7qctools Training Slides

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7 QC Tools

Training module

on

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7 QC ToolsBy Ankur Dhir

Learning Objectives:

•Hands-on learning of Quality Tools and Continuous Improvement Tools !• Learn TRANSFORM monthly reports to deliver more important information instantly

Agenda: 10:00-10:30 : Process Flow Chart, 10 30 11 15 Cause and Effect Diagram 10.30-11.15 Cause and Effect Diagram, 11.15-11.45 Check sheet, 11.45 -12.15 Histogram12:150 - 01: 00 : Pareto Chart,01:00 – 2.00 Lunch 2.00 -3.00 pm, Scatter Plot, Stratification3.00 – 4.30 Control Chart, 4.30-5.00 Quality Tools in Reporting,5.00-5.30 quiz and test

Trainer profile

Qualification: B-tech, Advanced Diploma in Quality Management, Certified Quality Manager (ASQ), Lead Auditor ISO 9001, 14001, OHSAS . Six Sigma Green Belt , Lean champion ( Lean Institute)

Work Experience : more than 12 year experience in field of quality, environment and Safety as Management representative, consultancy, Auditing and trainings . Have delivered more than

H bbi L i hil t l ( ll ti t

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Hobbies: Learning , philately ( collecting stamps, and vintage coins)

“ I n f l u e n t i a l P r o f e s s i o n a l s w h o s h a p e d

QUALITY GURUS4

f f pt h e Q u a l i t y p a t h ”

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5 6

Ishikawa’s Basic Tools of Quality

Kaoru Ishikawa developed seven basic visual tools of quality so that the average person could analyze and interpret data.

These tools have been used worldwide by companies, managers of all levels and employees

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managers of all levels and employees.

What are 7 QC Tools ?

QC tools are the means for Colleting data , analyzing data , identifying root causes and measuring the results.

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THESE TOOLS ARE RELATED TO Numerical DATA processing

USER HAS TO DEVELOP THE SOLUTION & IMPLEMENT

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• Pareto Diagram

• Stratification

•Scatter Diagram

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•Cause and Effect Diagram

•Histogram

•Check Sheet

•Control Chart/Graph

Detecting causes of

Record of facts

Defining the problem

Identification of problem

Control Chart

Scatter Diagram

Histogram

Cause & Effect Diagram

Pareto Diagram

Stratification

Check sheet

Graphs

Application of QC tools in Problem Solving

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Process control ( Standardization )

Evaluation of result

Implementation

Develop Improvement method ( Solution )

problem

Quality Tool Box – Flow ChartFlowchart

Also called: process flowchart, process flow diagram.

Description A flowchart is a picture of the separate steps of a process in sequential order.

Elements that may be included are: sequence of actions, materials or services entering or leaving the process (inputs and outputs), decisions that must be made, people who become involved, time involved at each step and/or process

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measurements.

The process described can be anything: a manufacturing process, an administrative or service process, a project plan. This is a generic tool that can be adapted for a wide variety of purposes.

) to see if they agree that the process is drawn accurately.

Quality Tool Box - Flow Chart

When to Use a Flowchart

• To develop understanding of how a process is done.

•To study a process for improvement.

•To communicate to others how a process is done.

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•When better communication is needed between people involved with the same process.

•To document a process.

•When planning a project.

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Steps in Making Flow ChartFlowchart Basic Procedure

Materials needed: Sticky notes or cards, a large piece of flipchart paper , marking pens. Steps

• Define the process to be diagrammed. Write its title at the top of the work surface. • Discuss and decide on the boundaries of your process: Where or when does the process start? Where or when does it end? Discuss and decide on the level of

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detail to be included in the diagram. • Brainstorm the activities that take place. Write each on a card or sticky note. Sequence is not important at this point, although thinking in sequence may help people remember all the steps. • Arrange the activities in proper sequence. • When all activities are included and everyone agrees that the sequence is correct, draw arrows to show the flow of the process. • Review the flowchart with others involved in the process (workers, supervisors, suppliers, customers

Detailed Flow Chart

High Level Flow Chart

Flow Chart example

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1. What is Cause & effect Diagram ?

