04 - Quality Tools

Quality Tools
Contents
 Pareto Chart
 Cause and Effect
 Check Sheet
 Histogram
 Flow Chart
 Affinity Diagram
 Scatter Diagram
 Control Charts
www.BrooklynAcademy.net 1
1- Pareto Chart
In any population that contributes to a common effect, a relative few of

the contributors (the vital few) account for the bulk of the effect.
220 100
80
165
Vital Few Useful Many
Cumulative Ratio
60
Defects
110
40
55 40
33 31 20
26 21 18 17 15 12 7
0 0
1 2 3 4 5 6 7 8 9 10
Process
2- Cause and Effect
 Also, called Fishbone or Ishikawa Diagram

 Identify the possible reasons
Workshop
 Using Fishbone, identify potential reasons for:
1. Traffic jam
2. Garbage spread
3. Unemployment
4. Education level deterioration
5. Healthcare service declining
Workshop
3- Affinity Diagram
 Organizing large amounts of data in categories
What are the issues involved in missing shipping dates?

SPACE RESOURCES METHOD
Overcrowded Lack of enough Error on bill of

dock fork lift loading
No place for
returns Computer crashes Shipping turnover
Insufficient Engineering
training changes
Inexperienced
supervisor Teams not used
4- Tally Sheet / Check Sheet
 A check sheet is a structured, prepared form for

collecting and analyzing data
5- Histogram
 The shape of the histogram provides insight into the

pattern of variation in the data.
Histogram Example
Target Diameter = 120mm + 10mm
121 129 117 122 115 123 120 106 112 134
113 138 122 128 111 123 138 104 105 120
130 118 109 139 128 140 134 113 114 120
124 114 136 116 105 114 106 113 135 119
122 117 121 105 120 111 113 111 125 107
How to build a Histogram
 Determine the largest and the smallest number in the array of
data and define the range.
 Divide the range into a convenient number of class intervals
having the same size (between 5 & 20), K=1+3.3 log n
where K = no. of intervals, n = no of data
(n, K) = (10, 4.3) (100, 7.6) (1000, 10.9)
 Determine the number of observations falling into each class
to find the class frequency.
How to build a Histogram
 Class boundaries: upper and lower limits of the class.
 Class size: class width or class interval. The
difference between the upper and lower limits of the

class.
 Class mark: It is the class midpoint.
 Class interval: Difference between any two adjacent
class marks.
Histogram Drawing
Class Start Class End Class Mark (X) Frequency (F)
102 108 105 7
109 115 112 13
116 122 119 14
123 129 126 7
130 136 133 5
137 143 140 4
Histogram Drawing
16
14
12
10
0
90 100 110 120 130 140 150
Histogram
Bell shape
 This is the classic normal distribution,
Bimodal shape
 Two distinct peaks, indicating two
distinct processes at work (two shifts)
Skewed shape
 Positive (skewed to the right)
 Negative (skewed to the left)
 Lower or upper target to the data
 (working hours or overtime)
Histogram
Truncated shape
 Usually means that a screening
process is in place to remove
part of output data
Plateau shape
 This could be because:
 Intervals are too wide to
 Mixing several different
processes are at work,
Histogram
Comb shape
 It indicates incorrect width of the
intervals or errors in the data
Isolated peak shape

 bell-shaped distribution with a
second small peak:
 Second process at work,
 Infrequently process that occurs,
 Measurement error
Standard Deviation Calculation
X X – X¯ (X – X¯)2
121 1.4 2.0

129 9.4 88.4
117 -2.6 6.8
122 2.4 5.8
X¯ = 120
115 -4.6 21.2
n = 50 ‐‐‐‐‐ ‐‐‐‐‐ ‐‐‐‐‐
 = 10 ‐‐‐‐‐ ‐‐‐‐‐ ‐‐‐‐‐
‐‐‐‐‐ ‐‐‐‐‐ ‐‐‐‐‐
‐‐‐‐‐ ‐‐‐‐‐ ‐‐‐‐‐
‐‐‐‐‐ ‐‐‐‐‐ ‐‐‐‐‐
‐‐‐‐‐ ‐‐‐‐‐ ‐‐‐‐‐
Total = 5980 Total = 4944
Standard Deviation
 Statistically measures variability
6- Flow Chart
 Graphic symbols to depict the nature and flow of
the steps in a process
Flow Start/End
Storage Process Step
Document Decision
Pile Construction Flow Chart
Workshop
 Draw the flow chart of one reasonable process in:

1. Hotel
2. Airline
3. Bank
4. Hospital
5. Training Center
6. Car Maintenance Workshop
7. Mobile Service Provider
8. Computer manufacturing company
7- Scatter Diagram
Determine if there is a relationship between 2 variables & Find the trend
8- Control Charts
Control Charts Tests

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Quality Tools

 Cause and Effect

In any population that contributes to a common effect, a relative few of

2- Cause and Effect

 Also, called Fishbone or Ishikawa Diagram

 Using Fishbone, identify potential reasons for:

4. Education level deterioration

5. Healthcare service declining

 Organizing large amounts of data in categories

What are the issues involved in missing shipping dates?

Overcrowded Lack of enough Error on bill of

4- Tally Sheet / Check Sheet

 A check sheet is a structured, prepared form for

 The shape of the histogram provides insight into the

Target Diameter = 120mm + 10mm

 Determine the largest and the smallest number in the array of

data and define the range.

 Divide the range into a convenient number of class intervals

having the same size (between 5 & 20), K=1+3.3 log n

where K = no. of intervals, n = no of data

(n, K) = (10, 4.3) (100, 7.6) (1000, 10.9)

 Determine the number of observations falling into each class

to find the class frequency.

How to build a Histogram

 Class boundaries: upper and lower limits of the class.

 Class size: class width or class interval. The

difference between the upper and lower limits of the

 Class mark: It is the class midpoint.

 Class interval: Difference between any two adjacent

Class Start Class End Class Mark (X) Frequency (F)

102 108 105 7

109 115 112 13

116 122 119 14

123 129 126 7

130 136 133 5

137 143 140 4

Isolated peak shape

Standard Deviation Calculation

121 1.4 2.0

 = 10 ‐‐‐‐‐ ‐‐‐‐‐ ‐‐‐‐‐

‐‐‐‐‐ ‐‐‐‐‐ ‐‐‐‐‐

‐‐‐‐‐ ‐‐‐‐‐ ‐‐‐‐‐

‐‐‐‐‐ ‐‐‐‐‐ ‐‐‐‐‐

‐‐‐‐‐ ‐‐‐‐‐ ‐‐‐‐‐

Total = 5980 Total = 4944

 Statistically measures variability

 Graphic symbols to depict the nature and flow of

the steps in a process

Storage Process Step

 Draw the flow chart of one reasonable process in:

Determine if there is a relationship between 2 variables & Find the trend

Control Charts Tests

Control Charts Tests

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