New Quality Control Tools

Need for Seven New Q.C. Tools

• The practice of Total Quality Control (TQC) not only requires

numerical data but also verbal data and verbal communication,

which may not be computed.

• There should be suitable methods to process these information

with a view of arriving at a complete plan.

• New tools organizes verbal data diagrammatically

• New tools work in conjunction with the original seven basic tools
 Seven New Tols

• Affinity Diagram
• Relations Diagram
• Tree Diagram
• Matrix Diagram
• Matrix Data Analysis
• Process Decision Program Chart (PDPC)
• Arrow / Activity Diagram
AFFINITY DIAGRAM
 Affinity Diagram

Gathers large amounts of language data (ideas, opinions, issues, etc.)

and organizes it into groupings based on the natural relationship
between each item. It is largely a creative rather than a logical process.

When to use it:

• to bring order to fragmented/uncertain information and where there is
no clear structure.
• when information is subjective and emotive, to gain consensus.
• when the situation calls more for creative organization than for logical
organization
Affinity Diagram Example
Affinity Diagram Example

High resignation rate of good

checkout staff of a food super
market chain
 Affinity Diagram
-Construction-
i. Form a team of 4-7 creative thinking people to work on the problem.
The member should have complimentary rather than supplementary
knowledge

ii. Define the task in such a way that the problem is clear.

iii. Collect verbal data about the problem by brainstorming, Surveys etc.

iv. Transfer each data on separate data card (one item per card).
• Avoid abbreviations.

v. Shuffle the cards (to remove any patterns) and spread them out in a
'parking area' so that they can all be seen.
 Affinity Diagram
-Construction-

vi. Silently, the group members reads and moves the cards one by
one from the parking area into the organization area, placing
together those that seem to be most closely related. This stage
ends when the movement of cards ceases.
 Affinity Diagram
-Construction-
vii. Discuss each group, aiming to identify the common characteristics of
the group. This may result in cards being moved to or from other
groups/Headers. Create a header card to summarize the spirit of the
group (may be from within the group or a new one).
viii. Repeat the process, building up a multi-level tree made up of groups
which contain other groups and individual cards.
ix. The cards and groups may then be documented in a single diagram i.e.
affinity diagram for communication, discussion, etc.
 Affinity Diagram
-Advantage-
• Facilitates breakthrough thinking and simulates
fresh ideas
• Permits the problems to be pinned down
accurately
• Considers opinion of entire group - fosters team
spirit
• Raises everyone’s level of awareness
 RELATIONS DIAGRAM /
INTERRELATIONSHIP DIAGRAM
 Relations Diagram

The Relations Diagram is a tool for finding solution to

problems that have complex casual relationships.

• The Relations Diagram addresses these situations by showing

relationships between items with a network of boxes and
arrows.

• Allows multi-dimensional thinking rather than linear

thinking
 Relations Diagram

• Eliminating root causes can result in subsequent causes also

being eliminated, giving a significant improvement for a
relatively small effort.
• The Bottleneck cause can be difficult to eliminate, due to the
multiple contributory causes.
 Relation Diagram
-Construction-
i. Form a team of 4-7 people with close working knowledge of the problem
area (to be able to identify why things happen)

ii. Identify the type of relationship to be mapped, and how this is to be

displayed. Most common among them is Cause-Effect Relations Diagram

iii. Define each problem clearly, writing it as a complete, but brief, sentence on
a card. There may be more than one such problem statement.

iv. Produce the set of items to be related in the diagram by using techniques
like Brainstorming, nominal group technique, surveys, inputs from Affinity
Diagram, Cause-Effect Diagram or Tree Diagram. Write each item on a
card, distinguishing item cards from problem cards. Aim for around 15 to
50 cards.
 Relation Diagram
-Construction-
v. Put the item cards randomly in a 'parking area' where they may be

transferred to the main 'organization area'.

vi. Select a card in the organization area and look for a card in the parking area

which answers the question identified in step (ii). For a cause-effect Relations

Diagram this will be a card which is a direct cause of a problem card. Repeat

this step, selecting and placing cards near the problem cards, until all cards

with a direct relationship have been moved.

vii. When placing cards, also look for links to or from other cards in the

organization area and position the card accordingly.