A cause and effect diagram is “a fish-bone diagram that presents a systematic representation of the relationship between the effect (result) and affecting factors (causes).”

Solving a problem in a scientific manner requires

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g p qclarification of a cause and effect relationship, where the effect (e.g., the result of work) varies according to factors (e.g., facilities and machines used, method of work, workers, and materials and parts used). To obtain a good work result, we must identify the effects of various factors and develop measures to improve the result accordingly.


2. When is it used and what results will be obtained?

A cause and effect diagram is mainly used to study the cause of a certain matter. As mentioned above, the use of a cause and effect diagram allows

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clarification of causal relation for efficient problem solving. It is also effective in assessing measures developed and can be applied to other fields according to your needs.

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Can obtain a clear overall picture of causal relation. (A change in the cause triggers a variation in the result.)○ Can clarify the cause and effect

Method Usage Result


Used when clarifying a cause and effect relationship.[Used during a phase to analyze causes.]

ManMachine

Eff

ect

Cause and Effect Cause and Effect DiagramDiagram

ManMachine

Eff

ect

Cause and Effect Cause and Effect DiagramDiagram

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relationship.

Can list up all causes to identify important causes.

Can determine the direction of action (countermeasure).

y ]

Used to develop countermeasures.

[Used during a phase to plan countermeasures.]

Material Method

Cause (4M’s) Result (Controlled State)

Material Method

Cause (4M’s) Result (Controlled State)


Mechanism of Copying Machine

Quality of Copying Paper

Smudges on the copied surface

Internal devices not working smoothly

Malfunction of the roller

Printing too lightly

Too thin

Folded

Running out of stock

Dampened

ying

Err

ors!

Mechanism of Copying Machine

Quality of Copying Paper

Smudges on the copied surface

Internal devices not working smoothly

Malfunction of the roller

Printing too lightly

Too thin

Folded

Running out of stock

Dampened

ying

Err

ors!

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User Surrounding Environment

Keyboard handling error

Error in selecting a scale of reduction

Error in placement of paper (setting its face up)

Error in selecting shading

Deterioration of performance due to high temperatures

Nicotine-stained

Dirt on the glass surface

Dust

Man

y C

opy

User Surrounding Environment

Keyboard handling error

Error in selecting a scale of reduction

Error in placement of paper (setting its face up)

Error in selecting shading

Deterioration of performance due to high temperatures

Nicotine-stained

Dirt on the glass surface

Dust

Man

y C

opy

Check sheet

DescriptionA check sheet is a structured, prepared form for collecting and analyzing data. This is a generic tool that can be adapted for a wide variety of purposes.

When to Use a Check Sheet

•When data can be observed and collected repeatedly by the same

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p y yperson or at the same location. •When collecting data on the frequency or patterns of events, problems, defects, defect location, defect causes, etc.

Check Sheet

1. What is Check sheet ?

A check sheet is “a sheet designed in advance to allow easy collection and aggregation of data.” By just entering check marks on a check sheet, data can be collected to extract necessary information, or a thorough inspection can be performed in an efficient manner eliminating a possibility

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performed in an efficient manner, eliminating a possibility of skipping any of the required inspection items.

A check sheet is also effective in performing stratification (categorization).

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Check Sheet


Please refer to the table on next slide for the usage and benefits of a check sheet. It is frequently used in daily business operations, often not specifically for

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QC purposes.

Ensures collection of required data.

Allows a thorough inspection of all check items.

C d t d

Method Usage Result

Check Sheet

Check SheetCheck SheetDay

Process

Process 1

Process 2

Process 3

Check SheetCheck SheetDay

Process

Process 1

Process 2

Process 3

Used to collect data.

Used when performing a th h i ti

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Can understand tendencies and variations.

Can record required data.

thorough inspection.Used during phases to monitor the situation, analyze causes, review effectiveness of an action, perform standardization, and implement a selected control measure

Check Sheet Procedure

23• Decide what event or problem will be observed. Develop

operational definitions.

• Decide when data will be collected and for how long.

• Design the form. Set it up so that data can be recorded simply by making check marks or Xs or similar symbols and so that data do not have to be recopied for analysis

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and so that data do not have to be recopied for analysis.

• Label all spaces on the form.

