7 QC

Vulcan Cold Forge Pvt. Ltd.
Manufacturer of Specialty Cold Forged Fasteners

7QC TOOLS
© Vulcan Cold Forge Pvt. Ltd., 2018

PRESENTATION

Plot No. 432, IMT Manesar, Sector-8 Gurgaon, Haryana, 122051
Website: vulcancoldforge.com
For further details contact at: info@vulcancoldforge.com

WHY DO WE NEED 7QC TOOLS?


How do we solve quality
related issues?

What if people do not have
advanced statistics training?

Plants need continuous
improvement cycle to remove
waste and improve quality

Need very basic tools to
troubleshoot problems
WHAT ARE THE 7 QC TOOLS

1. CHECK SHEET 2. CONTROL CHART 3. STRATIFICATION
4. CAUSE/EFFECT 5. PARETO CHART 6. HISTOGRAM 7. SCATTER DIAGRAM

HOW ARE THE 7 QC TOOLS USED?




DMAIC METHOD

1. Define
2. Measure
3. Analyze
4. Improve

5. ControlDMADV METHOD
(Six-Sigma)
1. Define
2. Measure
3. Analyze
4. Design
5. Verify

1. CHECK SHEET

Data is recorded by making marks (checks) on a sheet

Data represents location and number of marks

Can be qualitative or quantitative

5 Ws: WHO, WHAT, WHERE,
WHEN, WHY
Types of Check sheets:

1. CHECK SHEET
1. Quantify defects by type

2. Quantify defects by location
3. Quantify defects by cause
4. Check shape of probability distribution of process
5. Completion of steps in a multistep procedure /
CheckListQuantify Defects by Type

1. CHECK SHEET
Quantify Defects by Location

1. CHECK SHEET

1. CHECK SHEET
Quantify Defects by Cause

1. CHECK SHEET
Check Shape of Probability Distribution of a Process

1. CHECK SHEET
Checklist
2. CONTROL CHARTS

2. CONTROL CHARTS

2. CONTROL CHARTS

2. CONTROL CHARTS

2. CONTROL CHARTS
Why we do not use specification limits ?

2. CONTROL CHARTS
Let subgroup size

be 2
Specifications are
in one unit (items)
while the control
chart is in another
(average of several
items).
Why do we need
Control Charts?

Monitor process
variation over
time

Differentiate
between special cause and common cause variation

Assess effectiveness of changes

2. CONTROL CHARTS

Communicate process performance or variation

Show if a process is in control or out of control
Can any type of process be controlled?

2. CONTROL CHARTS

All random or natural processes show common-cause variation, i.e.
they form a bell-curve or are normal


Any process which is not-
normal is already out of control
and hence unstable and
unpredictable.

2. CONTROL CHARTS

2. CONTROL CHARTS
What is a Summary Statistic?

Summarize a set of observations. Can be central tendency like mean or measure
of variation like standard deviation.
What is a Sample in Control Charts?

Samples are subgroups. Select the number of subgroups such that :

Variation between subgroups is maximized

Variation within subgroups is minimized

Make the chart more sensitive to shifts in process
Types of Control Charts
1. Variables

X_x0016_ bar and R charts display subgroup means and ranges.

2. CONTROL CHARTS

_x000f_X_x0016_ bar and s charts display subgroup means and standard
deviations.
2. Attributes

A p chart displays the proportion of defective items in a subgroup sample.

An np chart displays the number of defective items in a subgroup sample.

_x000f_A u chart displays the number of defects per unit in a subgroup sample
consisting of an arbitrary number of units.

