Welcomes to all of you

in
Training Programme
 

Dr. K. Ishikawa

Dr. Deming

Dr. Juran
 

Dr.. walter
Dr walter Andr
Andrew
ew Shewhart
Shewhart
1.Birth-1891, Place-New canton, USA

2.Engineer and Statistician,

3.He was the mentor of Dr. Deming

4.He was the first to have given Quality and Quality Control
5.He is popularly known as the “ Father of Statistical Quality Control

6.Dr. Shewhart
6.Dr.
Chance Causes framed the problem in
in terms of Assignable Causes and
and
Sh ewhart was introduced the “ Control chart “ in 1924
7.Dr.. Shewhart
7.Dr

8.He was made

boundaries a mathematical
of variations formula
for a given that could established
process
 

9.His more conventional work led him to formulate the

statistical idea of tolerance intervals and to propose his data
Presentation rules Data have no meaning apart from
Presentation from their
conte
context.
xt. Dat
Data
a contains
contains both Signal
Signal and Noise

10.Dr. Shewhart visited India in 1947 under

10.Dr. under the sponsorship
sponsorship
of Prof.P
Prof.P.C.Mahalanobis
.C.Mahalanobis of Indian Statis
Statistical
tical institute

11.Dr.. Shewhart was bequeathed

11.Dr bequeathed his personal
personal library
library
including his manuscripts to Indian Statistical
Statistical institute of
Kolkata
 

William Edward Deming

Birth – 19
1900
00,, Place
Place-- USA,
USA, Deat
Death-
h- 1993
1993

He had the unique honour of developing Sampling

Sampling Techniques
Techniques that was the used for

the first time for conducting census in the USA

In 1950 , Gen. Mac arthur first invited

invited Dr.
Dr. Deming to Japan

The popular Deming prize established in 1951 in the honor of Dr

Dr.. Deming was
originally designated to Japanese

Companies for major contribution in quality improvement

improvement under the guidance of JUSE
 

William Edward Deming

DEMING’S Contribution :-

1.Theory of optimization ,

2. Theory of variation,

3. Theory of Knowledge

4. Theory of Psychology

Dr. Deming was popularized the PDCA Cycle originated by the Dr.
Shewhart
 

Joseph Moses Jur

Juran
an ( J.M.Jur
J.M.Juran)
an)

1.Birth-1904,
1.Birth-1904, Place
Place-- Roman
Romania
ia ,Death-20
,Death-2008
08

2.Dr.
2.Dr. Juran is known as the foremost teachers
teachers and Consultants in the world

3.Dr.. Juran
3.Dr Juran is man of millennium
millennium,, he spanned more than 80 years in the field
field of quality
quality

4.In 1954
1954 Dr.
Dr. Juran alter
altered
ed global competition
competition when
when he accepted the invitation
invitation of the JUSE

5.And KAI-DAN-REN to prepare and deliver a series of lectures for the leaders of Japanese
industries

6.Juran’s congressional testimonies in 1986 helped create “The Malcolm Bridge National
Quality Award

7.Juran Institute was founded in 1979 to create New tools , New techniques and New
principles to serve the emerging need of society

8.We all benefit from Dr. Juran’s accomplishment . He has created New Methods ,Tools and
concepts
 

Joseph Moses Jur

Juran
an ( J.M.Jur
J.M.Juran
an)

The Pare
Pareto
to Principle is used all over the world to help us focus on the ““VIT
VITAL
AL FEW”

Dr. Jur
Dr. Juran
an has given the Step by Step bre
breakt
akthr
hrough
ough proce
process
ss is the bas
basis
is ffor
or the
the
Quality improvement
improvement processes and quality action
ac tion used through out the world
including the “Six Sigma” approach

Juran’s Quality Trilogy :- Quali

Quality
ty Planni
Planning
ng ,
Quality Control
and Quality Improvement

Awards :- 1.Orde
Orderr of the secr
secret
et trea
treasure
sure - Awar
Awarded
ded by Empe
Emperor
ror of Japan

2.National Medal of Technology –Awarded by President George Bush

 

Dr.Ka
Dr.Kaoru
oru Ishik
Ishikaw
awa
a

1.Birth-1915, Place –Japan

2.He Created a course entitled “ How to use Experimental Data

3.He was
was graduate in Applied Chemistry then He was employed by a company engaged in
Coal liquefaction -
4. He was com
commissi
missioned
oned as a Nov
Noval
al tec
technic
hnical
al offi
officer
cer - On the req
request
uest of JUSE
JUSE

5.He Joined QCRG

6.He has given the most popular tool “Cause and Eff
Effect
ect Diagram,

7.He had popularized the Scatt

Scatter
er Diagram

8.He is Known as Father of QC

9.His nick name was Buldojor

 

KAIZEN
INDIVIDUAL GROUP
STRUCTURED UNSTRUCTURED

FIRST LINE/ GRASS ROOT SR. & Mdl. MANAGEMENT

(QUALITY IMPROVEMENT TEAM
LQIT,)

DEVELOPMENT PROBLEM SOLVING

QUALITY CIRCLES LQC / TPM CIRCLES
 

Birth of Quality Circle

@vaailaTI saik-la ka janma
dUsaro ivaSva yauqd ko samaya Amaoirka nao jaapana ko dao Sahrao naagaasaakI tqaa
hIraoiSamaa pr prmaaNaU bama igarayaa ijasasao jaapana ka Qana jana kI BaarI xait
hu)-- .jaa
hu) .jaapan
pana
a

TapuAao, / jva
TapuAao, jvaalaama
alaamauKI
uKI vaalaa doSa hO jaha^ p
prr kao[- naoca
naocaurla
urla ir
irsaao-s
saao-sa
a nah
nahII
hO.yauQd #a%ma haonao ko baad jaapana nao Apnao xait kao pura krnao ko ilae
bastuAao ko gauNava%ta

mao sauQaar krko pura ikyaa .jaapana mao ]sa samaya dao sasqaayao jausao tqaa ko[
Dona rona jaao jaapana ko caIf ei@yaiTva ko esaaoisayaosana qqaa
aa nao imalakr
Da@Tr Doimaga ko

lao@car kI vyavasqaa ikyaa .[sa lao@car kao saunanao ko ilae @vaailaTI knT/aola
irsa-ca ga/up banaayaa AaOr t%kalaIna maojar janarla maOk Aaqar kao Da@Tr
Doimaga

kao baulaanao kha tba 1950 mao Da@Tr Doimaga jaapana Aae AaOr ]nhaonao
sToTIsaiTkla @vaailaTI knT,aola ko ]pr Apnaa BaaPaNa idyaa . sana 1954 mao
Da@Tr jaurana
 

Beginning of Quality Circle In India

sabasao phlao @vaailaTI saik-la baI eca [- ela hOdrabaad mao 1981 mao Aayaa . jao ko
 jauT imala ko t%kalaIna p/osaIDonT Da@Tr Aar saI Aga/vaala nao jaba

[sako baaro mao

mao saunaa tao ]nhaonao jausao sao baat kI tao jausao nao ]nakao baI eca
[- ela hOdrab
hOdrabaad
aad sao samp-k krnao kao kha tba baI eca [- ela hOdrab
hOdrabaad
aad sao dao

baar kanapur mao Apnao @vaailaTI saik-la TIma ko saaqa Aae . [sako baad jao ko jauT
imala nao @yau saI kao caalaU ikyaa AaOr 1982 @vaailaTI saik-la faorma Aaf

[inDyaa ka gazna huAa

 

Quality Circle concept

Quality circle is a small group in which employees works in first line
work place continually control

and improve
improve the products, services , jobs and
and so on . These small group
operate autonomously

Utilize the quality control tools and techniques and others improvement
tools and promotes self & Mutual development .

QUALITY CIRCLE ACTIVITIES AIM IS TO : Develop members capabilities

and achieve self

Actualization , make the work place more pleasant ,vital and satisfying
improve customers Satisfaction
Satisfaction and contribute to society
 

Quality Circle Concept

Definition
1. Qual
Qualityity Cir
Circle
cle is small gr
group
oup acti
activitie
vitiess
2. It is a team bu buildin
ilding
g philosoph
philosophy y.
3. It is fo
forr self and mutua
mutuall develop
developmentment of mem
member
berss
4. It oper
operateate aut
autonomous
onomously ly i.e. empowerin
empowering g gross rroot
oot
level people to take work related decision
5. It is a knowle
knowledgedge and e experi
xperience
ence sharin
sharingg platform
platform
6. Its pro
promote
mote cr creativ
eativity
ity and remo
remove ve mind blocks
blocks

7. It is a learning platf
platform
orm especially sstatis
tatistical
tical quality con
control
trol
8. It con
contributes
tributes to customer satisfaction
satisfaction and thereb
thereby y
organization
organiz ation and finally society
 

Quality Circle Concept

Definition
9. It is not an
an isol
isolated
ated concept
concept but ccomplem
omplement
entary
ary and
supplementary to other quality
qua lity concept

10.It is an integral part of TPM

11.The above definition clarify too many aspect

a) Deali
Dealing
ng with first
first line
line employees
employees and their ttotal
otal particip
participation
ation
b) Manag
Managerial
erial responsi
responsibility
bility to make
make this concept suc
success
cessful
ful in

the organization by forming QIT simultaneously and taking

organizational
Development related to projects

12. It fully reveals human capabilities by creative as well as logical

thinking and
eventually draw out endless possibilities continually
continually..
 

What Quality Circle Is not?

•Quality of products only

•Suggestion Scheme

•Substitute of quality control department

•Substitutes of task force, works committees, product committee.

•Means for management to unload all their problems

•Forums for Grievance

Grievance are a spring board for demands

•Individual Problems

•Panacea for all ills

•Money Gains

•Organiz
Organization
ation Only
On ly
 

STRUCTURE FOR QUALITY CIRCLE

AND ROLE OF ITS CONSITITUENTS
Structure for Quality Circle

TM
Corporate Coordinator
St.Comtt.

Facilitator &
Dy.Facilitator
Unit Level Coordinator
Leader /Dy. Leader

Members

Potential Members
 

ROLE OF TOP MANAGEMENT

Top management is a monitoring group Headed by the head of the organization.
To review and improve the functioning of Quality Circles through periodic and
regular meeting .

STEERING COMMITTEE ; It comprises of all departmental heads by headed by

Chief executive of organization.

Responsibilities of steering committee

committee;;

1. Es
Esta
tabli
blishi
shingng the
the obj
object
ectiv
ive
e of Qua
Qualit
lity
y Cir
Circle
cle
2. Fina
Financ
ncia
iall rres
esou
ourrce

3.
4. Re
Requir
To quired
see edth guida
guidance
that
at QC nce and
activitiesdir
activitiesdirecti
ection
bec on tto
becomes
omes oa w
move
may
ovemen
way ment
of lifetin o
life org
rganiz
anizatio
ation
n
5. S.C member
memberss should attend the man management
agement present
presentation
ation organized
organized periodically
periodically
6. They shou
should ld at
atten
tendd the annu
annualal soc
social
ial ge
gett tog
togethe
etherr of Q
QC
C
7. Th
Theey sse
erve
rve as QIT
8. Ape
Apexx lleve
evell SC meet
meeting
ing will
will b
be
ehheld
eld bi-m
bi-month
onthly ly
9. CEO as Ch
Chairm
airmanan of SC shou
should
ld con
conduct
duct the meetin
meeting
g and committ
committee
ee memb
member
erss should
participate to review of QC activities
 

ROLE OF MANAGEMENT TO SUSTAIN

SUSTAIN QC ACTIVITY

1.Listening (Caring)
(Caring)
It is to understand peoples problems in work and removing the hurdles and irritants

2. Teaching
While teaching his people ,it is not only transmitting knowledge and values, but also
reinforcing

3.Facilitating
Mere teaching and leaving
leaving people to fend for themselv
themselves
es will not help to bring result
Management people should be enablers.
 

