Quality Control Tools

Ketaki Kumar, Moatasim Sheikh, Ashish Viswanath, Niranjan Naik,Prashanth K N 2nd year MBA School of Management Manipal Institute of Technology

PROBLEM SOLVING APPROACH

Traditional

Scientific

How is he related to quality? Any guess?

Significance of 7
The term 7 tools for Q.C is named after the 7 tools of the famous warrior, Benkei. Benkei owned 7 weapons, which he used to win all his battles. Similarly, from my own experience, you will find that you will be able to solve 95% of the problems around you if you wisely use the 7 tools of QC.
ISHIKAWA KAORU, Professor Emeritus, University of Tokyo

Check list/ sheet

Description
Structure form for collecting and analyzing data.

Purpose
Check sheets are used to systematically collect data. The data collected may be used to plotting histograms, pareto charts, etc.

Can be used as an inspection checksheet, to ensure that all related items are checked.

TWO BASIC TYPE OF CHECKSHEET

Data collecting checksheet Confirmation checksheet

DISADVANTAGE OF CHECKSHEET
Cannot reveal any changes overtime.
Possibility of checks not entered by data collector. Need to analyse several sheets arranged in chronological order to determine the trend. Misinterpreting the data due to different influencing conditions are present.

Pareto chart

HISTORY
Vilfredo Pareto, a 19th century economist observed that 80% of wealth was owned by only 20% of the populations.
1950 Dr. J.M.Juran discovered that if quality problems were arranged in order of frequency of occurrence, relatively few causes accounted for the bulk of the problems.

DESCRIPTION
Pareto chart is a bar graph with a cumulative curve
The length of the bars represent frequency of occurrence or cost.

The Pareto chart visually shows which are the most significant problems, cause or situations.

WHY USE PARETO CHART?

Identify the major problem or concern for improvements.
Can be applied for improvement in all areas. Shows whether the actions taken are effective.

CONSTRUCTION OF PARETO CHART

Step 1 Step 2 Step 3 Step 4 Determine the problem to be studied Identify the data to be used, frequency cost, etc Identify the categories Decide the period for data collection ( If comparing the results or different Pareto chart, the time period should be the same) Collect the data and total the frequency of occurrences in each category

Step 5

Step 6
Arrange the categories in descending order, calculate the percentage and cumulative percentage for each category.

Example : Cause of Machine Breakdown

Frequency Occur Component failure Program Hang Elec. Contact Elec. Component Jammed 20 14 4 3 3 Frequency % (20/47) x 100 = 42.6 29.8 8.5 6.4 6.4 Cumulative % 42.6 72.4 80.9 87.3 93.7

Operation
Others

2
1 47

4.2
2.1 100

97.9
100

Step 7
On a piece of graph, draw the vertical axis and horizontal axis.

15

10

Step 8
Place the categories in the horizontal axis in the descending order, the category having maximum count on the left and so on. ( keep all the horizontal scale same width for all categories )

Cause of Machine Breakdown

20 15 10 5 A B C D E F G

A - Component failure B - Program Hang C - Elec. Contact D - Elec. Component E - Jammed F - Operation G - Others

Step 9
Draw the right vertical scale for cumulative percentage, set the maximum value (100%) on the scale corresponding to the left vertical axis.

Plot the cumulative percentage line on the chart

Step 10
Give title to all the axis and chart

Cause of Machine Breakdown

F R E Q U E N C Y

100

C U M. P E R C E N T A G E %

20 15 10 5 A B C D E F G

50

A - Component failure B - Program Hang C - Elec. Contact D - Elec. Component E - Jammed F - Operation G - Others

Scatter diagram

Background:
Sometimes two separate things appear to change together and there may be suspicion that they are related somehow. The Scatter Diagram visually shows how well correlated they are. The Japanese guru Kaoru Ishikawa included Scatter Diagrams as one of his 7 basic tools.

Uses:
Use it during the analysis phase to understand the behaviour of a process and how a pair of variables change relative to one another (correlation).
Use it to provide an input to cause and effect analysis. After improvement, to find out how much the behaviour of the process has changed.