_x000f_A c chart displays the number of defects in a unit.
Types of Control Charts

2. CONTROL CHARTS
How is Run Chart Different from Control Chart

2. CONTROL CHARTS
Run Chart Control Chart

●
No UCL / LCL
● Cannot differentiate b/w special or common cause

2. CONTROL CHARTS
+ 3 sigma line
- 3 sigma line
Subgroup Index / Samples

2. CONTROL CHARTS

2. CONTROL CHARTS

2. CONTROL CHARTS
Random Sampling
Each member of the population has an equal
chance of being included in the sample
Stratified Sampling
The population is divided into subgroups and
then randomly sampled
Systematic Sampling
Samples are taken at specific points in time
or intervals
Sample Size?
Detect small changes or large changes?
Normal vs Non-normal data?
Make subgroups and choose frequency of sampling

2. CONTROL CHARTS
Each member of the population has an equal

chance of being included in the sample
Stratified Sampling
The population is divided into subgroups
and then randomly sampled Systematic
Sampling
Samples are taken at specific points in time or
intervals

2. CONTROL CHARTS

2. CONTROL CHARTS
Subgroups
●
For each subgroup , subgroup Mean and Range is calculated
●
The subgroup ranges provide information about short-term (within subgroup) variability.
●
The subgroup means, when viewed over time, provide information about longer-term (between
subgroup) variability.
●
Control limits are established based on the short-term variability (the ranges) and the average of
the subgroup means.

2. CONTROL CHARTS
Subgroup Size matters
●
If too low, then process shifts may go undetected
●
If too large then sensitive to insignificant process shifts
●
As the subgroup size increases, the standard deviation of
the distribution of averages decreases

2. CONTROL CHARTS
●
Subgroup size is a function of the desired sensitivity,
the process standard deviation, and the willingness
to tolerate type II errors (where the process shifts
but the chart fails to detect the shift)
Type I error
probability (α) – A
Type I error occurs
when we conclude
that a control chart is
giving us an out-of-
control signal but the process is actually stable. This may

2. CONTROL CHARTS
be considered as a “false alarm.” In control chart applications, it is customary to set α = 0.0027. This is
done so that the control limits trap 99.73% of the statistic that is being plotted on the control chart
(note that 99.73% is trapped by placing control limits at ±3 standard deviations from the process
average for normally distributed statistics such as sample averages). Because α is typically 0.0027, the
formula term involving α is typically Ζ 0.0027/2 = Ζ 0.000135 = 3.
Type II error probability (β) – A Type II error occurs when we fail to detect an out-of-control
condition when the process is actually not stable. This is a serious error, as the whole purpose of the
control chart is to detect a change quickly after the change occurs! As the Type II error is decreased,
the required sample size to detect a process change increases (provided all other factors are
unchanged). Once β is specified by the chart designer (a function of risk tolerance), Ζ β/2 can be
found from a standard normal table, which is available in any statistics textbook.

2. CONTROL CHARTS
n = sample size required
Ζ α/2 = the number of standard deviations above zero on the standard normal distribution such that the
area in the tail of the distribution is α/2 (α is the type I error probability and is typically 0.0027 for
control chart applications. In this case, Ζ 0.00135 =3).
Ζ β = the number of standard deviations above zero on the standard normal distribution such that
the area in the tail of the distribution is β (β is the type II error probability). σ = the standard
deviation of the characteristic being charted.
D = the difference we are trying to detect.

Suppose that a beer bottler is filling containers labeled as 12 oz. The process standard deviation is
estimated to be 0.12 ounces. The bottle weights follow a Normal distribution, so the bottler decides to
center the process at 12.36 ounces to protect themselves against potential “underfills.” In addition the
company is worried about overfilling, so the risk of a process shift is on both ends.
What sample size is required to detect a shift of 0.18 oz with 80% probability? (20% probability that
the chart does not detect the shift).
We have:

2. CONTROL CHARTS
Ζ α/2 = Ζ 0.00135 = 3 Ζ β =
Ζ 0.20 = 0.84 σ = 0.12
D = 0.18 oz
Thus, the required sample size is

7.
How does the required

sample size change if we are only willing to tolerate a 10%
chance that the chart fails to detect the shift? (Answer n =
8.14, so a sample size of 9 is required).
The average chart is concerned with variation between
subgroups.

2. CONTROL CHARTS

2. CONTROL CHARTS
Can we estimate standard deviation?
What is d2?

2. CONTROL CHARTS

2. CONTROL CHARTS
Mean = 0, standard deviation = 1

2. CONTROL CHARTS

2. CONTROL CHARTS

2. CONTROL CHARTS

2. CONTROL CHARTS

2. CONTROL CHARTS

2. CONTROL CHARTS
RULE 1 : Beyond Limits

One or more points beyond the control limits
One point is more than 3

standard deviations from the
mean.