COORDINATOR
As the name implies ,coordinator carries out coordination work , He is link with
Top management, Steering committee , Facilitators/ Dy. Facilitators , Leader/ Dy.leaders
Circle members and potential members.
ROLE OF COORDINA
COOR DINATOR
TOR
1.Liais with facilitators for ensuring regularity of circle meeting and presentation

2.Convene Steering Committee meeting periodically

3.Handle request for starting new circle

4.Organize training sessions for facilitators, leaders and members of QC

5.Arrange facilities for QC meetings

6.Organize management presentations and case stud presentation of QCs out side the
company and also to the Steering committee.

7.Monitor meeting of QCs regularity and suggests corrective action needed

8.Develop faculty for QC programmes

9.Organize annual conventions within the company and act as conscience keeper as far
as QCs are concerned.
 

Facilitator
Facilitator is a nominated executive of an area and he/she ought to catalyze and
stimulate the QC.

He should ensure Role of Facilitator

1. Regu
Regula
lari
rity
ty of
of the
the meet
meetin
ing
g
2. Regul
Regulari
arity
ty o
off membe
members
rs att
attend
endance
ance
3. Effect
ffectiv
ivene
eness
ss of meeti
meeting
ng conduct
conducted
ed

He should assist in
1. Clarifying and defining the problem, goal setting & planning
2. Proper choice and application of problem solving tools and techniques
3. Preparation for management presentation
4. He should give proper feedback to circle for improvement

Quality of Facilita
Facilitator
tor
1. Cari
Caring
ng lik
like par
paren
entt
2. Good
Good comm
commun unic
ica
ator
tor
3. Crea
Creativ
tive
e , Posit
Positiv
ive
e and commi
committ
tted
ed
4. Cons
Consis
iste
tent
nt & Acc
Accepepta
tabl
ble
e
5. Enthus
thusia
iassti
ticc
6. Preservi
rving
 7. Integri
grity
 

Leader
Leader is a person chosen by the members of the circle on consensus

Leader role
effective is most
role, important
he should function
be given in a Quality
the requisites Circle . For
education andatraining
leader to
to play
lead an
and to
develop leadership qualities and skills.
Aside from Facilitator , the success of the quality circle will depend upon how well the
leader leads the group

Quality of Leader
A QC leader should have broad knowledge and skills
1. Tec
echn
hnic
ical
al know
knowleledg
dgee
2. Qu
Qual
alit
ity
y Con
Contr
trol
ol tec
techn
hniq
ique
uess
3. Im
Impr
prov
ovememen
entt tec
techn
hniq
ique
uess
4. Hu
Huma
man n re
rela
lati
tion
on ttec
echn
hniq
ique
uess
5. So
Soci
cial
al rel
relat
atio
ionn te
tech
chni
niqu
ques
es
6. Le
Leade
aderr sho
should
uld be
be a highly
highly didisci
scipli
plined
ned p
per
erson
son
7. Re
Ready
ady to tak
takee res
respons
ponsibili
ibilities
ties & de
delega
legates
tes rrespo
esponsib
nsibility
ility
8. Co
Coor
ordin
dinat
ates
es a
and
nd lea
lead
d by
by e exa
xampl
mples
es
9. Tole
olera
rant
nt and enenthu
thusia
siasti
sticc
10. He sho
should
uld be accommod
accommodative ative
11. Friendly and a symbsymbolol of cognitive ffocus
ocus for gr
group
oup unity
 

Role of Leader
1. Leader
Leader sshou
hould
ld co
condu
nduct
ct m
mee
eetin
ting
g regula
regularly
rly

2. He is expect
expected
ed to be task
task orient
oriented
ed and the same
same time
time play
play a socio- emotional
emotional p
part
art

3. Lea
Leader
der shou
should
ld lead
lead his team
team tow
towar
ards
ds goals
goals

4. Main
Maintain
tain reco
records
rds of circle
circle activit
activities
ies in a regist
register
er

5. Works to plan and assign roles

6. Prepares for management presentation and involved everyone

7. He is quite knowledgeable
knowledgeable and clarifies
clarifies doubts of group
group members
members

8. He does not take credit for

for him self
self but gives
gives credit to
to his members
members when the
group wins
 

CONDUCTING EFFECTIVE MEETING

1)Before the meeting;
a) Plan who should attend ?

Apart from QC leader, Members and facilitator , potential members or senior

colleague or an expert to invited.
b) What is the purpose of discussion ?
Define the objective and purpose of discussion
Where and when the meeting is going to be
2) During the meeting
a) Start on time and end on time
b) Stick to agenda
c) Reach consensus on agenda
d) Ensure participation of all and encourage it
e) Assign role
f) Encourage listening and thinking
3)At the end of meeting
• Summaries discussion and end with the positive note
• Draw out an action plan
• Assign responsibilities
responsibilities to achieve goal / plan
4) After the meeting
a) QCs can record
record “ Minutes and action plan’ in a regist
register
er and communicate
communicate
b) Evaluate meeting result
 

The characteristi
characteristics
cs of effective team work are
1. Clear
Clear object
objectiv
ive
e and
and agreed
agreed goal
goal

2. Openn
Opennes
esss and conf
confrronta
ontati
tion
on

3. Supp
Suppor
ortt and
and trus
trustt

4. Coop
Cooper
erat
atio
ion
n and
and ccon
onfl
flic
ictt

5. Sound
Sound pro
proced
cedur
ure
e iin
n decis
decision
ion making
making

6. Leadership

7. Lear
Learni
ning
ng fr
from exp
exper
erie
ienc
nce
e

8. Deve
Develo
lopm
pmen
entt of QC
QC memb
member
erss

9. Inte
Intera
racti
ctive
ve behav
behavior
ior in a group
group

10.Feed back to QC group

 

Types of participants that can wreck the meeting

1. Bull do
dog -----------------
----------------- Fights everything

2. Ho
Hors
rse
e ---
-----
----
----
----
----
-----
-----
----------Accept everything
------

3. Mon
Monk
key ---
------
------
------
------
------
-------
-------
--- Knows everything

4. Fr
Frog
og -----
--------
------
-------
-------
------------Talks and talks
-------

5. Doe ---
------
------
-------
--------
--------
-------
------
---Shy and rarely open the mouth

6. Por
Porcupin
cupine
e -----
----------
------------------Always put-up resistance
-------------

7. Hip
Hippop
popota
otamus
mus---
------
------
------
------
------
---No reaction-
reaction- join with
with majorit
majority
y

8. Gir
Giraff
affe
e ------
-----------
------------
---------------Superman – knows all
--------
9. Fo
Foxx ---
------
------
------
-------
-------
-------
-------
-----Ask wild questions
 

MONTHLY QUALITY CIRCLE ACTIVITY REPORT

Period from _______________ to _________________

Name of the Circle ___________ Area/Dept. ______
Number of meetings to be held ________ Actual ______
% Attendance
Attendance of members ___Number of A=__ D=__
No. of Meeting attended by
Facilitator:
Facilitator: ___________ Dy.Facilit
Dy.Facilitator:
ator: ____________
No. of Meeting minutes signed by
HOD: ______
______Facilitator:
Facilitator: ______
________ Dy
Dy.Facilitator:
.Facilitator: ______
Project taken: ___________________________________
Status of project: Selection of problem/Defining the problem /Problem Analysis/ Finding out
causes /Root cause analysis /Data analysis / development
development of solution /Trial implement
implementation
ation and check
performance / Project ready for approval
Remarks:
 Faciltator/Dy.Facilitator HOD
 

PROBLEM SOL
SOLVING
VING TECHNIQUES
• 1 MILE STONE/GANTT CHART

• 2 BRAIN STORMING

• 3 FLOW DIAGRAM

• 4 PRIORTY NUMBER

• 5 P-D-C-A
 

ELEMENTARY PROBLEM SOLVING TOOLS

• 1 CHECKSHEET(DATA COLLECTION)

• 2 STRATIFICATION

• 3 PARETO DIAGRAM

• 4 CAUSE AND EFFECT DIAGRAM

• 5 SCATTER DIAGRAM

• 6 HISTOGRAM
 • 7 GRAPH AND CONTROL CHART
 

INTERMEDIATE PROBLEM SOLVING TOOLS

• 1 THEORY OF SAMPLE SURVEY

• 2 STATIS
TISTICAL SAMPLING INSPECTIO
TION

• 3 VARIO
ARIOUS
US METH
METHOD
ODS
S OF
OF MAK
MAKIN
ING
G ST
STATIST
TISTIC
ICAL
AL ESTI
ESTIMA
MATE
TES
SAAND
ND TEST
TESTS
S

• 4 METHODS OF UTILISING SENSORY TE

TESTS

• 5 METHODS OF
OF DE
DESIGN OF
OF EX
EXPERIMENTS

• These methods are used by Engineers and Quality Control

personnel
 

ADV
ADVANCE
ANCEDD PROBLE
PROBLEMM SOL
SOLVIN
VINGG TOOLS

• 1 ADVANCED MET
ETH
HODS OF DESIGN OF EXPERIME
MEN
NTS

• 2 MULTIVARIATE ANALYSIS

• 3 VARIOU
IOUS M
ME
ETHO
THODS OF OP
OPE
ERA
RATI
TIO
ON R
RE
ESEARC
ARCH

These methods are used by technicians and engineers for

optimization of processes and securing reduction in costs
 

Overview of Tools / Techniques

1. Flo
low
w diaiag
gram :- To enable underst
understanding
anding of the process/
process/ flow an
andd locate problem
2. Br
Brai
ains
nsttor
ormi
ming
ng :- For gener
generation
ation of ideas in pr
problem
oblem listin
listing
g and listing of causes in
problem analysis and for finding the solutions.
s olutions.
3. Data collection :- To underst
understand
and the magnitude of the problem
problem and understand
understand the
problem. It is the foundation for statistical analysis.
4. Graphs :- Presentation
Presentation of large amount of data in a cohecohesive
sive manner
manner in the
pictorial form to enable better understanding of data and the problem

and also to comprehend the trend at a glance.

5.Stratification:- To segregate dat
data
a according to contributing
contributing sources ( Suppliers,
Machines and operators etc.)
6.Cause & effect :-To map out all probable causes and relate the logical linking of
diagram causes to the problem to help narrow down to cause or causes

7.Pareto Chart - or
Forcontrol
identification/sel
identific
toation/selection
ection
differentiate of majorvital
between problem or area
and useful for problems.
many impro
improvement
vement
8.Scatter Diagram :-For examining
examining relationship between two variables , nature and
strength of relationship between process factors and product quality
in a way , it is also a cause &Effect approach between two variables.
9.Histogram :- For study of proc
process
ess variation and assess process
process capability.
capability. The is
an off line quality control method.
10.Control Charts :-For maintaining running control on a process. It is a tool for ON-Line
 quality control.
 

