Seven QC Tools

Problem Solving

Quality Improvement: Problem Sol

ving

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Pareto Principle

Vilfredo Pareto (1848-1923) Italian

economist

20% of the population has 80% of the

wealth

Juran used the term vital few, trivial

many. He noted that 20% of the quality
problems caused 80% of the dollar loss.
7 Quality Tools

Pareto chart
Pareto for Module X Problems
52

80%

50
40
30
20

42%

91%

99%

100%
100%

67%

80%

31

60%
16

10

13

40%
7

Cum %

QTY (No.s)

60

97%

20%
0%

No. of Cases

Cum %
7 Quality Tools

Grand total

%
100 %

How to Construct a Pareto Diagram

80 %

Contributors

1. Total the data on effect of each contributor & sum these to determine grand total.
2. Re order the contributors from largest to the smallest
3. Determine the cumulative percent of total
4. Draw & label the left vertical axis.
5. Draw & label the horizontal axis.
6. Draw & label the right vertical axis.
7. Draw bars to represent the magnitude of each contributors effect.
8. Draw a line graph to represent the cumulative percent of total
9. Analyze the diagram
10. Title the chart, label the vital few and useful many & show the cumulative
percent contribution of the vital few.

S.No
1
2
3
4
5
6
7

Problem
No. of Cases
Diameter Oversize
52
Damages
31
Surface Roughness Poor
16
Excess Ovality
13
Excess Taper
7
NC Patch
3
Tool Mark
1
Total
123

%
42%
25%
13%
11%
6%
2%
1%

Cum %
42%
67%
80%
91%
97%
99%
100%

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Flowcharts

Flowcharts

Graphical description of how work is done.

Used to describe processes that are to be
improved.

7 Quality Tools

Flow Diagrams
" Draw a flowchart for whatever you do.
Until you do, you do not know what you are
doing, you just have a job.
-- Dr. W. Edwards Deming.

Flowchart
Activity

Decision

Yes

No
7 Quality Tools

Flowchart

Flow Diagrams

Process Chart Symbols

Operations
Inspection
Transportation
Delay
Storage

Process: Apple Sauce

Description
of
process

Time
(min)

Analyst: TLR
Operation
Transport
Inspect
Delay
Storage

Location: Graves Mountain

Step

Date: 9-30-00

Unload apples from truck

Move to inspection station

Weigh, inspect, sort

Move to storage

Wait until needed

Move to peeler

Apples peeled and cored

15

Soak in water until needed

20

Place in conveyor

20
100 ft
30
50 ft
360
20 ft

10

Move to mixing area

11

Weigh, inspect, sort

Page 1 0f 3

Distance
(feet)

Process Chart

Total

20 ft
30
480

190 ft

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Cause-and-Effect Diagrams

Show the relationships between a

problem and its possible causes.

Developed by Kaoru Ishikawa (1953)

Also known as

Fishbone diagrams
Ishikawa diagrams

7 Quality Tools

Cause and Effect

Skeleton
Materials

Procedures

Quality
Problem

People

Equipment
7 Quality Tools

Fishbone Diagram
Measurement
Faulty testing equipment
Incorrect specifications
Improper methods

Inaccurate
temperature
control
Dust and
Dirt

Environment

Human

Machines
Out of adjustment

Poor supervision
Lack of concentration

Tooling problems
Old / worn

Inadequate training

Quality
Problem
Defective from vendor
Not to specifications
Materialhandling problems

Materials

Poor process
design
Ineffective quality
management
Deficiencies
in product
design

Process

Cause and effect diagrams

To construct the skeleton, remember:
For manufacturing - the 4 Ms & E
man,

method, machine, material,

environment.

For service applications

equipment,

policies, procedures, people

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

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Planning for Data collection

What question do we need to answer
How we will recognize & communicate the answers to
the questions -Tells about required data
What Data Analysis tools we need to use
What type of data do we need in order to construct the
tool
Where in the process can we get this data
Who in the process can give this data
How we can collect data from those people with
minimum efforts & chance of error.
What additional information do we need to capture for
future analysis, reference & traceability

Check Sheet

Defect Type

Shifts

7 Quality Tools

Check Sheet
COMPONENTS REPLACED BY LAB
TIME PERIOD: 22 Feb to 27 Feb 1998
REPAIR TECHNICIAN: Bob
TV SET MODEL 1013

Integrated Circuits
Capacitors
Resistors
Transformers
Commands
CRT

||||
|||| |||| |||| |||| |||| ||
||
||||
|

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Check sheet

Histogram

Cause and Effect Diagram

Control chart

Scatter diagram

Histograms
A Histogram is a Graphic summary of variation in a set
of data. The pictorial nature of the Histogram enables us
to see patterns that are difficult to see in a simple table
of numbers.
This is a good tool to analyze data that contain variation.
It tells us about pattern of variation of the process.
The tool is most useful to work out Process Capability Index.
Hence this tool is used to compare before project &
after project process variation spread, pattern, improvement
in Cp.