• Test the check sheet for a short trial period to be sure it collects the appropriate data and is easy to use.

• Each time the targeted event or problem occurs, record data on the check sheet.

Check sheet ExampleThe figure below shows a check sheet used to collect data on telephone interruptions. The tick marks were added as data was collected over several weeks.

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Check Sheet

A check sheet used to identify defects

Date

Defect

Vertical Scratch

TotalDate

Defect

Vertical Scratch

Total

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Scratch

Dent

Scratch

Dent

Histogram

1. What is Histogram ?

When creating a histogram, “a range of data is divided intosmaller sections having a uniform span,and the number of datacontained in each section (the number of occurrences) iscounted to develop a frequency distribution table ” Then “a

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counted to develop a frequency distribution table. Then, agraph is formed from this table by using vertical bars, eachhaving the height proportional to the number of occurrences ineach section.”

Histogram2. When is it used and what results will be obtained?

A histogram is mainly used to analyze a process byexamining the location of the mean value in thegraph or degree of variations, to find a problem pointthat needs to be improved. Its other applications arelisted in the table below.

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Histogram Construction Collect at least 50 consecutive data points from a process.

Use the histogram worksheet to set up the histogram.

Histogram Analysis

Before drawing any conclusions from your histogram, satisfy yourself that the

Histogram

Microsoft Office el 97-2003 Worksh

Double Click on file to construct Histogram.Note : Use “Paste Values”

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process was operating normally during the time period being studied.

If any unusual events affected the process during the time period of the histogram, your analysis of the histogram shape probably cannot be generalized to all time periods.

Analyze the meaning of your histogram’s shape.

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HistogramTypical Histogram Shapes and What They Mean

Normal. A common pattern is the bell-shaped curve known as the “normal distribution.” In a normal distribution, points are as likely to occur on one side of the average as on the other.

Example : Distribution of heights (in cm) of all employees.

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Histogram

Skewed. The skewed distribution is asymmetrical because a natural limit prevents outcomes on one side. The distribution’s peak is off center toward the limit and a tail stretches away from it.

For example, a distribution of analyses of time difference between employees arriving at work (clock in time) and official company start time.

Typical Histogram Shapes and What They Mean

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Or , differences in actual turn around to resolve certain types of complaints compared to goal for that segment.

These distributions are called right- or left-skewed according to the direction of the tail.

TAIL

This is right-skewed since the tail is at our right

Histogram

Double-peaked or bimodal. The bimodal distribution looks like the back of a two-humped camel.

The outcomes of two processes with different distributions are combined in one set of data.

Typical Histogram Shapes and What They Mean

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For example, a distribution of production data from a two-shift operation might be bimodal, if each shift produces a different distribution of results. Stratification often reveals this problem.

Method Usage Result

Histogram

HistogramHistogramStandard

Range

HistogramHistogramStandard

Range

•Used to assess the actual conditions.•Used to analyze a process to identify a problem point that needs to be improved by finding the location of the mean value or degree of variations in the graph.•Used to examine that the target

•Can identify the location of the mean (central) value or degree of variations.•Can find out the scope of a defect by inserting

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Range of Variations

X Axis (Values Actually

Measured)Range of Variations

X Axis (Values Actually

Measured)

Used to examine that the target quality is maintained throughout the process.•Others

[Used during phases to monitor the situation, analyze causes, and review effectiveness of an action.]

standard values.•Can identify the condition of distribution (e.g., whether there is an isolated, extreme value).

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Histogram

Frequency Distribution Table

Cutting Length of Steel Wire]

Standard

Lower Limit Upper LimitStandard

Standard ValueProduct

(Standard: 255 5 mm)±

Section Frequency Marking OccurrencesMean

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[Histogram of Cutting Length of Steel

Wire]

DescriptionA Pareto chart is a bar graph. The lengths of the bars represent frequency or cost (time or money), and are arranged with longest bars on the left and the shortest to the right. In this way the chart visually depicts which situations are more significant.

Pareto Chart or Pareto AnalysisBased on 80-20 Rule : 80% of the problem is caused by 20% of the causes

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When to Use a Pareto Chart

•When analyzing data about the frequency of problems or causes in a process.•When there are many problems or causes and you want to focus on the most significant.•When analyzing broad causes by looking at their specific components.