PDCA cycle or Deming

Deming’’s Wheel
Before learning about problem solving technique we should first
Before f irst concentrate
concentrate upon
how to prevent problem.
samasyaa samaaQaana tknaIkao kao isaKnao sao phlao hmao sabasao phlao
samasyaayaao kao kOsao raoko Qyaana donaa caaihe
Problem can be control
control or minimiz
minimizeded by effective
effective use of P-D- C-A cycle
samasyaao kao pI DI saI e saa[-ikla ko p/BaavaI ]pyaao
]pyaaoga
ga krko inayan~It Aqavaa
Aqavaa
GaTayaa jaa sakta hO

ACT PLAN
kaya-vaahI yaaojanaa

Check Do
 jaaca kaya-
 

PDCA cycle or Deming

Deming’’s Wheel
Dr. K. Ishikawa made these four steps into six steps
When these six steps have been follow
followed
ed , a seventh step is needed to
ensure whether the corrective action has been worked out or not .

Decide on
the objective
ACT And PLAN
targets Decide
Take action Methods of 
Achieving the
objective

Carryout education
and training
Check the
Check result
Do the
work DO
 

FLOW DIAGRAM
Flow Diagram
Diagram is a graphical or a pictorial
pictorial way
way to depict
depict a process.
process. With the help of a
flow diagram we can show process
process sequence . It can be used to dissect a process
process for
Better underst
Better understanding
anding and analyzing. It can also be used for replanning or making a
Change. The process may manufacturing process of a product , a service provided, to
Convey
Conve y some information or a combination of any of them.

TYPES OF FLOW DIAGRAM

There are three types of Flow diagram.
1. High
High Le
Leve
vell Fl
Flow
ow Diag
Diagra
ram
m
2. Matr
Matrix
ix Flow
Flow Diag
Diagrram
3. Deta
Detail
iled
ed Fl
Flow
ow Diag
Diagrram

When to draw Flow Diagram ?

1.For defining the process
process flow
2.For defining the problem
3.For identifying the root causes
4.For devising the solution.
5.For implementing
implementing the solution.
 6.Att the time
6.A time of review/
review/ follow
follow up
 

Useful Symbols for Detailed Flow Diagram

 

How to ensure accuracy ?

1.Ensure that it is about actual process and not what is intended.
2.Ensure rework
rework loops are not omitted
3.Be honest about what you do
4.Observe actual process before drawing a flow diagram
5.Elicit support of other members for accuracy and completeness and allow them to
review it.

HIGH LEVEL Material

User sends
FLOW DIAGRAM
User obtained
Indent inspected

Quotation Material
received
obtained

Material Material
ordered made
 

MA
MATRIX
TRIX FLOW DIAGRAM
DIAGRAM

USER PURCHASE MANUFACTURER STORES

User sends Quotation

Indent obtained

Material Material Material

ordered made received

Material
inspected

User
obtained
 

DETAILED FLOW DIGRAM

Raise Indent Mtrl. Made
Start
Indent received Mtrl. Received
Mtrl needed

N Inspection
Mtrl Is it OK ? Return for
database correction Return to
Supplier
Y Is it OK?
N

N Send Enqrs

Y
Y N
Qtn. OK ? Take as Stock
Send reqsn

Y
Mtrl. Obtained
Place order Put in
database
End
 

MATRIX
MATRIX FLOW DIAGRAM
DIAGRAM

Registration Kit bag collection Events Prize distribution

tt
ttT
Take registra
registration
tion tt
ttDis
Distri
tribut
bute
e the tt
ttOther
Other ttT
ttTake
ake your
your seat
seat as
form coupon competitions per seat no.

ttTake registra
ttT registration
tion ttWaitt for y
ttWai your
our team
team
tt
ttT
Take
ake Ki
Kitt bags
bags ttKnowledge
ttKnowledge test
form no.

Tt
TtColl
Collect
ect the tt
ttCas
Case
e study
study
ttT
ttTak
ake
e Gift
Giftss ttT
ttTake
ake prize
prize cou
coupon
pon
coupon presentation

ttCas
ttCase
e study
study tt
ttGroup
Group photograph
photograph
presentation

ttCollec
ttCollectt your prize
prize
 

DETAILED FLOW DIAGRAM

Start
S

Reach to Venueto

Is Y
Knowledge Participate in knowledge
test ? Test at right time

N
Stop
Reach to right Hall for
Case Study Presentation

Participate in other
Present the Case Study competitions

Do you want
knowledge N
 test ? Y
 

Milestone Chart-Quality Circle Activity Planning

Quality Circle Name Department Facilitator    Members’ Name
Project Reason for selection

Project No. Dt.of s

sttart Dt.of c
co
ompletion

S.N  Activity/ Week 1 2 3 4 5 6 7 8 9 10

Target Actual

1 Defining the problem

2  Analyzing the problem

3 Identifying the causes

4 Finding Out root causes

5 Data Analysis

6 Developing solution

7 Foreseeing possible resistance

8 Trial Imp. & check performance

9 Regular Implementation

10 Follow up/Review
 

Brainstorming
Definition:
Brainstorming is a group technique
technique for gen
generating
erating ne
new
w and useful ideas. It uses a few simple rules
for discussion on a subject matter that contributes to Originality and innovation
innovation..

Types of  Brainstorming: There are three types of brainstorming

a) Fr
Free
ee whe
wheeli
eling
ng or
or Unstr
Unstruct
uctur
ured
ed :No hold , no bar system. No limit on number of ideas at a time.
It is spontaneous and stimulates the creativity of the individual.

b) Slip Me
Method
od::When you need the involvemen
involvementt of a large groups such metho
methodd is used .
c) Ro
Round
und Ro
Robin
bin or Stru
Structu
cture
red
d Meth
Method:
od:It is a systematic BBrainstormin
rainstorming
g method it follows some
rules in a structured manner, which are given below.
1.Keep the participants ,preferably between six to ten.
2.Give required time for incubation.
3.Make it very clear to all the participants on what subject the brainstorming is done.
4.Enter the points on a black board ,Flip chart or in a transparency for all to see .
5.Expain the guidelines. 6.One idea only at a time . 7.Contribu
7.Contribution
tion in turn.
8.You may say pass if no idea is generated .
9.Clarify the poin
pointt but d
don’t
on’t e
explain
xplain the ideas. 10. No criticism
11.If session looses grip, have a break or change.
12.To bring creativity use five Ws and one H appropriately.
13.Get maximum nos. of ideas.
14. Guests are welcome but will abide by rules.
 15.Clarify each contribution.
16.Agree on a evaluation criteria.
 

Brainstorming
Key Elements concerning
concerning Human Creative Ability :
There are five Key
Key elements concerning human creative ability and these are research findings of

Mr. J.P. Gilford.

1.Fluency: Capability of mind producing maximum ideas with in a given
g iven time It measured by quantity
quantity..
Regular Brainstorming
Brainstorming makes creative side of the brain more active.

2.Flexbility : Ability of mind to move from one aspect to another quickly.

quickly. When we listen to others ,it
opens up new avenues for our thinking .W .We
e call this Hitch – Hiking process. Thinking power of an
individual either lies in his memory ,perception about a situation , creativity or imagination. Flexibility is
measured by the number of categories of ideas generated.

3.Originality: Ability of mind one can think of innovative or new ideas. This is ability to identify
uncommon ones .Originality does not come in large numbers. But even one original idea can lead to a
lot of benefits. Thinking without any barrier and away from conventional method lead to originality.

4.Awareness : Ability of mind to look ahead into future i.e. beyond the immediate facts.

5.Drive : Willingness to participate and contribute without any hesitation and to achieve the end goal
without the fear of failure. Getting into the habit of brainstormin
brainstormingg helps people to shed their fear
,inhabitations and mak
make e them to participate willingly .Such willingness and drive in people mak
make e them
 to try unconventional way . Dr. Juran calls it as “ Cutting new windows”
 

Brainstorming
Some difficulties and pit falls connected with Brainstorming
Brainstorming
First and foremost we should remember that brainstorming is not a replacement to data.
In a brainstorming some people may very close to the problem and some may not .Some
Times when an idea comes from an outsiders ,the insiders of the group may not give
importance to it. Some people are difficult to deal within a group , they get off the track
Which disrupts the group works.

Use of Brainsto
Brainstorming
rming :
Brainstorming can be used at various stages of problem solving. It can be used for .
1.Identification of problems
2.Finding out possible causes to a problem.
3.Generating
3.Gener ating ideas for arriving at a solution
4.Predicting the possible resistance to the solution.

5.Finding out the process to overcome the resistance .

Four conceptual rules are
are::
1. No criticism or evaluation
2.T
2.Try not to be conventional
3.Aim for quantity

4.Hitch- Hike on other’s ideas

approach:1
Four practical rules for structural approach :1.Contr
.Contribut
ibute
e in turn
 2.One Idea per turn 3.You may pass if no idea could be given in one round 4.Do not explain Ideas
 

Data
Data Collection
Def : Data collection is nothing but collection of the required information in the form of
Figures for statistical analysis of a problem. This provides a sound basis for decision
Making and corrective action.
Purpose of Data Collection :Data are collected for a variety of purposes .In industry
,the following are more common.
Quality Evaluation Raw Materials, intermediate products and finished products.
Process Control : To assure that products turned out meet the specified requirements of
customers/ design
Improvement Trials: To improve product quality , to reduce costs and to increase
Productivity.
Problem Solving : For information throughout the problem solving process by Quality Circles

Compare Performance
and competitiveness etc.
:From time to time measure improvement in production ,profit. quality

TYPES of DATA : Generally data are of two types

a) Measurement data or Variable data :Weight , diameter, tensile strength, % carbon ,

reaction time process.

or measuring , pressure , temperature
These etc.. Basic observation
data are continuous obtained
, they are also by using anvariables
called continuous instrument
 

Data collection
b) Attribute Data or Countable Data : Data obtained
obtained by classification
classification into two or
more categories .For example nos. of rejected , nos. of passed ,data obtained by count of
defects, count of occurrences etc. These data are in whole numbers and also called
discontinuous or discrete variables .

USEFUL POINTS FOR DATA COLLECTION

information as Dr. J.M. Juran says “begins and ends
Collection of information or generation of information
with questions. Useful points for data collection are
1.Be clear in mind about the objective.
2.Prepare the questions ( use four’ Ws’ and one ‘ H’ which will make it clear and precise.
3.Use data sheet , check sheet, and/ or check list as per the requirement.
4.Reduce opportunities for error
5.Capture data for analysis , reference and traceability.
6.Form / data sheet should be self explanatory .
7.Analyze the collected data for its credibility and relevance (for whom, when or who ,What
collected the data are important)
8.Present data in a way that clearly answers the questions.
 9. Collected data relevant to purpose.

Check Sheet
An easy and effective way of collecting data is by using well design formats is known as check
sheet. A check sheet is a simple data recording form specially designed so that data can be
interpreted readily from the sheet itself.
TYPES OF CHECK SHEETS:
a) Pr
Proce
ocess
ss cont
controroll inf
inform
ormati
ation
on check
checks.
s.
b) Pr
Produ
oductct qu
quali
ality
ty assur
assuranc
ancee check
checks.
s.
c) De
Deffec
ecti
tive
ve it
item
emss ccheheck
cks.
s.
d) De
Deffect
ectiv
ive
e loc
locati
ation
on che
check
ckss

e) De
Deffec
ecti
tive
ve ccau
ause
se che
check
cks.
s.
f) Pr
Proce
ocess
ss varia
variatio
tion
nddis
istri
tribut
bution
ion ch
check
eckss
g) Others.
a) Process control information checks : This format enables us to record
process control checks
SOLDER BATH TEMPERATURE
Checked By---Mr.
By---Mr. Das Date:-15.07.15
Solder Bath -A
Tim
ime
e Temp.
emp. ( Deg. C)   Tim
Time
e Temp.
emp. ( Deg. C)
0800 60 1300 61
0900 62 1400 58
1000 59 1500 60
1100 58 1600 63
 1200 59 1700 62
 

b) Product quality assurance checks : This check sheet is useful in the final test of
the product
product at the end of manufacturing
manufacturing line.
line.