Steps for Constructing a Histogram

1. Collect the measurements / data.
2. Arrange / Group the data column wise in Table form
3. Find & mark the largest and smallest number / value in each
group.
4. Find the largest(Max) and smallest value(Min.) in whole set.
5. Calculate the range of measurements, i.e. Range = Max. - Min.
6. Determine the number of class intervals for the Frequency diagram
Guidelines :No of Readings
No of Class intervals
< 50
5 to 7
50 to 100
6 to 10
> 100
7 to 12
7. Determine Intervals and Boundaries
Interval = Range / Class Interval
8. Determine the frequencies of each class interval with tallies.
9. Prepare the frequency Histogram
- mark & label the vertical scale (Frequency)
- Mark & label the horizontal scale ( Measurement value)
- Draw the columns according to the frequency tallies.
- Label the Histogram.

Data of 40 Diameter measurements

( Nominal value 25 mm)
22
25
26
27
24
25
23
27
28
23

24
26
25
25
24
25
25
27
28
26

Range= 28 - 22=6
No of Class interval = 6
Interval = Range/Class interval =1
The Boundries Frequency
21.5 - 22.5
2
22.5 - 23.5
5
23.5 - 24.5
7
24.5 - 25.5
9
25.5 - 26.5
8
26.5 - 27.5
5
27.5 - 28.5
4
Total
40

25
24
23
25
26
26
27
28
26
26

Histogram
10

Frequency

23
27
26
24
22
25
24
28
23
24

5
4

4
3
2

1
0

21.5 - 22.5

22.5 - 23.5

23.5 - 24.5

24.5 - 25.5

Diameter

25.5- 26.5

26.5 - 27.5

27.5 - 28.5

Stem and leaf displays

Data
Integrated Circuit Response Time (ps)

4.6 4.0 3.7 4.1 4.1 5.6 4.5 6.0 6.0 3.4
3.4 4.6 3.7 4.2 4.6 4.7 4.1 3.7 3.4 3.3
3.7 4.1 4.5 4.6 4.4 4.8 4.3 4.4 5.1 3.9

Stem and leaf displays

Integrated Circuit Response Time (ps)

7 4 4 7 7 4 3 7 9

6 0 1 5 6 2 6 7 1 1 5 6 4 8 3 4

6 1

0 0

Dot diagrams
Integrated Circuit Response Time (ps)

5
Plant A
Plant B

What is Graph ?
Graph is a diagram which explains connections or
inter relations amongst 2 or more things. These connections
are represented by a number of distinctive dots, lines, bars,
columns.
Common type of graphs Line Graph
Column / Bar Graph
Pie Graph

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Definition of Control Chart

A Control Chart is a special type of trend chart used to
detect the special causes of variation in the process.
Types of Control Charts For Variables , i.e. For the characteristics that can be
measured - X - R Chart
For Attributes - For characteristics that can be judges as
pass or fail, go or no-go, defective or non-defective etc.
- np chart, p chart, c chart, u chart

Advantages of using control charts It is a effective tool to control the process statistically (SPC)
It helps to detect changes in the process over a period of time
and take corrective action.
It differentiates chance cause variation & assignable cause
variation in the process.
It is an effective tool which helps to reduce variations in the
process
It provides information about process capability.

Control Charts

Control Chart
27
24
UCL = 23.35

Number of defects

21

c = 12.67

18
15
12
9
6

LCL = 1.99

3
2

10

12

Sample number

14

16

Seven Quality Control Tools

Pareto Chart

Process flow diagram

Cause and Effect Diagram

Check sheet

Histogram

Control chart

Scatter diagram

Scatter Diagram

Scatter Diagram
A Scatter diagram is a graphic presentation of the relationship
between two variables. In quality improvement, scatter diagrams
are usually used to explore cause - effect relationships in the
diagnostic journey.
It establishes correlation
A example - A Hydraulic system was tripping for indication
of overload. The tripping mechanism is provided as safety.
The electronic control circuitry was executing safety
shut down of the hydraulic system, with Voltage as a signal.
The complaint was more in Summer months from areas that
were close to large bodies of Water.

One of the Probable cause was The higher Relative

Humidity causes stickiness in the system, leading to
increased load and subsequent tripping.
The diagram clearly shows that as Relative Humidity
increases the sensor reads higher voltage. This causes
circuitry to believe that the hydraulic system had exceeded it
limits & trips.
Effect

Voltage

Cause
Relative
Humidity

The graphic nature of the scatter diagram helps a team to see

the relationship between the variables.
It can be statistically described as Pearsons Correlation Coefficient

The patterns of Correlation A) Linear

( It can be strong or Weak correlation)

Positive Correlation
B) Non Linear

C) No Correlation

Negative correlation

Thank You

Quality Improvement: Problem Sol

Farm
Equipment Sector
ving