Scatter Diagram - Example

1. Identify purpose Understand factors that may lead to road accidents 2. Identify two factors Traffic speed and density 5. Plot Scatter Diagram

Accidents in day

6. Interpret
10 8 6 4 2 0 0 10 20 30 40 50 60 Average speed

Close correlation between speed and accidents when speed is above about 25

3. Identify measures Speed = Average Speed Density = Vehicles per minute

Weak correlation between traffic density and accidents

Average Vehicles Accidents Speed per m inute in day 15.40 0 1 43.40 3 6 31.00 2 2 27.40 1 1 32.80 1 3 40.20 3 5 34.20 6 4 8.40 0 1 20.80 1 1 33.40 3 3 32.00 1 2 17.00 0 1 26.60 1 1 15.40 1 2 29.40 2 2

Accidents in day

4. Collect data

10 8 6 4 2 0 0 5 10 15 Vehicles per minute

7. Take action Do trials in three areas with speed limits at 20, 25 and 30.

ABB Group 9AKK105151D0107

15 July 2010, Slide21

Scatter Diagram - Correlation

Degrees of correlation:

None

Low

High

Perfect

Types of correlation:

Positive

Negative

Curved

Partial

flowchart
Flowcharting is a tool for analyzing processes. It allows you to break any process down into individual events or activities and to display these in shorthand form showing the logical relationships between them. Constructing flowcharts promotes better understanding of processes, and better understanding of processes is a pre-requisite for improvement.

Flow chart
Purpose:
Visual illustration of the sequence of operations required to complete a task
Schematic drawing of the process to measure or improve. Starting point for process improvement Potential weakness in the process are made visual. Picture of process as it should be.

Benefits:
Identify process improvements Understand the process Shows duplicated effort and other non-value-added steps Clarify working relationships between people and organizations Target specific steps in the process for improvement.

In order to analyze the second condition for a flow process chart, one should use the ANSI standard symbols. The ANSI standard symbols used most often include the following:

Drive Nail, Cement, Type Letter.

Move Material by truck, conveyor, or hand.

Raw Material in bins, finished product on pallets, or filed documents.

Wait for elevator, papers waiting, material waiting

Connector Indicates that the flow continues where a matching symbol (containing the same letter) has been placed.

Flow Line Lines indicate the sequence of steps and the direction of flow.

Action or Process A box can represent a single step ("add two cups of flour"), or and entire sub-process ("make bread") within a larger process.

Document A printed document or report.

Decision A decision or branching point. Lines representing different decisions emerge from different points of the diamond.
Input/Output Represents material or information entering or leaving the system, such as customer order (input) or a product (output).

Graphs

Graphs refer to the results of statistical analysis of data (numbers) which are shown in diagrammatic form to communicate information.

There are numerous types of graphs : Bar Graph Belt Graph Line Graph Radar Graph Pie Graph

Radar graph
A radar chart is a graphical method of displaying multivariate data in the form of a two-dimensional chat of three or more quantitative variables represented on axes starting from the same point. The relative position and angle of the axes is typically uninformative.

Cause and effect diagram

Fishbone diagrams, Herringbone diagrams, Cause-and-effect diagrams, or Fishikawa 1968 - Kaoru Ishikawa Root cause of a problem 6M TPS 6M + 2M (Management, Maintenance)

How can it help me?

Indicates possible causes of variation Helps determine root causes Uses an orderly, easy-to-read format

Encourages group participation

Increases process knowledge

Criticism
Failing to make the distinction between necessary conditions and sufficient conditions. Even Ishikawa was not aware of this distinction.

Control charts
Shewhart charts - Walter A. Shewhart - Bell Labs - 1920 Process-behavior charts in SPC

Used to study how a process changes over time

 Consists of :
central line an upper line for the upper control limit a lower line for the lower control limit.

These lines are determined from historical data. By comparing current data to these lines:

in control or out of control

Types of data
Variables
Characteristics that can take any real value can be measured on a continuous scale May be in whole or in fractional numbers Continuous random variables

Attributes
Defect-related characteristics Classify products as either good or bad or count defects Categorical or discrete random variables Assessed by judgment and are dichotomous, i.e. have two states such as right or wrong, looks OK or not OK.

Logical order of B7
Big Picture Data Collection Data Analysis Problem Identification Prioritization

Flow Chart

Check Sheet

Histograms

Cause & Effect

Pareto Analysis

Scatter Diagrams

Control Charts

New Seven Q.C. Tools

Affinity Diagrams Relations Diagrams Tree Diagrams Matrix Diagrams Arrow Diagrams Process Decision Program Charts Matrix data analysis

N7 History

Committee of J.U.S.E. 1972 Yoshinobu Nayatani seven management and planning (MP) tools

Work in conjunction with original Basic Seven Tools

1977

Why do we need N7 ?
Problems: Qualitative vs Quantitative

Which one is difficult??

need a new solution to solve challenges presented by Qualitative problem.