S PARAMETER
N
Spec
 Actual
1
Obs
Observation
2
ervation
3 4 5

1 Axial Clearance 0.1 to 0.45 0.3 0 .1 8 0.22 0 .1 7 0.21

2 Cleanliness of Clean OK OK Not OK OK OK

Crank shaft
3 Surface Finish 320 320 320 325 315 300

24 Paint F
Fiinish Glossy OK OK OK OK OK
 

c) Defective items checks. To reduce the numbers of defectives ,it is first necessary to
know the type of defects and their magnitude .Since each defect may have different causes ,it is
of no use to just list the total no. of defects.

S.N. DEFECT TALLY MARK TOTAL

1 BAR METAL IIII IIII IIII IIII IIII IIII IIII IIII IIII IIII IIII 54
2 OVERFLOW IIII IIII IIII IIII IIII IIII IIII IIII IIII III 48
3 DUST IIII IIII IIII IIII IIII IIII IIII IIII IIII IIII IIII 100
IIII IIII IIII IIII IIII IIII IIII IIII IIII

4 LESS GLOSSY IIII IIII IIII IIII IIII IIII IIII IIII IIII 40
5 PAINT PEEL IIII IIII IIII IIII IIII IIII IIII 34
:
:
:
12 OTHERS IIII IIII 9
 

d) Def
Defectiv
ective
e location
location checks
checks: This kind of check sheet is meant to be placed in the
drawing or sketch of the product so that location of defects can be identified and investigated.
Such type of check sheets are helpful in controlling defects in casting, glassware plastic
components etc.
 

e) Defective cause checks: This type of check sheet is used to generate information on
causes and their correspondence to the observed defects.
Data may have to be later analyzed by stratification or scatter diagram to get the clues. This is a
rough analysis for cause and effect relationship
M/C Oper  Monday Tuesday Wednesday Th
Thursday Friday Saturday
ator 

00 0xx x# # xxx 000 +++ 00x xx0 xxx 00x 00x 00x xxx 00x 00x # 00x
 A 1 xx
+
+0 #00
0
000
#
### +
##
xx 0##
#
000
#
xx#
#
xx xx# 000
#
xx x+ #00
0
xx

++

# ## # 00x +++ 00x 00x xxx 00x # 00x 00x xxx +++ 00x # 00x xxx

2 #0
00
00 #0
00
xx# +
##
xx
#
xx#
#
000
#
xx#
#
#00
0
xx
#
xx#
#
000
#
+
##
xx
#
#00
0
x+ 000
#

00 ++ xxx 00x 00x 00x 00x 00x 00x 00x 00x 00x 00x 00x 00x 00x 00x 00x
3 xxx
#
xx0 00
0#
x+ xx xx# x+ xx#
#
x+ xx xx# x+ xx#
#
xx x+ xx# x+ xx#
#

00 x0 00 00x 00x 00x 00x # 00x 00x +++ 00x 00x 00x 00x +++ 00x 00x

B 1 xxx
#
+x
#
xx
+
xx
#
x+ xx xx
#
#00
0
xx#
#
xx
#
+
##
xx#
#
x+ xx xx
#
+
##
xx# xx

00 00 # 00x +++ 00x xxx 00x 00x 00x 00x 00x 00x 00x 00x 00x #
2 xxx xx
+
#0
00
xx# +
##
xx#
#
000
#
xx# x+ x+ xx#
#
xx x+ xx# xx x+ #00
0

00 00 ++ 00x 00x 00x # 00x +++ 00x xxx 00x # +++ 00x xxx 00x +++

3 xx
+
xxx
##
++
##
xx
#
x+ xx #00
0
xx
#
+
##
xx 000
#
xxx #00
0
+
##
xx
#
000
#
xx +
##
 
X-surface scratch,
scratch, 0-blow hole,+- oor ffiinish,# distorted,
0-blow

. CHECK SHEET
f) Process variation distribution checks: Measurements taken on a product or
rejects of inspection at incoming material stage or in process can
can straightaway be recorded in a

check sheet to reveal the variation in quality.

productivity.
Component- Nozzle, Operation  –dril
drilli
ling
ng , Para
Parame
mete
ter-
r- Sack
Sack hole
hole th
thji
jick
ckne
ness
ss Spec
Specs-
s- 0.8
0.8 +_ 0.05
LSL USL
13

12
11   X
10   X
9   X
8   X x

7   X X
6   X X
5   X X X X
4   x X X X X
3   X X X X X X

2   X X X X X X X
1   X X X X X X X X
 .75 .7 .77 .78 .79 .80 .81 .82 .83 .84 .85 .86 .87 .88 .89 .90 .91 .92 .93
6
 

CHECK SHEET

Such check sheets are handy in discovering patterns

patterns of different
different vendors
supplying the same part. Inferences can be drawn by just looking at the
information
informa tion filled check sheets.
This type of check
ch eck sheet can be exexamined
amined for the following information.
information.
1. Does the pattern resemble a symmetric
symmetric shape like single peak or are there
two or more peaks ?
2.Are the values skewed
skewed to one side and are there isolated values ?
3.
3.What
What is the conformance to specifications limits ?
4. Is the center of the distribution
distribution close to the target
target value given in specification
specification ?
5. Is the width of the distribution greater than the specification band ?
BENEFITS of DAT
DATA collection
co llection : 1. Right decision can be made
2.Errors due to subjective feeling or personal bias are avoided.
3.Agreementt on decisions necessary rather than differ
3.Agreemen different
ent or subjective opinion.
4.Measurement
4.Measurem ent understandable to all.
5.Assessments of magnitude of improv
improvements.
ements.
6.Discovery
6.Discove ry of causes affecting quality and
 

Check list type Check sheet : Frequent checks must be made to

keep the equipment’s efficiently and trouble free . It helps to carry out work with
certainty ,it will also reveal the forgotten test items.

Mill no. Location Shop manager/ supervisor

Component Check points Sun Mon Tue Wed Thu Fri Sat

Drive Noise Ok ok ok not ok ok ok ok

Gear Box Vibration Ok ok ok ok ok ok ok

Bearing Temperature Ok ok ok ok not ok ok ok

Transmitter Operation Ok not ok ok ok not ok ok ok

 

Useful points for data collection

• Be clear in mind about the objectives

•Prepare the questions which will make it clear

c lear and precise

•Collect data relevant to problem

•Use data sheet ,check sheet

sheet and check list as per the requirement
requirement

•Keep them simple and easy

•Datasheet/ check sheet should be self explanatory

•Analyze the collected data for its credibility and relevance

relevance ( for whom, when, who

collected the data are important .

 •Present data in a way that clearly answers the questions
 

GRAPH
What is Graph ?
Graph is a pictorial representation
representation of data which, when presented, is easily underst
understandable.
andable. It help
to represent large amount of information comprehensively and in a compact manner.

When ar
are
e Graphs
Graphs to be used ?
Graphs are generally used

a) For explanation to others : We can explain the phenomena in the work shop and make people
understand better .It can be used to explain defect ratio, productivity, increase in turnover etc.

b) For Recording data: Data are sequential

sequentially
ly recorded in graphs.

c) For understanding : Past and present situation/ position.

d) For process control : Plotting the data in the order of day or time will often reveal trends or
abnormality, when corrective action has to be taken . Even for production planning and control,
graphs are handy.

e) For Data Analysis : Graphs show what figures mean and clarify the facts that may be over
 looked otherwise , if the data are seen as just figure.
 

How many types of graphs ?

There are eleven types of graphs, they can be divided into two main
groups,
1. Co
Comm
mmon only
ly u
use
sed
d Gr
Grap
aphs
hs
2. Spe
Specia
ciall purpos
purposee Gr
Graph
aphss
Commonly used Graphs are ;
a) Line Graph
b) Bar Chart / Graph
c) Pie Chart or Circle Graph
d) Pictorial Graph
Special purpose Graphs
a) Be
Bellt G
Grraph
aph
b) Ra
Rada
darr Gr
Graph
aph
c) Co
Comp
mpouound
nd G
Grrap
aphs
hs
d) St
Stra
rata
ta Gr
Grap
aph
h
e) Fl
Floa
oatt Gr
Graph
aph
 f) Zee Graph
g) Py
Pyrramid
amid G
Grrap
aph
h
 

Line Graph
How are line graph made ?

In these graphs , the abscissa ( X axis) shows Time and the ordinate (Y axis)

shows quantity.

Such graphs are commonly used for watching production , sales, inven
inventory
tory ,

absenteeism
absenteeism , rejection and rework.

Where to use Line graph ?

1. To display comparison of two different series.

2. Used when data defines more meaningful patterns.

 

Line Graph

Off Spec Material Trend

35

31
30
29
28
26
25
 M 22 23
 T 20 20

15 15
14
13
12
10 10

0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Off Spec Linear (Off Spec)
 

Line Graph

CB Off spec Trend from 01 Mar, to 08 Mar.2012

1.5
1.4
1.3
1.2
1.1
1
nMi 0.9
yt 0.8
it 0.7
n 0.6
a
u 0.5
Q 0.4
0.3
0.2
0.1
0

1 2 3 4 5 6 7 8

Month

This is used for observing off spec quantity changing ove

overr time or trend
trend
 

BAR Graph
Bar graph is used for comparison . It can be vertical . Or it can be horizontal
horizontal

CB Sales
Sales from
fr om 01Sept.
01Sept. to
t o 10 SSee pt 2012
in MT
110
11 0
120
105 90   90   10
1000
   y
   t
80 80
   t 90
   i 70
   n
   a 75
   u 60
   Q 50
60
45 40
30
15
0
 1 2 3 4 5 6 7 8 9 10
DATE

4rth qtr  South

3rd qtr  North

West
2nd qtr 
East

1st qtr 
 0 20 40 60

Pie Graph or Circle Graph

This is used for showing relative proportion of various components..To convey approximate
relative values

When to use a Pie Graph ?

Use a Pie graph to convey approximate relative value.
Use an exploded Pie to emphasize a small portion of the parts.
Steps for construction.
Draw a circle of any diameter
Collect the data , calculate the ratio of each component or item in the data to the total , multiply
this ratio by 360 deg. Draw
Draw a line from any
any point on the circumfer
circumference
ence to the centre of the
circle.
Draw each segment in clockwise order. Usually segments are placed in descending order and

miscellaneous is shownofatU.P.
For Ex. Let population the
U.P . isend.
21 Corers for all caste.
Caste Ratio
OBC = 10/21 = 10/21x360=171.4 deg.
Muslim= 4/21 = 4/21x360=68.6 deg.
Upper Caste= 3/21 = 3/21x360 = 51.4 deg.
SC =2/21 =2/21x360 = 34.32 deg.
 Sikh=1/21 = 1/21x360 = 17.14
Others=1/21 =1/21x360 = 17.14 deg.
 

PIE Graph or CIRCLE Graph

Relative population
pop ulation of various Caste in U.P.
U.P.

  5%
5%
OBC

9% Muslim

48% Upper caste

14% S.Caste

Sikh
19% Others
 

BELT GRAPH
It is like Pie Graph but using bars and is suitable for showing comparative levels.

