data into groups. Obtain max and min X in each group. 3) To obtain difference between L and S divide the difference by the number of classes (k).To obtain the class width (h) the following table

is used.

4. HISTOGRAM
NO OF ENTRIES (N) 50 - 100 100 - 250 OVER 250 APPROPRIATE OF CLASSES (K) 610 712 10 - 20 GENERALLY ADOPTED (K) 10

Class width h = L-S / K = 29 - 0 / 10 = 29 = 3

Class width h = S + h / 2 = 0 + 3/2 = + 1.5

CONTROL CHART
The control chart is a line chart with control limits. It is based on the work of Shewhart and Deming. By mathematically constructing control limits at 3 standard deviations above and below the average, one can determine what variation is due to normal ongoing causes (common causes ) and what variation is produced by unique events (Special causes). By eliminating the special causes first and then reducing common causes, quality can be improved.

STRATIFICATION
This a problem resolution tool called also as classification of data collected on a specific characteristic. All data must be stratified according to individuals, equipment, time period, specification and so on, in order to understand the significance of the assumed factors. Effective criteria for stratification are:

Type of defect
Cause of defect Location of defect

Material, Product & date of production

Working group, individual operator, part supplier, lots etc. Principle of stratification Identification of data with the possible source of variation e.g. cause-wise, worker-wise, machine-wise History of data to be classified A standard format to be prepared in advance to facilitate quick summarisation.

CONTROL CHART CO EFFICIENT TABLE

SIZE OF SUB FOR X CHART GROUP A2 2 3 4 5 6 7 8 9 10 1.880 1.023 0.729 0.577 0.483 0.419 0.373 0.337 0.308 FOR R CHART D3 D4 3.267 2.575 2.282 2.115 2.004 1.924 1.864 1.816 1.777

SCATTER DIAGRAM

A graphical technique to analyse the relationship between Two variables Two sets of data are plotted on a graph The graph will show the possible relationships SCATTER DIAGRAM A graph displaying the correlation of two characteristics. Relationship between two variables. EXAMPLES a) Training Vs Quality b) Absenteeism Vs Productivity c) Hardness Vs Tensile Strength d) Impurity in Material Vs Yield USES Shows relationship or no relationship Used as a prediction tool Used to investigate unusual observations Stratification of data

COORDINATING
AGENCY

TOP MANAGEMENT STEERING COMMITTEE FACILITATOR LEADER / DEPUTY LEADER MEMBERS NON-MEMBERS

5
4 3 2 1

STRUCTURE OF QC

THE SEVEN QUALITY CONTROL TOOLS

In the 1950s the Japanese began to learn and apply the statistical quality control tools and thinking that Walter Shewhart and W. Edward Deming developed in the 1930s and 1940s. Their progress in Continuous Improvement lead to the expansion of the use of these tools. Kaoru Ishikawa, head of the Japanese Union of Scientists and Engineers (JUSE.) expanded the use of these approaches in Japanese manufacturing in the 1960s by the introduction of the 7 Quality Control (7QC) tools.

PURPOSE OF DATA COLLECTION

1. What is the problem? 2. How to collect data ? (methodology) 3. What will be the quantum of data ? 4. What will be the form of check sheet ?

After data entry and check sheet

preparation, verify the following 5. Does it meet the objective ? Yes / No

6. If no, do we have to modify it ?

1.2 Sources of Variation

In Engineering Components, variations may occur in:
a. Materials b. Machine Dimensions, Hardness Backlash and Clearances within a Machine and its fixtures. Bearing Wear, Temperature of the Coolant Strength, Rate of Wear Part Feed, Accuracy of Centering Bias, Repeatability Lubrication, Replacement of Worn Parts Temperature, Voltage Fluctuations

c. Tool d. Operator

e. Measurement f. Maintenance g. Environment -

EXERCISE: CHECK SHEET DATA SHEET FOR DIMENSIONS OBSERVED Date : 16.10.99 Shift : I Shift 4.98 5.00 4.96 5.00 4.98 5.00 5.02 5.00 5.04 5.04 5.04 5.00 5.00 5.00 4.98 Machine : A Operator : X 5.06 5.02 5.06 5.08 5.00 5.02 4.96 4.96 5.00 5.00 5.00 4.96 5.02 5.04 4.98 5.06 4.94 5.04 4.98 4.98

