Quality Control Tools

ME3130 QUALITY PLANNING AND ANALYSIS (G Slot)

7 QC Tools
A. Ramesh PhD Department of Mechanical Engineering National Institute of technology Caliccut-673601 ramesh@nitc.ac.in

1. 2. 3. 4. 5. 6. 7.

Pareto chart Histogram Process flow diagram Check sheet Scatter diagram Cause and effect diagram Control chart
1. Run chart

1. Pareto Principle
Vilfredo Pareto (1848-1923) Italian economist

30

1.Pareto chart
28

% Complaints

20% of the population has 80% of the wealth

25 20 15 10 5 0
Loose Threads Stitching flaws Button problems Material flaws

Juran used the term vital few, trivial many. He noted that 20% of the quality problems caused 80% of the dollar loss.

16 12 12 6 4

1.Pareto Chart
Percent from each cause

70 60 50

(64)

2.Histogram
25 20

40 30
Frequency 15 10 5 0

20 10 0

(13)

(10) (6) (3) (2) (2)

Category

Causes of poor quality

9. 9 10 .9 11 .9 12 .9 13 .9 14 .9 15 .9 M or e

3. 9

6. 9

7. 9

1. 9

4. 9

5. 9

2. 9

8. 9

2.Histogram
40 35 30 25 20 15 10 5 0

3.Flowcharts
Flowcharts
Graphical description of how work is done. Used to describe processes that are to be improved.

1 2

6 13 10 16 19 17 12 16 20 17 13

5 6 2

3. 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.

3.Flowchart
Activity

Decision

Yes

No

3.Flowchart

3.Flow Diagrams

3.Flow Diagrams

3.Process Chart Symbols

Operations Inspection Transportation Delay Storage

3.Process Chart
Date: 9-30-00 Analyst: TLR Location: Graves Mountain Process: Apple Sauce Description of process Unload apples from truck Move to inspection station Weigh, inspect, sort Move to storage Wait until needed Move to peeler Apples peeled and cored Soak in water until needed Place in conveyor Move to mixing area Weigh, inspect, sort Page 1 0f 3 Total 30 480 190 ft 15 20 5 20 ft 360 20 ft 30 50 ft

Operation Transport Inspect Delay Storage

1 2 3 4 5 6 7 8 9 10 11

20 100 ft

4.Check Sheet
Shifts

Distance (feet)

Step

Time (min)

4.Check Sheet
COMPONENTS REPLACED BY LAB TIME PERIOD: 22 Feb to 27 Feb 1998 REPAIR TECHNICIAN: Bob

Defect Type

TV SET MODEL 1013

7 Quality Tools

Integrated Circuits Capacitors Resistors Transformers Commands CRT

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5.Scatter Diagram

6. 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

6. Cause and Effect Skeleton

Materials Procedures

6.Fishbone Diagram
Measurement
Faulty testing equipment Incorrect specifications Improper methods

Human

Machines
Out of adjustment Tooling problems Old / worn

Poor supervision Lack of concentration Inadequate training

Quality Problem

Inaccurate temperature control Dust and Dirt

Quality Problem
Defective from vendor Not to specifications Materialhandling problems Poor process design Ineffective quality management Deficiencies in product design

People

Equipment
7 Quality Tools

Environment

Materials

Process

6.Cause and effect diagrams

Advantages

6.Cause and effect diagrams

To construct the skeleton, remember: For manufacturing - the 4 Ms
man, method, machine, material

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

For service applications

equipment, policies, procedures, people

7. Run Charts
Run Charts (time series plot)
Number of defects

27 24 21 18 15 12 9 6 3

7.Control Chart
UCL = 23.35 c = 12.67

Examine the behavior of a variable over time. Basis for Control Charts

LCL = 1.99

10

12

14

16

Sample number

Control Charts 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)

3 4 5 6

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