It can bebars
Vertical madeor on
canpercentage
be made asbasis as wellbars.
horizontal as on quantitative basis. It can be made as
How to make it ?
Collect the data and make the graph like Bar graph , procedure is something similar to
making a bar graph . Only difference
difference is each bar rrepresents
epresents multiple information.

Production
Production Grade
Grade w ise and month w ise Prodn. of CB Gr.W
Gr.Wise
ise & Month w ise

2500 100%
90%
2000 80%
May
  n 70%   May
    y    1500
     t
     i
     t  A
 Apr 
pr     i
  o
   t 60%  Apr 
  c
    n Mar    u
    a     d 50% Mar 
    u  1000   o
  r
     Q  Feb   p
  40% Feb
Feb
   % 30%
Jan Jan
500 20%
10%

0 0%
N220 N330 N339 N550 N660 N650 N220 N330 N339 N550 N660 N650
 N220 N330 N339 N550 N660 N650
Grade Grade

RADAR GRAPH
Radar graph is used mostly in comparison of after and before
before status . It
is gaining
gaining popularity in quality Circles . For ex. The organiz
organization
ation wan
wantt to
improve the knowledge of QC circle on eight problem solving
techniques. Organization
Organization tested the knowledge of their people before
before
training against
against eight problem solving techniques and then imparted
training program
program on it and again tested knowledge for same after
training and collect data and Plotted Radar graph.
graph.
Sl.No. Techniques Score (Max. 100)
Before Training After Training
1 Check sheet 48 88
2 Pareto Diagram 50 80
3 Cause& Effect Diagram 42 60
4 Stratification. 54 84
5 Scatter Diagram 36 76
6 Control Chart 42 78
 7 Histogram 48 68
8 Gra h 40 80
Radar Graph
 

Comparison of Eight Problem Solving T

Techniques
echniques knowledge before & after training
Using Radar Graph
88
C.S
90
80
80 70 80
Gr  P.D
P.D
60
50

40
30
20
10
His 68 0 60 C&E D

C.Ch
78 Stra.
84

76
S.D.
 

FLOAT GRAPH
This is an ideal graph for comparison of two distinct aspects.
This helps to find out the total problem in relation to the entire aspect.
It shows the whole process at one glance , and this is a simple graph to
draw . 88%
68% 78%

25% 34%    r

   o 30%
Mature wise Pro Hindu    o
   P
Pro muslim Strong

No No No No Rich
    k
   a
32% 22% 12%    e
   W
75% 66% 70%
 

STRATA/ AREA GRAPH

This is used to show the trend in the total and components of the total

22

20

18
7
16

14

12 Preventive %

10
6 3  Appraisal %

8 2 1 Failure %
3
6 1 3 4 1
2
4
8 2
6 5
2 4 4
3
0
2008 2009 2010 2011 2012 2013
 

ZEE Graph
1250 1220 1240 1208 1198 1240 1224 1138 1248
1200 1215 1199
1150 1235 1208
1232
1100
1050
1030
1000
950
928
900
850
800 824
750
700 716

650
600 616

550
521
500
450
400 417
350
300 315

250
200 210
150
100 100 110 105 102 104 95 100 108 104 102 108 110
50
0
 J F M A M J J A S O N D

Frequency Commu Last 12 month commu

 

Pyramid Graph or Side by Side Graph

Use it to show contrasting trends
trends between level of an independent variable.
Use it for displaying of more than two independent variables and when comparison
Between individual pair of value is very impartment

MALE FEMALE
HP
PUNJAB
ORRISA
RAJASTHAN
TAMIL NADU
WEST BENGAL
U.P.

35000 30000 25000 20000 10000 20000 25000 30000 350000

 

Compound graph
100
76 96.05   98.68 100
10 0
72
68 89.47 90
64
60 80.26 80
56
52 70
48
59.21 60
44
40
50
36
32
40
28 32.89
24 30
20
16 20
12
8 10
4
0 0
 B C A G E H D

Useful points for making graph

1.Be clear on the purpose of making a graph
2.Arrange the information in order
3.Decide on type of graph
4.Decide on title
5.Show the data
6.Substance is more important than method. Good graph are those which draw
attention to data.
7.Avoid distorting the information
8.Make it easier for eyes to compare
Benefits of Graphs
1 Numerical data are expressed
expressed in visual form
2.Helps in comparison
3.Easy to understand
4.No strain of going through large volume of information
5.Creates interest
6.Quick to understand
7.Useful to express data clearly and strikingly
 8.No need to have special skill to make them
9.Helps in accurate analysis of cause
 

STRATIFICATION
Stratification
Stratification is the process of separation of data into categories.

Ex.In a manufacturing
Data collected organization
organization
and stratified them. absenteeism was very high.
60

50

40

30

20
10

J an Fe b M ar Ap r M ay Ju n Ju l Au g Se p t Oct No v De c
 0
absenteeism
 

45
40
35
30
25
20
15
10

5
0
A B C
 Dec Jan

50

40

30

20

10

0
A B C
 M ay Jun

80
70
60

50
40
30

20
10
0
 Colony City

CAUSE AND EFFECT DIAGRAM

Any defect
defect in a component, product or serservice
vice could be one or more
causes to find out the relationship between the cause and effeffect
ect , a
diagram drawn systematically
systematically by Mapping out all the probable
causes influencing the effect . This diagram is called Cause and Effect
diagram.

Types of Cause
Cause & eff
effect
ect diagram

1. Dis
Disper
persio
sion
n anal
analysi
ysiss type
type
2. Production
Production proc
process
ess class
classific
ification
ation type
3. Caus
Cause
e en
enume
umeraratio
tion
nTType
ype

Cause and effect diagram is also known as Ishikawa diagram to

 Dr. K.Ishikawa. By its shape it also called as Fish
honor its originator Dr.
bone diagram
 

CAUSE & EFFECT DIAGRAM

Production process Classification Type

Defeat in
Bating
Selection Balling Fielding Cricket
Match
 

HABIT TRAFFIC WEATHER

LATE
COMING
IN DAY

VEHICLE HOME MANAGEMENT ROAD

 CAUSE ENUMERATION TYPE
 

CAUSE & EFFECT DIAGRAM (Dispersion analysis type)

Man Machine

Problem
 Method Material

FINDING OUT THE ROOT CAUSES

VALIDATION OF CAUSES

SN symbol Causes No. of Findings Result Remarks

observation

1 A 76 16 Valid
2 B 76 25 Valid
3 C 76 20 Valid
4 D 76 1 Valid
5 E 76 5 Valid
6 F 76 0 Not Valid
7 G 76 7 Valid
8 H 76 2 Valid
 9 I 76 0 Not valid

PARETO DIAGRAM
Pareto Diagram is a technique of arranging data according to priority importance and
using it into a problem solving frame work . This helps to find o
out
ut the “VIT
“ VITAL
AL FEW”

from the “USEFUL MANY” for problem selection .

Pareto
Pare to Diagram is compound graph . To To draw the diagram , collect data and arrange it
In descending order. If “others” is there which consist of several small defects but not
more than the specified defects ,then others will be always
always come at the end as this
will be cumulative
cumulative of more
more than one of defect.
defect. Some times
times specific def
defect
ect may be

equal or less than others, even others will be at the end.

Data of 500 defectiv
defective
e Biscuit packe
packets
ts out of 1000 packets inspected on 10.05 2015

Defect Type of defect No. of Defects

symbol

A Loose packets 16
B Cross packets 130
C Crimping 40
D Tapered 107

E Seal open 161

 E Seal open 161
F White line 28
O Others 18
 

Arranging in descending order

Defect
symbol NO. of defect % of Defects Cumulative
%

E 161 32.2 32.2

B 130 26.0 58.2

D 107 21.4 79.6

C 40 8.0 87.6

F 28 5.6 93.22

A 16 3.2 96.44

O 18 3.6 100
 

Pareto Diagram
100
500 100
96.44
93.22
450 90
87.6
Vital Few
400 79.6 80

   t
   c
350 70

    f
   e
   e
300
58.2
Lorenze
Lorenze curve of concentr
concentration
ation 60

   D250
 .
   s
50

   o200
   N
40
32.2
Useful Many
150 30

100 20

50 10

0 0
E B D C F A O
 CAUSES

DAT
DATA OF THE ROOT CAU
CAUSES
SES
SN Symbol Causes No. of observation Findings

1  A Cause-1 76 16
2 B Cause-2 76 25
3 C Cause-3 76 20
4 D Cause-4 76 1
5 E Cause-5 76 5
7 F Cause-6 76 7
8 G Cause-7 76 2

Arranging in descending order

SN Symbol Causes No. of observation Findings

1 B Cause-2 76 25
2 C Cause-3 76 20
3  A Cause-1 76 16
4 F Cause-5 76 7
 5 E Cause 6 76 5
7 G Cause-5 76 2
8 D Cause-4 76 1
 

PARETO CHART

symbol Causes Frequency Cumulative sum % Cumulative %

B Cause-2 25 25 32.89 32.89

C Cause-3 20 45 26.32 59.21
 A Cause-1 16 61 21.05 80.26
F Cause-5 7 68 9.21 89.47
E Cause-6 5 73 6.58 96.05

G Cause-5 2 75 2.63 98.68

D Cause-4 1 76 1.32 100
76 100
 

Pareto
Pareto Diagram
Diagram
100
76 96.05   98.68 10 0
100
72
68 Vital Few 89.47 90
64
60 80.26 80
56
70
52
48 Lorenze
Lorenze curve of concentr
concentration
ation
44 59.21 60
40 50
   y
   c
36
   n32 Useful Many
   e 40
   u28
   q
   e
   r24 32.89 30
   F20
16 20
12
8 10
4
 0 0
B C A G E H D
Causes
 

SCATTER DIAGRAM

Definition :-
Scatter diagram is a graphical representation of relationship
between two variables .

It can be between Cause and Effect

Effect and between two causes .

It also reveals the nature of relationship between two

variables and their approximate strength.
 

80

60
70
60
50
40
30
20
10

10 20 30 40 50 60 70 80

It is normally used to examine relationship

before
 proceeding for further analysis.
analysis.
 

   L
   E
   V
   E
   L
   T
   C
   E
   F
   E
   D

LEVEL OF OIL

He plotted them in a graph i.e. in 'Y' axis the

defect level and in 'X' axis the level of oil used.
 This showed that there was no correlation
between the two variables.
 

   0
   9
   0
   G    8
   N    0
   I    7
   P    0
   P    6
   A
   L    0
   R    5
   E    0
   T    4
   F
   A    0
   E    3
   L    0
   G    2
   N    0
   A    1
10 20 30 40 50 60 70 80 90

 ANGLE BEFORE
BEFORE LAPPING
LAPPING

If the picture is slightly spread like this then we

 say that there is a possibility of positive
correlation.
 

   0
   9

   G    0
   8
   N
   I    0
   P    7
   P    0
   A    6
   L
   R    0
   E    5
   T
   F
   A    0
   4
   E
   L    0
   G    3
   N    0
   A    2
   0
   1
10 20 30 40 50 60 70 80 90
 ANGLE BEFORE
BEFORE LAPPING
LAPPING

Sometimes an emerging diagram can be like this, then

 we can say that there is a possibility of negativ
negative
e
correlation.
 

   0
   9
   0
   G    8
   N
   I    0
   P    7
   P    0
   A    6
   L
   R    0
   E    5
   T
   A    4
   F    0
   E    0
   L    3
   G    0
   N    2
   A    0
   1

10 20 30 40 50 60 70 80 90
 ANGLE BEFORE
BEFORE LAPPING
LAPPING

If it is like
like this we can say
say that there
there is a negative
 relationship or negative correlation between the two
variables.
 