 Relation Diagram
-Construction-

viii. Review the layout with the team and draw arrows between cards on the
diagram as relationships are agreed.
• Beware of adding arrows for weak relationships, as this can result in
the important link being hidden in a mass of arrows.
• Also avoid two-way arrows; where the relationship is bidirectional,
place the arrowhead to show the most significant direction.
 Relation Diagram
-Construction-
ix. Identify and mark key items that are to be addressed further by

indicating bottleneck cause, key cause and root cause cards

x. Review the whole diagram to check that assumed causes are actual

causes. Review it for other changes, marking up changes on the copies.

xi. Review the marked changes, update the document accordingly and

repeat the review as necessary. Plan and implement concrete actions to

address key items.

Relations Diagram Example

The design department of a company which

produces industrial cabinets were continually
irritated by the production department, who
kept modifying their designs.
WHERE AS
• The production department blamed the design
department of not considering the production
issues while designing.
Relations Diagram Example
 Relations Diagram
-When to use it-

• when analyzing complex situations with multiple interrelated issues.

• where the current problem is perceived as being a symptom of a more
important underlying problem.
• useful in building consensus within groups.
• commonly used to map cause-effect relationships, but also can map
other relationship.
• use it, rather than an Affinity Diagram, when there are logical rather
than subjective relationships.
• use it, rather than a Cause-Effect Diagram, when causes are non-
hierarchic or when there are complex issues.
 Relations Diagram
-Advantage-
• Useful at planning stage for obtaining perspective
on overall situation
• Facilitates consensus among teams
• Enables priorities to be identified accurately
• Makes the problem recognizable by clarifying the
relationship among causes
 TREE DIAGRAM /
TREE ANALYSIS /
DENDOGRAMS/
SYSTEMATIC DIAGRAM
 Tree Diagram

• Tree Diagram systematically maps out in increasing detail

the full range of paths and tasks that need to be accomplished

in order to achieve a primary goal and every related subgoal.

• Graphically, it resembles an organization chart or family

tree.

• Tree Diagram uses logical and systematic method, repeating

the same process of analysis and breakdown for each node.

 Tree Diagram

• Each position or node on the tree has one predecessor or parent and one or
more successor nodes, or children
• There is one initial node (or root), which has no parent, and multiple
bottom-level nodes (or leaves) which have no children
 Tree Diagram
-Construction-
i. Identify the objective of using the Tree Diagram. Examples of this
include:
• Determine the individual tasks that each person on a project team must carry
out to achieve a known objective.

• Describe all sub-assemblies and basic components in a competitor's product.

• Identify a customer's basic needs of a product.

ii. Assemble a small team of people to work on the diagram. These people
should be of an analytical (rather than creative) nature, and should have
sufficient subject expertise between them to be able to break down the
problem to the required level of detail.
 Tree Diagram
-Construction-
iii. Define the top-level 'root' statement so that it can easily
identify its individual sub-components.

iv. Define the process for breaking down each 'parent' statement
into 'child' statements.

v. Define the criteria to be used to identify when bottom-level

'leaves' have been arrived at. For example, 'Tasks that may be
allocated to a single person, and will take no more than one week each to
complete'.
 Tree Diagram
-Construction-
vi. Break down each 'parent' statement into 'child' in order to produce the
first-level child statements. Write these statements on cards, and arrange
them to the right of the top-level statement card, as below.

vii. Repeat this process until we reach the ‘leaves’.

 Tree Diagram
-Construction-
viii. When the diagram is complete, review the stages, looking
for improvements, such as:

• Statements which are in the wrong place,

• Levels where the child statements is not appropriate.

ix. Use the completed tree to help achieve the objective

Tree Diagram Example
 Why-Why Tree Diagram
• A Why-Why Diagram
is a Tree Diagram
where each child
statement is
determined simply
by asking 'why' the
parent occurs
 How-How Tree Diagram
 How-How Diagram
is a Tree Diagram
where each child is
determined by
asking 'how' the
parent can be
achieved.