First Example of Pareto Chart

Example 1 shows how many customer complaints were received in each of five categories of processes or departments.

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Example 2 takes the largest category, “documents,” from Example #1, breaks it down into six categories of document-related complaints, and shows cumulative values.

Second Example of Pareto Chart

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If all complaints cause equal distress to the customer, working on eliminating document-related complaints would have the most impact, and of those, working on quality certificates should be most fruitful.

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Pareto Chart Procedure

Decide what categories you will use to group items. (Horizontal Axis or X Axis)

Decide what measurement is appropriate. Common measurements are frequency, quantity, cost and time. (Vertical Axis or Y Axis)

Pareto Chart

Double Click on file to construct Pareto ChartNote : Use “paste Values”

Microsoft Office el 97-2003 Worksh

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Decide what period of time the Pareto chart will cover: One work cycle? One full day? A week?

Collect the data, recording the category each time. (Or assemble data that already exist.)

Subtotal the measurements for each category.

Pareto Diagram

1. What is Pareto diagram ?

A Pareto diagram is a combination of bar and line graphs of accumulated data, where data associated with a problem (e.g., a defect found, mechanical failure, or a complaint from a customer) are divided into smaller groups by cause or by phenomenon and sorted for example by the number

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or by phenomenon and sorted, for example, by the number of occurrences or the amount of money involved. (The name “Pareto” came from an Italian mathematician who created the diagram.)

Pareto Diagram


Please refer to the table on next slide for the usage and benefits of a Pareto diagram. It is mainly used to prioritize matters, and because f f

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of its easiness of use, the diagram is used in a wide variety of fields.

Pareto Diagram Pareto Diagram (No. of Occurrences)

Pareto Diagram Pareto Diagram (No. of Occurrences)

Used to identify a problem.

Used to identify the cause of a problem.

Used to review the effects of an action to be taken.

Allows clarification of important tasks.

Allows identification of a starting point (which task to start with)

Method Usage Result

Pareto Diagram

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Used to prioritize actions.(Used during phases to monitor the situation, analyze causes, and review effectiveness of an action.)

with).

Allows projection of the effects of a measure to be taken

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Pareto Diagram

To identify a course of action to be emphasized

using a variety of data

Example

Assessment using Pareto diagram (prioritization)

Confirmation of Effect (Comparison)

Frequently used to check the effect of an

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using a variety of data.

Details of “ A”

improvement.

Improved

Construct Pareto of M&M colors

Produce a Pareto Chart of colors of M&M chocolate in a pack of M&M

Compare differences between your colleagues

80% of your M&M content consists of what color?

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Stratification

1. What is Stratification ?

Stratification means to “divide the whole into smaller portionsaccording to certain criteria.” In case of quality control,stratification generally means to divide data into several groupsaccording to common factors or tendencies (e g type of defect

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according to common factors or tendencies (e.g., type of defectand cause of defect).

Dividing into groups “fosters understanding of a situation.”This represents the basic principle of quality control.

Stratification2. When is it used and what results will be obtained?

The “common and basic principle” of quality control isstratification, i.e., to think a matter out by breaking itinto smaller portions. Stratification has a number ofuseful purposes. The table below shows only a fewexamples of these purposes.

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p p p

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Stratification (Categorization)DescriptionStratification is a technique used in combination with other data analysis tools. When data from a variety of sources or categories have been lumped together, the meaning of the data can be impossible to see. This technique separates the data so that patterns can be seen.

When to Use Stratification • Before collecting data.

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• When data come from several sources or conditions, such as shifts, days of the week, suppliers or population groups.• When data analysis may require separating different sources or conditions.

Stratification Procedure

•Before collecting data, consider which information about thesources of the data might have an effect on the results. Set up thedata collection so that you collect that information as well.

•When plotting or graphing the collected data on a scatterdiagram, control chart, histogram or other analysis tool, usediff t k l t di ti i h d t f i

Stratification (CATEGORIZATION OF DATA)

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different marks or colors to distinguish data from various sources.

•Data that are distinguished in this way are said to be “stratified.”