   0
   9
   0
   G
   N    8
   I    0
   P    7
   P
   A    0
   L    6
   R    0
   E    5
   T
   F    0
   A    4
   E    0
   L    3
   G
   N    0
   2
   A
   0
   1

10 20 30 40
 ANGLE BEF50
BEFORE60LAPPING
ORE 70PING
LAP 80 90

Sometime we may have Scatter like this also i.e.

 positive correla
correlation
tion up to certain level and then
negative.
 

   0
   9
   0
   G    8
   N    0
   I    7
   P
   P    0
   A    6
   L    0
   R    5
   E
   T    0
   F    4
   A    0
   E    3
   L
   G    0
   2
   N
   A    0
   1

10 20 30 40 50 60 70 80 90
 ANGLE BEFORE
BEFORE LAPPING
LAPPING

It can be vice ver

versa
sa also i.e negative
negative corr
correlation
elation
 up to one level and then positive.
 

   0
   9

   0
   8
   0
   7
   G
   N    0
   I    6
   P
   P    0
   A    5
   L
   R    0
   4
   E
   T    0
   F    3
   A
   E    0
   L    2
   G
   N    0
   A
   1

10 20 30 40 50 60 70 80 90
 ANGLE BEFORE
BEFORE LAP
LAPPING
PING
 Take a scatter diagram where the values
are already plotted.
 

This can be found

out by using
 formula.
 form ula. a

Procedure is as
 follows:
 follows:
 

Take
ake sample of observation for the two
variables
varia bles under study.
study.
'Data on Hardness and Tensile
Tensile strength of copper alloy casting' 

Test Piece Hardness Tensile Strength

1 84 38.0
2 93 40.7
3 89 35.3

4 86 37.6
5 87 33.1
6 93 24.9
 7 88 28.3

2
Find out the value of X i.e
84X84 = 7056
93X93 = 8849

and so on
 

2
Find out the value of Y i.e
38X38 = 1444
40.7X40.7 = 1656.49

and so on
 

Find out tthe

he 'X
'XY'v
Y'value
alue of ob
observa
servation
tion ie
84X38 = 3192
93X40.7 = 3785.1
and so on
 

2 2

No. X Y XY
1. 7056 1444.00 3192.0

2. 8649 1659.49 3785.1

3. 7921 1246.09 3141.7

4. 7396 1413.76 3233.6

5. 7569 1310.44 3149.4

6. 8649 1413.76 3496.8

 7. 7744 1095.61 2912.8

Step 1

Find out 'n' and

2 2 obtain total of 
X, Y, X, Y and 'XY'
n = 25
Sx = 2147
SY = 899.7
2
SX 2= 185597
SY = 32715.29
 SXY = 77749.20
 

Step 2

Simplified formula for co-efficient of

correlation

S xy - (Sx) (nSy)
r=
2 2 2 2
{ S x - (Sx) } { S y - (Sy) }
n n
 

Step 3

Substitute
Substitute the values in the formula

77749. 2 - (2
77749. (2147
147)) (89
(899.7
9.7))
25
r=
2 2
{185
{18559
597
7 - (2
(214 7) } {3
147) {327
2715
15.2
.29
9 - (8
(899 .7)) }
99.7
25 25
 

Step 4

Find out the value of ‘r’. If the 'r' value is above

0.7, then the correlation is useful .

r = 483

639.15
 r = 0.7557
 

Step 5

2
Find out 100 r.

This gives percentage of variation in 'Y'

influence
influenceddbby
y 'X' i.e the iindep
ndepende
endent
nt

variable. In this case

2
100r = 57.1
 

Step 5

Therefore correlation between these

useful.
two variables is useful.

2
r = 0.5710

2
100 r =57.10
 

Calculation of coefficien
coefficientt of correla
correlation
tion and
contribution of X to Y
Step 1
Obtain pairs of observation for the two v
variables
ariables .
Data on height Vs Weight study for newly born children
Observation Height Weight
(No.) of child of child
(inches) (Kg)
(n ) (X) (Y) XxY X2 Y2
1 20 5

2 25 8

3 30 7

4 35 11
 5 40 9

n=   ∑X= ∑Y= ∑XY= ∑X2=   ∑Y2=

 

Calculation of coefficient of correlation and contribution of X

to Y
Step 2
Find out X2, Y2 and XY for the observation
obser vation value calculation
calculation
Height of child Weight of child
(inches) (kg)
XY X2 Y2

X Y
20 5 100 400 25

25 8 200 625 64

30 7 210 900 49
35 11 385 1225 121

40 9 360 1600 81
 ∑X=150 ∑Y=40 ∑XY=1255 ∑X2=4750   ∑Y2=340

coefficient of correlation and contribution of X to Y

Calculation of coefficient

Step 3
Note down the values of N observation, Y 2 and XY for the observation value calculation

n = 5 , ∑X =150 , ∑Y = 40 , ∑X2 =4750 , ∑Y2 =340 , ∑XY =1255

Step 4

Simplified formula for coefficient of correlation

∑XY - ∑x. ∑Y
n
r=
∑X2- (∑X )2 ∑Y2- (∑Y )2
 √{ n }{ n }

coefficient of correlation and contribution of X to Y

Calculation of coefficient

Step 5

1255
1255 - (150
(150).
).(4
(40)
0)
5
r=
√{47
4750-
50- (150 ) }{34
(150 2
340-
0- (40) }
(40 2

5 5
Find out the value of r, if the value of r is more than 0.7 then the correlation is useful

55
r=

250X20
 55
r= = 0.78
70.71

Step 6
To calculate contribution of X to Y find out 100 r2 .

In this X is independent variable and Y is dependent of x

% Contribution of X y = 100r2

= 100x0.78x0.78

= 61%

Based on data taken we can conclude that the contribution of height to

weight is 61%

And 39% is due to other effects

 

HISTOGRAM
Histogram
Histogram is a graphical representation
representation of a frequency distribution

which is summery of variation in a product or process.

To make Histogram
Hi stogram collect data for example
example , show the weight of 2kg. Sweet of a
shop. Least count of scale used was 1gm. Total
Total nos. of sweet pieces are 64

35 30 26 32 31 28 30 34
31 29 30 33 34 31 27 33
32 31 25 30 32 29 30 29

28 33 30 28 31 37 30 32
30 35 31 32 33 30 28 31
29 31 29 30 24 30 31 28
 31 34 31 33 31 33 30 33
29 32 30 26 30 28 31 27
 

X max = 37 highest Value

35 30 26 32 31 28 30 34 Xmin
Xm in = 24 lo
lowe
west
st val
alue
ue
31 29 30 33 34 31 27 33 Range R= 37-24 =13

32 31 25 30 32 29 30 29
28 33 30 28 31 37 30 32
30 35 31 32 33 30 28 31
29 31 29 30 24 30 31 28
31 34 31 33 31 33 30 33
29 32 30 26 30 28 31 27

35 34 32   37  35 31 34 32
 26 27 25 28 28   24 30 26
 

Table for recommenced

recommenced number of class intervals
intervals

Number of observation Recommended no. of class interval ( K )

Up to 50 6
51  – 100 7
101-
101- 20
2000 8
201 – 500 9
501 – 1000 10

Total nos. of observations = 64 Hence value of K =7

Now approximate
approximate width of class intervals “ C “ based on the formula

C=( R+W ) / K R= range, W = least count of scale

C = (13+1)/7 = 2 K = No. of class intervals
Now lower limit of first class interval = xmin – W/2 = 24
24-- 0.5 = 23
23.5
.5
 Upper limit of first class interval = 23.5 + c = 23.5 +2 = 25.5
Lower limit of 2nd class interval =25.5
Upper limit of 2nd class interval = 25.5 + c = 25.5 +2 = 27.5
 

similarl
similarlyy after calculation we can get the all class intervals
23.5 – 25.5
25.5 – 27.5

27.5 – 29.5
29.5 – 31.5
31.5 – 33.5
33.5 – 35.5
35.5 – 37.5

Class intervals Tally Frequency

23.5 –
23.5 – 25.5 II 2
25.5 –
25.5 – 27.5 IIII 4

27.5 –
27.5 – 29.5 IIII IIII II 12

29.5 –
29.5 – 31.5 IIII II
IIII IIIIII IIIIII IIII IIII 27
31.5 –
31.5 – 33.5 IIII IIII III 13
 33.5 –
33.5 – 35.5 IIII 5
35.5 – 37.5 I 1
 

Histogram

30

25

20
     y  
     c 
     n
     e 
     u  15
     q  
     e 
     r
      F
10

5
 0
23.5 25.5 27.5 29.5 31.5 33.5 35.5 37.5

Class interval

Some of the
Shapes of
Histogram
 

Double Peaked

This pattern arises from a mixture of two

conditions , two suppliers of same parts, two
machines, two
two operator
operators.
s. Separate histogram
 for each condition has to be made.
 

Comb Type

This pattern is usually traceable to errors in

measurements, and observations are rounded
 off.. Check
off Check for bia
biass for even nu
numbers
mbers in the data.
 

Isolated Peak

It is small group of data from a different

lot/process condition. It shows that means or
 process levels are different and variation is
different.
 

Plateau Type

This is a mixture of several process

 conditions. Output
together in a lot. of several days mixed
 

Uses of Histogram:
Histogram:
To know the pattern of
variation
 

Uses of Histogram:
To assess
as sess status of
control
Lower Upper
spec. spec.
28 Limit Limit
24
   y
   c20
   n
   e16
   u
12
   q
   e
   r
   F 8
4

0
1.54 1.67 1.80 1.93 2.06 2.19 2.32 2.45 2.58 2.71
 Power
Power Consumption

Uses of Histogram:
Histogram:
Lower Upper
spec.
spec.
28 Limit Limit

24
   y
   c20
   n
   e
   u
16
   q12
   e
   r
   F 8
4

0
1.54 1.67 1.80 1.93 2.06 2.19 2.32 2.45 2.58 2.71

Power
Power Consumption
 To as
assess
sess conformance to speci
specifications
fications
 

Uses of Histogram:
Spread in the process
45
10-15
40
15-20
   s 35
   e
   m
   i 30 20-25
   r
   c 25-30
    f 25
   o 30-35
   o 20
   N 35-40
15
40-45
10 45-50
5
50-55
0
AGE OF CRIMINAL
 To assess spread or variation with
 
reference to specification

Uses of Histogram:

To assess
assess process
capability
 

Uses of Histogram:
We may have to adjust the process to
reduce weight.. The weight of the
soap is continuously on the higher
side

80

70 144

   p60 146

   a 50 148
   o
   s 150

    f 40 152

   o 154
   t 30
    h 156

20 158
   g
   i
   e 10 160

   W0

To get clues for bringing process under

 controll - whe
contro whether
ther tto
o shi
shift
ft mean or tto
o
 
reduce variation or both

Uses of Histogram:
Double Peaked Histogram

To get clues for possible assignable causes

 for observed
observed variat
variation
ion - mixtu
mixture
re of lots,
suppliers,
 

Uses of Histogram:
Comb Type Histogram
 instrument/measurement errors, bias
of written results etc
 

Summary

Histogram

* Display variability in a set of data

* Patterns of variability reveal facts about process
* Patterns
Patterns of variability can suggest and test theories

* Show the stat

status
us of control
control
* Show current conformance to specifications and
whether scope exists for improvement.
 