Total: 50 Nos 5.02 4.94 5.02 4.98 5.04 5.00 5.02 4.96 5.02 4.98
2 5 9 15 10 5 3 1 50

5.02 5.00 5.00 5.02 4.98

4.94 4.96 4.98 5.00 5.02 5.04 5.06 5.08

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

X X X X X X X X X X X X X X

X X X X X

TOTAL

THE NEED FOR PROCESS CONTROL

DETECTION PREVENTION TOLERATES WASTE AVOIDS WASTE

Chance Causes OR Common Causes OR Sporadic

Variation in raw material Speed variations Operators performance Play in machine spindle Play in linkages Voltage variations Temperature variation Tool wear Machine setting Operators fatigue Maintenance control

Assignable Causes OR Special Causes OR Chronic

SCATTER DIAGRAM
Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Speed 8.1 7.7 7.4 5.8 7.6 6.8 7.9 6.3 7.0 8.0 8.0 8.0 7.2 6.0 6.3 6.7 8.2 8.1 6.6 6.5 8.5 7.4 7.2 5.6 6.3 Length 1046 1030 1039 1027 1028 1025 1035 1015 1038 1036 1025 1041 1029 1010 1020 1024 1034 1036 1023 1011 1030 1014 1030 1016 1020 Number 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Speed 8.0 5.5 6.9 7.0 7.5 6.7 8.1 9.0 7.1 7.6 8.5 7.5 8.0 5.2 6.5 8.0 6.9 7.6 6.5 5.5 6.0 5.5 7.6 8.6 6.3 Length 1040 1013 1025 1020 1022 1020 1035 1052 1021 1024 1029 1015 1030 1010 1025 1031 1030 1034 1034 1020 1025 1023 1028 1020 1026

Length 1050 1045 1040 1035 1030 1025 1020 1015 1010 1005 Total

5.0

5.5

6.0

6.5

7.0

7.5

8.0 1 2 5 3 1

8.5

9.0 1

9.5

1 1 1 1 2 1 1 4 2 4 3 1 1 10 3 2 2

1 1 3 1 1 2

1 3

12

Total 1 1 4 7 11 11 7 5 3 0 50

EXERCISE: X & R CHART

Sl No 1 2 3 4 5 Total Mean Range 6 7 8 9 10 Total Mean Range 11 12 13 14 15 Total Mean Range 16 17 18 19 20 Total Mean Range 21 22 23 24 25 Total Mean Range 52 48 51 49 51 251 50.2 4 50 53 48 51 52 254 50.8 5 50 49 50 49 50 248 49.6 1 51 50 52 53 54 260 52.0 4 51 52 48 50 48 249 49.8 4 52 50 53 52 50 257 51.4 3 49 50 48 50 48 245 49.0 2 49 50 49 50 50 248 49.6 1 47 46 48 54 49 244 48.8 8 54 49 52 53 49 257 51.4 5 50 52 49 53 51 255 51.0 4 52 46 49 50 47 244 48.8 6 51 49 51 48 51 258 50.0 3 51 48 51 49 48 247 49.4 3 51 49 51 53 51 255 51.0 4 48 52 47 54 47 248 49.6 7 54 50 53 50 51 258 51.6 4 51 52 46 50 48 247 49.4 6 47 49 51 49 49 245 49.0 4 48 49 49 50 52 248 49.6 4 47 50 49 47 49 242 48.4 3 51 49 53 49 50 252 50.4 4 55 51 50 51 48 255 51.0 7 49 53 50 53 50 255 51.0 4 47 48 48 47 49 239 47.8 2