• Analyze the subsets of stratified data separately.

Example of Stratification – We want to reduce number of complaints but looking at the data by Region

Count of Case Description

RD Total

1 118

2 137

3 47

4 68

(Region) Number of Complaints

• Analyze the subsets of stratified data (category) separately. In this case, it’s recommended to look at the

bl i b i

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5 42

6 49

7 15

8 18

9 20

(blank)

Grand Total 514

problem region by region.

Method Usage Result

Stratification

Grouping by day, time, place, worker, or process

X

Number of Units

★★★★★★★

•Used to observe variations among strata.•Used to identify the relationship between cause and effect.•Used to identify a purpose

•Allows observation of variations among strata.•By performing a cause analysis using th t tifi d d t

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Y

Z ○○○

y p pand means to serve the purpose[Used during phases to monitor the situation, analyze causes, review effectiveness of an action, perform standardization, and implement a selected control measure.]

the stratified data, the following can be accomplished.

1.Identification and control of a problem 2.“Division of data (obtained by using each QC tool) into several groups”

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Stratification

Item Method of Stratification

Elapse of time Hour, a.m., p.m., immediately after start of work, shift, daytime, nighttime, day, week, month

Variations among workers Worker, age, male, female, years of experience, shift, team, newly employed, experienced worker

Variations among work methods

Processing method, work method, working conditions (temperature, pressure, and speed), temperature

Variations among Measurement tool, person performing

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measurement/inspection methods

measurement, method of measurement, inspector, sampling, place of inspection

Scatter Diagram

1. What is Scatter Diagram ?

A scatter diagram is used to “examine the relationship betweenthe two, paired, interrelated data types, ” such as “height andweight of a person.” A scatter diagram provides a means tofind whether or not these two data types are interrelated It is

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find whether or not these two data types are interrelated. It isalso utilized to determine how closely they are related toidentify a problem point that should be controlled or improved.

Scatter Diagram2. When is it used and what results will be obtained?

The table on next slide shows some examples ofscatter diagram’s usage. If, for example, there is arelationship where “an increase in the number ofrotations (x) causes an increase in abrasion (y),” thereexists “positive correlation.” If, on the other hand, the

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p , ,existence of a relationship where “an increase in thenumber of rotations (x) causes a decline in abrasion(y)” indicates that there is “negative correlation.”

Method Usage Result

Scatter Diagram

•Used to identify a relationship between two matters.•Used to identify a relationship between two matters and establish countermeasures based on their cause and effect relation.

Example Usage

Scatter DiagramScatter DiagramｙAxis

x Axis

Ab

rasi

on

Scatter DiagramScatter DiagramｙAxis

x Axis

Ab

rasi

on

•Can identify cause and effect relation.•Can understand the relationship between two

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p g1.Relationship between thermal treatment temperature of a steel material and its tensile strengths 2.Relationship between visit made by a salesman and volume of sales 3.Relationship between the number of persons visiting a department store and volume of sales4 Others

Number of RotationsNumber of Rotations

[Used during phases to monitor the situation, analyze causes, and review effectiveness of an action.]

results.

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Scatter Diagram

(m

icro

n)

ｙAxis

(m

icro

n)

ｙAxis

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Ab

rasi

on

x Axis

Number of Rotations

Ab

rasi

on

x Axis

Number of Rotations

Control Chart

Also called: statistical process control (SPC)

Description

•The control chart is a graph used to study how a process changes over time. Data are plotted in time order.

•A control chart always has a central line for the average, an upper line for the upper control limit and a lower line for the

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pp pplower control limit.

•These lines are determined from historical data.

•By comparing current data to these lines, you can draw conclusions about whether the process variation is consistent (in control) or is unpredictable (out of control, affected by special causes of variation).

Control Chart (Control Chart / Graph 1)

1. What is Control Chart ?

A control chart is used to examine a process to see ifit is stable or to maintain the stability of a process.

This method is often used to analyze a process. Todo so, a chart is created from data collected for a

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certain period of time, and dots plotted on the chartare examined to see how they are distributed or if theyare within the established control limit. After someactions are taken to control and standardize variousfactors, this method is also used to examine if aprocess is stabilized by these actions, and if so, tokeep the process in a stable state.