Control Chart
What is control chart ?
Control chart is a graphical device to aid in process control
Control control . It is an ON - line process
Control technique widely used for process control . It consists of a graph with a central
line denoting the target value or mean value and two limit lines on either side of the central
central
line called “Upper Control limit and Lower Control limit
limit”” generally indicated in dotted line.

UCL

Central line

LCL

We know that variation is always present due to inherent variation in the input for a given
out put .Such variation can be due to a variety of causes .They can be broadly classified
Into two categories .
1.Chance Causes
2.Assignable Causes
Based on the
inevitable requirement
.Depending uponand
theconditions prevalentsuch
working conditions , we inherent
accept certain variations
variations as
are accepted
as due to CHANCE CAUSES.. WeWe know ,however sophisticated the systems, production
production
condition etc. chance causes are bound to be there.
 

ASSIGNABLE causes are not present under normal working conditions. They suddenly
creep in due to various reasons causing changes in the control parameters .
Statistic
Statistical
al Control Process : When no Assignable causes of variation are present in a
process and it operates only under a constant system of chance causes , process is said
to be in a state of Statistical Control .
Occasionally ,assignable causes may enter the process
process resulting in a change to out of
control state when process out put shows large variation and hence fails to meet required
required
quality products.
A major objective of statistical quality control is to quickly detect process shifts due to
assignable causes so that corrective action can be taken to prevent nonconforming
Products being turned out. This facilitated by a CONTROL Chart.
X-R Control Chart

25
Assignable Cause 25
UCL 22.5 22.5

UCL 20 20

     s  17.5 17.5

     e 
     u 
       l CL 15 15
Central Line      a 
       V 12.5 12.5

LCL
LCL 10 10
 7.5 Assignable 7.5

5 5
LCL
1 2 3 4 5 6 7 8 9

 Data Time

Control Chart
How to set control Limits ?
Control limits are the permissible limits under chance causes variation or under state of

statistical
in a patterncontrol .For a measurable
of variation quality
called normal characteristic
distribution which is, chance causes variation
a symmetrical frequencywill result
distribution. This distribution is described completely by the mean and standard deviation
.One feature of this distribution is that with a span of + _ 3standard deviation (+_3 sigma)
from the mean form the limits for variation due to chance causes .
YPES OF CONTROL CHARTS :
Control charts classified into two categories .
a) Vari
ariabl
ables
es Contro
Controll Chart
Chart
b) At
Attri
tribut
butes
es Control
Control Charts
Charts
ariables Control Chart : If the quality characteristic can be measured with the help of an
instrument or measuring process , it is called a measurable characteristic .For example,
diameter,, electrical resistance, iodine no., yield, carbon content and tensile strength etc.
diameter etc.
In such cases , it is convenient to describe the quality characteristic by average and measure
of variability
variability by rang or standrd
standrd deviation.
here are three types of variable control charts.
1.Average and Range Chart ( X-R Chart)
1.Average
2.Individu
2.Individual
al and Range
Range Chart( X- R Chart)
3.Meadian and Range Chart
 

VARIABLE CONTROL CHART

(X-R Average and Range)

Characteristic-
Characteristic- Packed Spec. limit- 901.62
FI
FIBC
BC Bag
Bag pac
packe
ked
d Proc
Proces
ess-
s-Pa
Pack
ckin
ing
g Weight 900kg +_3kg X =

Operator- Packing M/
M/c no.03 Meas. Instrument- W
W..Bridge Unit of Measure- k
kgg R= 4.44
sub
Group Time 7 8 9 10 11 12 13 14 15

1 903 899 900 902 905 902 901 905 899

2 905 900 903 903 903 901 900 902 900

3 902 904 906 901 904 903 902 901 902

4 900 902 904 898 900 900 900 904 900

 5 901 901 900 900 901 900 901 900 903

SUM 4511 4506 4513 4504 4513 4506 4504 4512 4504

Average 902.2 901.2 902.6 900.8 902.6 901.2 900.8 902.4 900.8

 
Range 5 5 6 5 5 3 2 5 4

Factors for Control Limit

Size of sub
group (n)
 A2 D3 D4 d2* 3/d2

2 1.880 0 3.267 1.128 2.659

3 1.023 0 2.575 1.693 1.772

4 0.729 0 2.282 2.059 1.457

5 0.577 0 2.115 2.326 1.290

6 0.483 0 2.004 2.534 1.184
 

Control Limits for X as

Control Chart

UCL = X+A2R =901.62+(0.577x4.44)= 904.18

LCL = X-A2R =901.62-(0.577x4.4
=901.62-(0.577x4.44)
4) = 899.06

CL = X = 901.62

904.8
904.4
904
UCL
903.6
903.2
902.8
902.4
902.6 902.6 902.4
902 902.2
901.6
901.2 CL 901.2 901.2
900.8 900.8 900.8 900.8
900.4
900
899.6
899.2 LCL
 898.8

898.4
898

1 2 3 4 5 6 7 8 9

Control Limits for R as

UCLR =D4 R =2.115x4.44=9.4
UCLR =D3 R =0x4.44=0.00
CLR = R =4.44

10
9.5 UCLR
9
8.5
8
7.5
7
6.5
6 6
5.5
5 5 5 5 5 5
4.5 CLR
4 4
3.5
3
2.5 3
2 2
1.5
1
0.5
0 LCLR
 1 2 3 4 5 6 7 8 9

2. INDIVIDU
INDIVIDUAL
AL and RANGE CHART(X-R)
This is applicable when subgroup is not practicable and control is to be exercised based
On single values.
This can also be used on special occasion and where process is under control in normal
Condition. This chart does not detect the changes in the process level quickly.
Here individual value is taken rather than group value.
For Example:
We are interested in controlling the power consumption in home

Date Units Date Units Date Units Date Units

01.06.15 32.5 08.06.15 31.6 15.06.15 27.7 22.06.15 29.7
02.06.15 29.5 09.06.15 31.0 16.06.15 28.9 23.06.15 30.6

03.06.15 31.5 10.06.15 34.0 17.06.15 31.0 24.06.15 31.0

04.06.15 29.7 11.06.15 28.6 18.06.15 32.5 25.06.15 29.0

05.06.15 30.4 12.06.15 29.4 19.06.15 30.6

06.06.15 30.4 13.06.15 30.4 20.06.15 32.0
 07.06.15 29.4 14.06.15 31.7 21.06.15 26.7
Total Units X= 759.8 & Nos. of Data N = 25
X = X/N = 759.8/25 = 30.4
 

Moving Range
S.N. Moving S.N. Moving S.N. Moving S.N. Moving
range range range range
1 3. 0 8 0.6 15 1.2 22 0.9
2 2. 0 9 3.0 16 2.1 23 0.4
3 1. 8 10 5.4 17 1.5 24 2.0

4 0.7 11 0.8 18 1.9

5 0. 0 12 1.0 19 1.4
6 1. 0 13 1.3 20 5.3
7 2. 2 14 4.0 21 3.0

otal value of Range= 46.5

verage
verage of Range R = 46.5/24 =1.94

X =30.4
UCLX = X+(3R/d2) =30.4+(2.659x1.94) =35.56

LCLX = X-(3R/d2) =30.4-(2.659x1.94) =25.24

UCLR= D4xR =3.268x1.94 =6.34
LCLR =D3xR +0x1.94 =0
 

Individual Range Chart (X-R chart)

40
39
38
37
36 UCL
35
34 34
33
32.5 32.5
32 31.7 32
31.5 31.6
31 CL 31 31 31
30
29.5 29.7 30.430.429.4 29.4
30.4 30.6 29.730.6
29 28.9 29
28.6
28 27.7
27 26.7
26
LCL
25
24
23
22
21
20
        9          9          9          9          9          9          9          9          9          9          9          9          9          9          9          9          9          9          9          9          9          9          9          9          9 
        0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0 
        0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0 
        2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /         2 
        /
        1         2         3         4        5          6         7         8          9          0          1         2         3         4        5          6         7         8          9          0          1         2         3         4        5 
        /          /          /          /          /          /          /          /          /          1         1         1         1         1         1         1         1         1         1         2         2         2         2         2         2
        6          6          6          6          6          6          6          6          6          /          /          /          /          /          /          /          /          /          /          /          /          /          /          /          / 
        6          6          6          6          6          6          6          6          6          6          6          6          6          6          6          6 
 

Rang
Range-
e- Ch
Char
artt
6.8
6.4
6 UCL
5.6
5.2
5.4 5.3
4.8
4.4
4 4
3.6

3.2 3 3 3
2.8
2.4
2.2 2.1
2 2 1.9 2
1.6 CL 1.8
1.5 1.4
1.2   1.3 1.2
1  1 0.9
0.8
0.7 0.8
0.6
0.4 0.4
0 0
   0
LCL
   0   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9    0    0
   9
   2
   /    2
   /    2    /
   /    2    2    /
   /    2    2
   /    2    /
   /    2    /    2    /    2    /    2    /    2    /    2    /    2    /    2    /    2    /    2    /    2    /    2    /    2    /    2    /    2    /    2
  1
   /    2
   /    3
   /    6   4
   /    5
   /    6    6
   /    7
   /    8
   /    6    9
   /    0   1    2    3   4    5    6    7    8    9    0   1    2    3   4
   6    6    6    6    6    6    /  1    6
   6    /  1    6    /  1    6    /  1    6    /  1    6    /  1    6    /  1    6    /  1    6    /  1    6    /  1    6    2
   /    2    /
   /
   6
   2
   6
   2
   /
   6
   2
   /
   6

Interpretation : It is seen from the control chart that all points on X-

 Chart and R-Chart are within the control
control limit. It is that process is
under control.

2. ATTRIBUT
ATTRIBUTEE CONTROL CHARTS
These are used when we want to control non measurable characteristics process .
Types of Attribute control chart :
a) Number defective “np” chart.
b) Percentage defective “p” chart
c) Number of defects “c” chart.
d) Number of defect per unit “u” chart.
Number defective “np” chart : This chart is used when sample size size is fixed number
number..
Eg. In paper bag co. bags are in
inspected
spected ffor
or defec
defectives
tives .Every da
day
y 50 bags arare
e inspected .

