1 MALAYSIA TRAINING PROGRAM

PERFORM QUALITY CONTROL PROCESS 7 QC TOOLS

By :NOR ARNIZA BINTI JAMIL VOCATIONAL TRAINING OFFICER, J41

5. Check Sheet
Check sheets help organize data by category. They show how many times each particular value occurs, and their information is increasingly helpful as more data are collected. Main applications of a check sheet include registering how often different problems occur and registering the frequency of incidents that are believed to cause problems.

Advantages of using a check sheet

Effective way of displaying data Easy to use Can identify the root cause of a problem A first step in the construction of other graphical tools Provides a structure for uniform data collection Can be used to substantiate or refute allegations

How to construct a check sheet

1. Clearly define what events (problem or process) are to be recorded. (Add a category of other to capture incidents not easily categorized into any of the specified groups. 2. Define the period for data recording and suitable intervals. The time period should be representative (that is, a one day sample on Monday may not be representative of a typical day). 3. Design the check sheet to be used during data recording, allocating space for recording, and for summarizing within the intervals and the entire recording period.

How To Construct A Check Sheet Cont..

4. Develop a check sheet that is easy to understand. All columns should be clearly labeled. 5. Perform the data collection during the agreed period, ensuring that everyone understands the tasks and the events to be recorded. 6. Analyze the data to identify events with unusually high or low occurrences. 7. Train all those involved on gathering data. A uniform data collection technique is vital. 8. Plot the information on a check sheet.

An example of the use of a check sheet (taken from Root Cause Analysis)
A book store located in a large shopping mall consistently achieved lower sales per day than budgeted. The staff noted that quite a few customers came into the store to browse, but left without buying anything. When considering this problem (not tapping the customer base potential there), a wide range of possible causes surfaced including: The customers did not find what they were looking for. The staff did not offer the necessary help. Sought items were temporarily sold out. Sought items were not carried by the store. Prices were too high. There was too long a line at the checkout counter. Certain types of credit cards were not accepted. Lighting was poor in some areas of the store. There were no places to sit and look through books before deciding to buy.

Cont..
The difficultly in identifying the actual problem and how often it occurred make it difficult for the store personnel to implement any changes. Thus, during a two-week period, many of the customers leaving without making purchases were courteously asked why this happened. The responses were logged in a check sheet, shown below, and give a much clearer idea of where to start to improve the situation.

Result..

6. SCATTER DIAGRAM
Also called: scatter plot, X Y graph Description The scatter diagram graphs pairs of numerical data, with one variable on each axis, to look for a relationship between them. If the variables are correlated, the points will fall along a line or curve. The better the correlation, the tighter the points will hug the line.

5. SCATTER DIAGRAM cont..

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 o When trying to identify potential root causes of problems. o After brainstorming causes and effects using a fishbone diagram, to determine objectively whether a particular cause and effect are related. o When determining whether two effects that appear to be related both occur with the same cause. o When testing for autocorrelation before constructing a control chart.

X and Y Data Correlation

Strong Positive Correlation
25 20 15 10 5 0 0 5 10 X 15 20 25
25 20

Strong Negative Correlation

Series1

15 Y 10 5 0 0 5 10 X 15 20 25 Series1

Positive Correlation
25 20 15 Y 10 5 0 0 5 10 X 15 20 25 Series1 Y 25 20 15

Negative Correlation

Series1 10 5 0 0 5 10 X 15 20 25

No Correlation
25 20 Y 15 10 5 0 0 5 10 X 15 20 25 Series1

Steps in using a scatter diagrams

1. Select and define the two variables to be analyzed in the individual chart. 2. Measure the two variables, if data has not already been collected. 3. The set of data pairs should consist of the at least thirty, but preferably more like one hundred data pairs. 4. Design the chart by placing the independent variable on the horizontal axis. The independent variable is the factor believed to be governing relationship between the two variables.

Steps In Using A Scatter Diagrams cont..

5. On the vertical axis, insert the dependent variable that is, the factor believed to change in proportion to the independent variable. 6. Plot the data pairs themselves in the chart area. 7. Examine the completed chart, looking for patterns that indicate a connection between the two variables. 8. If correlation patterns are identified, investigate any third variable involvement before drawing definite conclusions.

Scatter Diagrams Example..

Situation: The new commissioner of the American Basketball League wants to construct a scatter diagram to find out if there is any relationship between a player s weight and her height. How should she go about making her scatter diagram? 1. Collect the data (Remember to use 30100 paired samples).

2. Data Collected..
PLAYER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 WEIGHT 57 58 59 59 60 62 66 67 68 68 68 68 68 69 69 70 70 71 71 72 HEIGHT 156 114 132 147 157 145 157 168 147 179 147 168 156 175 173 168 175 158 169 212 PLAYER 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 WEIGHT 72 72 72 73 74 74 74 75 75 75 76 76 77 78 78 79 79 80 81 84 HEIGHT 182 168 168 157 180 216 179 194 184 167 168 225 200 187 194 208 216 215 225 214

3. SCATTER DIAGRAM..ans..
PLAYER HEIGHT/WEIGHT
HEIGHT, cm

240 220 200 180 160 140 120 100 45 50 55 60

WEIGHT, kg

65

70

75

80

85

90

4. Interpret your chart

According to this scatter diagram the new commissioner was right. There does seem to be a positive correlation between a player's weight and her height. In other words, the taller a player is the more she tends to weight.

ASSIGNMENT..

Collect the data for car age and the price. Interpret your chart for the relations between the car age and the price. Collect at least for 50pcs data.

ADDITIONAL ASSIGNMENT..

REFER HANDOUT..

7. CONTROL CHART
Also called: statistical process control
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 lower 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 charts for variable data are used in pairs. The top chart monitors the average, or the centering of the distribution of data from the process. The bottom chart monitors the range, or the width of the distribution. If your data were shots in target practice, the average is where the shots are clustering, and the range is how tightly they are clustered. Control charts for attribute data are used singly.

When to Use a Control Chart?

When controlling ongoing processes by finding and correcting problems as they occur. When predicting the expected range of outcomes from a process. When determining whether a process is stable (in statistical control). When analyzing patterns of process variation from special causes (non-routine events) or common causes (built into the process). When determining whether your quality improvement project should aim to prevent specific problems or to make fundamental changes to the process.

Control Chart Basic Procedure

Choose the appropriate control chart for your data. Determine the appropriate time period for collecting and plotting data. Collect data, construct your chart and analyze the data. Look for out-of-control signals on the control chart. When one is identified, mark it on the chart and investigate the cause. Document how you investigated, what you learned, the cause and how it was corrected.

Out-of-control signals
A single point outside the control limits. In Figure 1, point sixteen is above the UCL (upper control limit). Two out of three successive points are on the same side of the centerline and farther than 2 from it. In Figure 1, point 4 sends that signal. Four out of five successive points are on the same side of the centerline and farther than 1 from it. In Figure 1, point 11 sends that signal. A run of eight in a row are on the same side of the centerline. Or 10 out of 11, 12 out of 14 or 16 out of 20. In Figure 1, point 21 is eighth in a row above the centerline. Obvious consistent or persistent patterns that suggest something unusual about your data and your process.

Continue to plot data as they are generated. As each new data point is plotted, check for new out-of-control signals. o When you start a new control chart, the process may be out of control. If so, the control limits calculated from the first 20 points are conditional limits. When you have at least 20 sequential points from a period when the process is operating in control, recalculate control limits

ASSIGNMENT..

REFER HANDOUT..