7 MP tools are planning and solving tools for strategic problem, which is based on uncertain qualitative data, inter-functional and multidiscipline matter. Developed to organize verbal data diagrammatically

FACTS
Data Numerical Data
Define problem after collecting numerical data

Verbal Data
Define problem before collecting numerical data

The Basic Seven Tools

Analytical approach

The Seven New Tools

Generate Ideas Formulate plans

Organize Information

Source: Nayatani, Y., The Seven New QC Tools (Tokyo, Japan, 3A Corporation, 1984)

Benefits of N7

 N7 are techniques for untangling the intricate relationships among the

different variables of a problem. Using the N7 makes it easy to:
clarify the situation,
establish a plan get to the root cause of the problem

Affinity diagram
created in the 1960s Japanese anthropologist Jiro Kawakita KJ method organizes the idea based on similarity, closeness, and its equivalent.

When to Use an Affinity Diagram?

When you are confronted with many facts or ideas in apparent chaos When issues seem too large and complex to grasp When group consensus is necessary E.g. After a brainstorming exercise When analyzing verbal data, such as survey results.

 Tool/method that gathers large amounts of intertwined verbal data. It organizes the verbal data into groups based on natural relationship.

Grouping - help a meaningful picture to emerge, thereby making it

feasible for further analysis

Procedure
Materials needed: sticky notes or cards, marking pens, large work surface (wall, table, or floor).
1. Record (separate sticky note) & spread 2. look for related ideas and group them : (Dont talk during this stage ) 3. Participants can discuss on surprising patterns, reasons for moving controversial notes. more changes may be made. Choose headings for each group. 4. Combine groups into supergroups if appropriate

Example : Brainstorming session on developing a

vision statement for a company
low product maintenance low production costs satisfied employees

high quality growth in shareholder value motivated employees Teamwork unique products responsive technical support small, lightweight designs personal employee growth

innovative product features

courteous order entry high return on investment

low price constant

technology innovation quick delivery

Affinity diagram

Phases
Problem identification Affinity diagram Relationship Diagram Preparing solution tree diagram Preparing implementation plan PDPC Arrow Diagram

matrix diagram
prioritization matrix

Relations Diagram
Also known as Inter relationship diagram or network diagram Resolves tangled issues by unraveling the logical connection Allows for Multi-directional thinking rather than lateral thinking When to use?

Procedure
1. 2. 3. 4. 5. Express the problem List the causes Explore the causeeffect relationships Connect to identify relations Analyze

Example(check n tel is it necessary)

Tree Diagram
Also called systematic diagram or hierarchy diagram Looks like a tree with trunk and multiple branches When to use? General to specific

Procedure
Define the aim Brainstorming Do until the goal is fully satisfied

Matrix Diagram
Also known as Matrix chart Compares two or more sets of data against one another Shows relationship between two, three or four groups of informations Six differently shaped matrices are possible: L, T, Y, X, C and roofshaped, depending on how many groups must be compared

 An L-shaped matrix relates two groups of items to each other (or one group to itself). A T-shaped matrix relates three groups of items: groups B and C are each related to A. Groups B and C are not related to each other A Y-shaped matrix relates three groups of items. Each group is related to the other two in a circular fashion

 A C-shaped matrix relates three groups of items all together simultaneously, in 3-D An X-shaped matrix relates four groups of items. Each group is related to two others in a circular fashion A roof-shaped matrix relates one group of items to itself. It is usually used along with an L or Tshaped matrix

Matrix Diagram
Example
1. Define purpose Revise service features to better meet customer needs
Key to cell scores 9 = high correlation 3 = moderate correlation 1 = low correlation

Service features

Local country agents

Specialist engineers

On-site education

Unweighted total
9 10 0 3 12 10

Priority shipping

2. Select matrix Two sets of data, so use L-Matrix

Customer priority (1 to 5) Customer service needs Understand my needs 4 On-time delivery 1 Works first time 4 Easy to learn 3 Rapid fixing of problems 5 Easy to call for help 5 Unweighted total Weighted total

9 1 3 3 9 22 97 9 1 9 45 4 14

3. Define sets of data

9 9

Weighted total
36 10 0 9 60 50

6. Take action 4. Score relationships

5. Interpret

Process Decisions Program Charts

It is a good tool to use for contingency planning The PDPC systematically identifies what might go wrong in a plan under development Countermeasures are developed to prevent or offset those problems Steers events in required direction if unanticipated problems occur

Matrix Data Analysis Chart

Principal Component Analysis One of the most rigorous, careful and time consuming of decision-making tools It is an L-shaped matrix that uses pair-wise comparisons of a list of options to set of criteria in order to choose the best option(s) Based solely on numerical data

Arrow Diagrams
Used to plan the implementation of complex undertaking For working out optimal schedules and controlling them effectively Shows the required order of task in a project or process and best schedule for the entire project Shows relationships among tasks needed to implement a plan

Thank you