Control Chart2. When is it used and what results will be obtained?

There are two types of control charts: one used formanagerial purposes and the other for analyticalpurposes. A control chart is used to identify dots thatare outside the control limit, which indicate someanomalies in a process. In addition, seven

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p ,consecutive dots showing values that are below orabove the mean (central) value, or an increment or adecline represented by seven consecutive dots alsoindicate “a problem in a process.”We need to examine what has caused such atendency or an increment/decline.

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Method Usage Result

Control Chart

Control ChartControl ChartControl ChartControl Chart

[Used during phases to monitor the situation,

l i

Used to observe a change caused by elapse of time.

Can identify a change caused by elapse of time.

Can judge the process if it is in its normal state or there

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x-R Control Chartx-R Control Chart analyze causes, review effectiveness of an action, perform standardization, and implement a selected control measure

In the example “x bar ” -R control chart, “X bar” represents the central value, while “R” indicates the range.

normal state or there are some anomalies by examining the dots plotted on the chart.

Control Chart for Managerial Purposes: Extends the line indicating the control limit used for analytical purposes to plot data obtained daily to keep a process in a good state.

Control Chart for Analytical Purposes: Examines a process if it is in a controlled state by collecting data for a certain period of time. If the process is not controlled, a survey is performed to identify its cause and develop countermeasures.

Control Chart

Examples of Values Represented by Dots

Values above the control limit represented by seven consecutive dots

Examples of Values Represented by Dots

Values above the control limit represented by seven consecutive dots

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x-Control Chart

Group Number

A decline represented by seven consecutive dots

x-Control Chart

Group Number

A decline represented by seven consecutive dots

Graph

1. What is Graph ?

A graph is “a graphical representation of data, which allows aperson to understand the meaning of these data at a glance.”Unprocessed data simply represent a list of numbers, andfinding certain tendencies or magnitude of situation from these

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finding certain tendencies or magnitude of situation from thesenumbers is difficult, sometimes resulting in an interpretationalerror. A graph is a effective means to monitor or judge thesituation, allowing quick and precise understanding of thecurrent or actual situation.

A graph is a visual and summarized representation of data thatneed to be quickly and precisely conveyed to others.

Graph2. When is it used and what results will be obtained?

A graph, although it is listed as one of the QC tools, iscommonly used in our daily life and is the mostfamiliar means of assessing a situation.

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Method Usage Result

Graph

0

20

40

60

80

100

120

1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

East

Changes in a time-sequential order – line graph

Amounts – bar graph, etc.

Ratios – pie graph, band

Can observe changes in a time-sequential order, ratios, and amounts.

A graphs is the most frequently used tool to

i th i

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1st Qtr13%

2nd Qtr17%

3rd Qtr57%

4th Qtr13%

chart, etc.

(The items listed above are representative examples.)

examine the various matters such as those listed on the left.

Graph

Sal

es

(¥million)

[Bar Graph of Sales]

・Survey Period: Dec. 1999

・Prepared by: M/T

[Band Chart of Expenses]

(¥million)

Before Taking Actions

Chemicals Chemicals (430)(430)

Oils Oils (200)(200)

Electricity Electricity

(170)(170)

(Total: ¥8 million)

Sal

es

(¥million)

[Bar Graph of Sales]

・Survey Period: Dec. 1999

・Prepared by: M/T

[Band Chart of Expenses]

(¥million)

Before Taking Actions




(170)(170)

(Total: ¥8 million)

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Sales Office

Iwate Tokyo Osaka Shizuoka

After Taking Actions




(108)(108)

(Total: ¥4.95 million)

Sales Office

Iwate Tokyo Osaka Shizuoka

After Taking Actions




(108)(108)

(Total: ¥4.95 million)

• Pareto Diagram To identify the current status and issues

• Stratification Basic processing performed when collecting data

• Scatter Diagram To identify the relationship between two things

• Cause and Effect Diagram

To sum up 7 QC tools (Numerical data ) are used as follow:

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To identify the cause and effect relationship

• Histogram To see the distribution of data

• Check Sheet To record data collection

• Control Chart/Graph To find out abnormalities and identify the current status

Thank you

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Thank you

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