2. CONTROL CHARTS
RULE 2 : Zone A
2 out of 3 points above or below the 2 sigma limits
There is a medium tendency

for samples to be mediumly
out of control.
The side of the mean for the
third point is unspecified.
RULE 3 : Zone B
2 out of 3 points above or below the 1 sigma limits

2. CONTROL CHARTS
There is a strong tendency for

samples to be slightly out of
control.
The side of the mean for the fifth
point is unspecified.
RULE 4 :
7/8/9 points in a row above or below the center

line
Some prolonged bias exists.

2. CONTROL CHARTS
RULE 5 : Trends
6/7 points in a row increasing or decreasing
Some prolonged trend exists.

RULE 6 : Zone C Hugging
15 Points in a row in Zone C

2. CONTROL CHARTS
With 1 standard deviation, greater variation would be expected.

RULE 7 : Increase/Decrease
14 Points in a row alternating between increasing
and decreasing

2. CONTROL CHARTS
This much oscillation is beyond noise.

This is directional and the
position of the mean and size of
the standard deviation do not
affect this rule.
RULE 8 : Out of Zone C
8 Points in a row out of Zone C
Jumping from above to below whilst

missing the first standard deviation
band is rarely random.

6. HISTOGRAM
●
Bar graph showing distribution of numerical data
●
Divide the data into bins or range of values or series of intervals of equal size
●
Calculate number of cases that fall into each bin also called frequency

6. HISTOGRAM

6. HISTOGRAM

6. HISTOGRAM
Bin Size Matters

There is no "best" number of bins, and different bin sizes can reveal different features of the
data.
1 rupee bins 0.01 rupee bins
Empty intervals are represented as empty and not skipped

6. HISTOGRAM
Bin Width Matters

●
Using wider bins where the density of the underlying data points is low reduces noise due to
sampling randomness;
●
Using narrower bins where the density is high (so the signal drowns the noise) gives greater
precision to the density estimation.
●
Thus varying the bin-width within a histogram can be beneficial.
●
Nonetheless, equal-width bins are widely used.

5. PARETO CHARTS

●
Contains both bar graph and line graph
●
Values in descending order of bars

●
Cumulative total by line graph

5. PARETO CHARTS

●
Used to separate the important from trivial
●
Decide where to focus the efforts given limited resources

●
Pareto principle or 80/20 rule: Roughly 80% of defects come from 20% of causes

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Vulcan Cold Forge Pvt. Ltd.

Manufacturer of Specialty Cold Forged Fasteners

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

For further details contact at: info@vulcancoldforge.com

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

4. CAUSE/EFFECT 5. PARETO CHART 6. HISTOGRAM 7. SCATTER DIAGRAM

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

Types of Check sheets:

© Vulcan Cold Forge Pvt. Ltd., 2018

1. Quantify defects by type

© Vulcan Cold Forge Pvt. Ltd., 2018

Quantify Defects by Location

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

Quantify Defects by Cause

© Vulcan Cold Forge Pvt. Ltd., 2018

Check Shape of Probability Distribution of a Process

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

Why we do not use specification limits ?

© Vulcan Cold Forge Pvt. Ltd., 2018

Let subgroup size

© Vulcan Cold Forge Pvt. Ltd., 2018

Can any type of process be controlled?

© Vulcan Cold Forge Pvt. Ltd., 2018

they form a bell-curve or are normal

normal is already out of control

and hence unstable and

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

What is a Summary Statistic?

What is a Sample in Control Charts?

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

How is Run Chart Different from Control Chart

© Vulcan Cold Forge Pvt. Ltd., 2018

Run Chart Control Chart

© Vulcan Cold Forge Pvt. Ltd., 2018

Subgroup Index / Samples

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

Each member of the population has an equal

© Vulcan Cold Forge Pvt. Ltd., 2018

© Vulcan Cold Forge Pvt. Ltd., 2018

the subgroup means.

© Vulcan Cold Forge Pvt. Ltd., 2018

Subgroup Size matters

the distribution of averages decreases

© Vulcan Cold Forge Pvt. Ltd., 2018

Subgroup Size matters