 It is thus useful for

creating solutions to
problems.
Different
Shapes of
Trees
 Tree Diagram
-When to use it?-

• when planning, to break down a task into manageable and assignable

units.
• when investigating a problem, to discover the detailed component parts of
any complex topic.
• Use it only when the problem can be broken down in a hierarchical
manner.
• Use it, rather than a Relations Diagram, to break down a problem when
the problem is hierarchical in nature
 Tree Diagram
-Advantage-
• Systematic and Logical approach

• Facilitates agreement among teams

MATRIX DIAGRAM
 Matrix Diagram

• Matrix Diagram shows the relationship between

two, three or four groups of information and
• can give information about the relationship, such as
its strength, the roles played by various individuals,
or measurements.
Matrix Diagram
 Types of
Matrix
Diagram

Roof-Shaped Matrix Diagram

Types of Matrix Diagram
 Types of Matrix Diagram
Customer Customer Customer Customer
D M R T
Purity % > 99.2 > 99.2 > 99.4 > 99.0
Trace metals (ppm) <5 — < 10 < 25
Water (ppm) < 10 <5 < 10 —
Viscosity (cp) 20-35 20-30 10-50 15-35
Color < 10 < 10 < 15 < 10

L-Shaped Matrix Diagram

T-Shaped Matrix Diagram

(Products—Customers—Manufacturing Locations )
 Types of Matrix Diagram

Y-Shaped Matrix Diagram

(Responsibilities for Performance
to Customer Requirements )

X-Shaped Matrix Diagram

(Manufacturing Sites—Products—
Customers—Freight Lines)
 Matrix Diagram
-Construction-
i. Define the objective of using the Matrix Diagram. Ex. 'Focus design
improvements on key customer requirements‘

ii. Form a team who have the time and knowledge to work on achieving
the objective.

iii. Decide what needs to be compared to achieve the objective. This will
result in two or more lists being identified where the investigation of
their relationships will help to achieve the objective.

iv. Identify the appropriate matrix to use. In approximate order of

common use, these are: The L, T, Y, X, C-matrices and roof matrix.

v. Decide how list items are to be compared. The most common is the
strong/medium/weak relationship and identify the symbols/no. if any.
 Matrix Diagram
-Construction-
vi. Derive the lists

vii. Perform the comparison of the matrices

viii. Evaluate the final matrix, looking for items of significance which will
result in specific actions being carried forwards. Things to look for
include:

• Unimportant items with few or no relationships with the other lists.

• Key items which relate to many of the items in the other lists.

• Patterns which strike you as odd, and which may bear further
investigation.
 Matrix Diagram
-When to use it?-

• when comparing two lists to understand the many-to-many relation

between them
• To determine the strength of the relationship between either single pairs
of items or a single item and another complete list.
• Use it when the second list is generated as a result of the first list, to
determine the success of that generation process. For example, customer
requirements versus design specifications.
 Matrix Diagram
-Advantage-
• Enables data or ideas based on extensive
experience
• Clarifies relationships among different elements
• Make overall structure of the problem
immediately obvious
MATRIX DATA ANALYSIS CHART
(MDAC)
Matrix Data Analysis Chart
(MDAC)
• The Matrix Data Analysis Chart (MDAC) is used to identify

clusters of related items within a larger group

• The Matrix Data Analysis Chart (or MDAC) helps classify

items by identifying two/three major characteristics common

to all items and then plotting each item as a point on a 2D/3D

chart.
Matrix Data Analysis Chart
(MDAC)
MDAC Example

A toy store: objective increase sales

 Matrix Data Analysis Chart
-Construction-
• Identify the items which are to be compared, and decide on the primary
objective of using the Matrix Data Analysis Chart.
• Identify measurement units for X-Y axes of the chart. These should be
two factors which are the most critical representations of the objective.
• Measure the factors with an aim to get realistic and unbiased values.
• Draw a chart and plot each point on it.
• Look for significant clusters of points on the chart, and highlight them
by linking them together into a ring.
• Interpret the chart and act on the results. Typical activities include the
investigation into and subsequent action on:
• Why items which might be expected to group closely do not.
• Why items unexpectedly form clusters.
• Why individual items are not positioned where they were expected to be on
the chart.
 Matrix Data Analysis Chart
-Construction-
NOTE:
• When multiple measurements are made, such as texture, color, taste,
etc., a number of MDACs can be drawn and then evaluated as a group,
looking for similar clusters in each chart.
• Another approach when there are multiple measurements is to combine
similar measurement sets. Ex. similar marks to texture and color, then
they may be averaged, and plotted as 'texture and color‘ one axis.
• The vertical and horizontal axes do not have to cross at their zero points.
PROCESS DECISION PROGRAM CHART
(PDPC)
 Process Decision Program Chart

• Process decision program chart (PDPC) is a tool to

maps out every conceivable event and contingency
that can occur when moving from a problem
statement to the possible solutions.
• This is used to plan each possible chain of events that
needs to happen when the problem or goal is an
unfamiliar one.
• The PDPC is used to identify potential problems and
countermeasures in a plan.
 PDPC
-When to Use it?-
 PDPC
-Construction-
i. Identify the objective of using PDPC. Ensure that the situation merits the
use of PDPC.
ii. Identify the key areas of the plan which need to be examined in order to
meet the objectives.
iii. Form a team to work on the PDPC. Between them, they should have
wider view of the possible situation, so that diverse risks may be
identified.
iv. Identify the criteria for making decisions during construction of the
PDPC e.g. Time, cost, control, information. These include:
• How to identify a risk.
• How to select risks that need countermeasures to be identified
• How to identify countermeasures
• How to select countermeasures to implement
 PDPC
-Construction-
 PDPC
-Construction-
 PDPC
Example
 PDPC
-When to Use it?-

• when making plans, to help identify potential risks for successful completion.
• when risks are identified, use it to help identify and select from a set of
possible countermeasures.
• It is of best value when risks are non-obvious, such as in unfamiliar
situations or in complex plans, and when the consequences of failure are
serious.
 PDPC
-Advantage-
• Facilitates forecasting

• Uses past to anticipate contingencies

• Enables problems to be pinpointed

• Illustrates how events will be directed to successful

conclusion
Arrow Diagram
 Arrow Diagram

• Activity network diagram is used to plan the most

appropriate schedule for any complex task and all of its
related subtasks.
• It projects likely completion time and monitors all
subtasks for adherence to the necessary schedule.
• This is used when the task at hand is a familiar one with
subtasks that are of a known duration.
Management and Planning
Tool Dependency
 Affinity Diagram Relations Diagram

Creative Logical

Tree Diagram

Matrix Data
Matrix Diagram
Analysis Chart

Unknown Known

Process Decision Activity Network

Program Chart Diagram
SUMMARY ON NEW Q.C TOOLS

Benefits of New QC Tools

•Provide Training in thinking
•Raise people’s problem solving confidence
•Increase people’s ability to predict future events

Role of New QC Tools

•Express verbal data diagrammatically
•Make information visible
•Organize information properly
•Work in consensus
Relationship Between 7 New
Q.C Tools and Basic 7 Tools
FACTS
Define problem
Define problem before collecting
after collecting Data numerical data
numerical data

Numerical Data Verbal Data

The Seven Basic Tools The Seven New Tools

•Analytical Organize •Generates Ideas

Approach •Formulates Plan

Information
SEVEN BASIC TOOLS
Check sheets

Histogram
SEVEN NEW PLANNING
Pareto Chart TOOLS
Affinity Diagram
Cause and Effect Relationship
Relations Diagram
Scatter Diagram
Tree Diagram
Control Charts (includes run
chart) Matrix Diagram
Flowchart
Matrix Data Analysis Chart
(MDAC)
Process Decision Program Chart
Arrow Diagram
THANKYOU