Sample No. 1 2 3 4 5 6 7 8 9 10 Total

Date 1 /6 2 /6 3 /6 4 /6 5/6 6 /6 7/6 8/6 9/6 10/6

No. inspected   50 50 50 50 50 50 50 50 50 50   500

No. defectives 4 5 8 6 7 12 9 4 3 2 60

Sample No. 11 12 13 14 15 16 17 18 19 20
 Date 11/6 12/6 13/6 14/6 15/6 16/6 17/6 18/6 19/6 20/6

No. inspected   50 50 50 50 50 50 50 50 50 50   500

No. defectives 1 5 10 4 6 7 4 9 8 6 60
 

Control limits for “ np” chart : Limits

= nP ±3 nP nP (1
(1-P
-P))
Total nos. of def
defectives
ectives in sample checked =120 = P
Total nos. inspected =20x50 =1000
P= P/ Total nos. inspected =120/1000 = 0.12
nP =50x
=50x0.
0.12
12 =6.0
=6.0
UCLnp= 6+3 5.28 =6+6.89 = 12.89
LCLnp
LCLnp = 6-6
6-6.89
.89 = --0.89
0.89

np con
contro
troll chart
chart : n=50
n=50
14
UCL
12 12

10 10
9 9
8 8 8
7 7
6 6 6 6
5 5
4 4 4 4 4
3
2 2
1
0 LCL
        9          9          9          9          9          9          9          9          9  9 9 9 9 9 9 9 9 9 9 9
                                                                                                              
        0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0 
        0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0 
        2         2         2         2         2         2         2         2         2         2         2         2         2         2         2         2         2         2         2         2
        / 
        1         /
        2          /
        3           /
        4          /
        5           /
        6           /
        7          /
        8           /
        9           /
        0           /
        1          /
        2          /
        3           /
        4          /
        5           /
        6           /
        7          /
        8           /
        9           /
        0  
        /          /          /          /          /          /          /          /          / 
        1         1         1         1         1         1         1         1         1         1         2
        6          6          6          6          6          6          6          6          6          /          /          /          /          /          /          /          /          /          /          / 
        6          6          6          6          6          6          6          6          6          6          6 

Interpretation: all point are within control limit i.e. process is under control
 

b) Percentage Defective “p” Chart

s the name indicates , this chart uses percentage .This is useful when the sample size
aries. Let us see an example for this.
In a paper bag manufacturing co. bags are checked for defectives. Date wise number of
bags inspected. Data are collected in ffollowing
ollowing check sheet

No. No. No. %of ( n) 3 UCL%= LCL%

inspected (n) defectives defective
3σp
n (P+3σp)
(P+3σ (P-3σ
(P-3 σp)
(p) s x100 x100
(p%)

1 185 17 9.19 13.60 0.221 0.067 16.90 3.50

2 210 22 10.48 14.49 0.207 0.063 16.50 3.90
3 196 16 8.16 14.00 0.214 0.065 16.70 3.70
4 214 26 12.15 14.63 0.205 0.062 16.40 4.00
5 225 22 9.78 15.00 0.200 0.061 16.30 4.10
6 176 18 10.23 13.27 0.226 0.069 17.10 3.30
7 182 16 8.79 13.49 0.222 0.067 16.90 3.50
 8 203 25 12.32 14.25 0.211 0.064 16.60 3.80
9 176 18 10.23 13.27 0.226 0.069 17.10 3.30
10 95 10 10.53 9.75 0.308 0.094 18.70 0.80

 
P =190
=190 18
1862
62 =0.
=0.10
102
2

Control limits for percentage p Chart

= P ± 3 p(1
p(1-p)
-p)/n
/n

Percentage Defective “P” Chart

20
UCLp
15

CLp 12.15 12.32

10   10.48 9.78   10.23 10.53
10.23
9.19 8.79
8.16

5 LCLp

0
1 2 3 4 5 6 7 8 9 10
 Interpretation : All points are within the upper controll limit and therefore process is under
Control .

C) Number of Defects “C” Chart.

This control chart is used when quality assessment is in terms of number of defects in
single items. The number of defects
defects on the produc
productt is noted and “C” chart help to know
whether the defect level is under the control.
For example a carpet manufacturing company wants to monitor defects in carpet. For
this purpose the number of defects per square meter is collected.
Time No. of defects Time No. of defects Total no. of defects = 28 +24 = 52
08:00 4 13:00 1 No. of sample taken =20

08:30 3 13:30 4
C =52/20 =2.60
09:00 2 14:00 3 Control
Control limits
limits = C ± 3σ
09:30 0 14:30 2 =C±3 C
10:00 1 15:00 0 UCLc = 2.6+
2.6+33 2.6 =7.44=7.44

10:30 5 15:30 0
11:00 6 16:00 3 LCLc =2
LCLc =2.6-
.6- 3 2. 2.6
6 = -2.24
-2.24
11:30 4 16:30 2 Take this as zero

12:00 0 17:00 5
 CLcc
CL 2
2.6
.6

12:30 3 17:30 4
Total 28 24

Number of Defects “ C” Chart

8
7 UCL
6 6

5 5 5

4 4 4 4 4

3 3 3 3 3

2 CL 2 2 2

1 1 1

0 LCL 0 0 0 0
        0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0          0 
        0
      :          3
      :          0
      :          3
      :          0
      :          3
      :          0
      :          3
      :          0
      :          3
      :          0
      :          3
      :          0
      :          3
      :          0
      :          3
      :          0
      :          3
      :          0
      :          3
      : 
        8          8          9          9          0          0          1         1         2         2         3          3          4         4         5          5          6          6          7         7
        1         1         1         1         1         1         1         1         1         1         1         1         1         1         1         1

Interpretation : it is seen from the chart that all the

t he points are below the upper
control Limit and there are no runs and trends. It is therefore the defect level
level is
 under statistical Control.

d) Number of defects per unit “U” Chart

his is used when inspection unit value changes .For example the carpet was earlier
checked for defects in one square meter ,after few checks instead of one sqm. 1.5 sqm
are checked
checked and after some time it was increased to 1.8 square meter
meter.. In such cases
control limits will change accordingly.
No.of defects =69
Time Inspection No.of Time Inspection No.of
Total Sq.m checked =27.60
unit(Sqm) defects unit(Sqm) defects
No.of defects/Sq
defects/Sq.M=69/27.60
.M=69/27.60
08:00 1.00 3 13:00 1.50 5 =2.50

08:30 1.00 4 13:30 1.50 6 UCLu = U+ 3 U/n

09:00 1.00 6 14:00 1.80 7
09:30 1.00 1 14:30 1.80 4 UCLu = U - 3 U/n
UCLu
For inspection unit 1Sqm
10:00 1.00 4 15:00 1.80 3
UCL = 2.5+3 2.5/1
10:30 1.00 3 15:30 1.80 2
=2.5+4.74 = 7.24
LCL=2.5-4.74 = -2.24
11:00 1.50 7 16:00 1.80 3
For insp.unit 1.5 Sq.M
11:30 1.50 4 16:30 1.80 4
UCL=2.5+3 2.5/1.5
12:00 1.50 2 17:00 1.80 1 =2.5+3.9 =6.4
 12:30 1.50 0   Total   27.60 69 LCL=2.5-3.9= -1.4
For insp.unit 1.8Sq.m
UCL=2.5+3 2.5/1.8
=2.5+3.6=6.1
LCL=2.5-3.6=-1.10
 

Number of defects per unit “U” Chart

8
UCL
7
6 6

5 4.7
4 4 4 4   3.9
3.3
3 3 3
2.7
CL 2.2 2.2
2 1.7 1.7
1.3 1.1
1 1
LCL 0.6
0 0

   0    3
   0    0    0
   0    3
   0    0   0    3   0    0
   0    3
   0    0   0    3   0    0   0    3   0    0
   0    3
   0    0   0    3   0    0   0    3   0    0   0
  :   :   :   :   :
   0   1   :   :   :
   0   1  1   1  1   1   :
   2   1   :
   2   1   :
   3   1   :   :   :
   3   1  4   1  4   1   :
   5   1   :
   5   1   :
   6   1   :
   6   1   :
   7
   8    8    9    9   1

Continuous plotting help in finding out whether process is under control or not . Lack
Of control is indicated by points falling on or out side control limits. But even when the
values are within the control limits, process can be consider out of control if it is reflecting
 Any one of the following pattern.
Run : It is a state when points occur continuously on one side of the central line and then
the number of points is called the length of Run
Run..

said earlier
As said earlier,, control charts
charts are
are
graphical aids in process control.

Continuous plotting
plotting help in finding
out whether process is under

contr
control
ol or not. Lack of control is
indicated by points falling on or
 outside control limits.

But even when the values are

within the control limit, process can
be considered out of control if it is
reflecting any one of the following
patterns.
 

Run
10 out of 11 consecutive points
Seven-point length of run
Seven-point
Upper is abnormal occuring
occuring on one side is abnorm
abnormal
al
control
Limit

Central
Line

Lower
control
Limit

It is a state
state when points occur continously on one
side of the control line and then number of points
 is called “length of the Run”

Trend 
Seven upwards points Drastic downward trend
Upper
control
Limit

Central
Line
Lower
control
Limit

When the points form a continuous upward or downward curve it is said

 to hav
have
e a TR
TREN
END
D.

central line.
 Approach to central line.
3 Sigma line

1.5 Sigma line

Central
Line
1.5 Sigma line

3 Sigma line

When most of the points are within 1.5 sigma line it is due to
 inappropriate
inappropriate way of sub grouping.

Control Limit 
 Approach to Control

Approach to the control limit

limit ( 2 out of
o f 3 points )
3 Sigma line

2 Sigma line

Central
Line

2 Sigma line
3 Sigma line
When two out of three points occur outside the 2 sigma line the case is considered abnormal.
 

PROBLEM SOLVING STEPS

• IDENTIFICATION OF PROBLEM

• SELECTION OF PROBLEM

• DEFINE THE PROBLEM

• ANALYSE THE PROBLEM

• FIND OUT CAUSES

• ROOT CAUSE ANALYSIS

• DATA ANALYSIS

• DEVELOPMENT OF SOLUTION
• FORESEEING PROBABLE RESISTANCE

• TRIAL IMPLEMENTATION AND CHECK PERFORMANCE

 • REGULAR IMPLEMENTATION .

• FOLLOW-UP AND REVIEW

STEPS FOR PROBLEM SOLVING

{A systematic
systema
also ticUse
to make approach not only
of problem helps
solving in studying
technique theappropriate
at the pr
problem
oblem in the proper perspective but
place}

There are 12 steps suggested for problem solving

STEP -1 Identification of work related problems

Method :-
a) Generate a list of problems using Brainstorming
b) Prioritize problems using “A” “B” “C” analysis

‘A’ category problem

Minimum involvement
involvement of other departments in solving the problems
‘B’ category problem
Involvement of other depar
departments
tments is a n
necessity
ecessity
 ‘C’ category problem
Management sanction may be needed in implementing the solution

STEP -2 “ SELECTION OF PROBLEM”

Method :-
a) “PARETO ANALYSIS”
ANALYSIS” or “RA
“RATING”
TING” ba
based
sed on past data or system
b) Register the selected problem with coordinating agency

STEP -3 “DEFINE THE PROBLEM”

Method :-
a) By using “ FLOW DIAGRAM”
b) By using “BRAINSTORMING”

STEP -4 “ANALYSE
ANALYSE THE PROBLEM
PROBLEM””

Method :-
a) By using “ DA
DAT
TA COLLECTION
COLLECTION””
b) By using “GRAPH”
 c) By using
us ing “STRA
“ STRATIFICA
TIFICATIN”
TIN”

STEP -5 “ IDENTIFICA
IDENTIFI CATION
TION OF CAUSES”

Method :-
a) “BRAIN STORMING”
b) “CAUSE and EFFECT Diagram

STEP -6 “FINDING OUT THE ROOT CAUSES”

Method :-
a) Identifyi
Identifying
ng the main causes in “ CAUSE and EFFECT DIAGRAM” by DA
DAT
TA
COLLECTION
COLLE CTION and discussion

STEP -7 “DATA ANALYSIS”

Method :-
By using techniques LINE GRAPH,BAR GRAPH,PIE GRAPH, AREA GRAPH
HISTOGRAM, STRATIFICA
STRATIFICATION
TION and SCA
SCATTER
TTER DIAGRAM
 STEP -8 “DEVELOPING SOLUTION”
Method :-
Using BRAINSTORMING
 

STEP -9 “ FORESEEING PROBABLE RESISTANCE”

RESISTANCE”

Method :-
“BRAIN STORMING”
Identifying the probable constraints and finding ways to overcome them.
Make a presentation to all involved with the solution i.e. Dept. head, Facilitator, other
officials and non-members involved with the implementation. Discuss and evaluate a system
for implementation.

STEP -10 “ TRIAL IMPLEMENTATION AND CHECK PERFORMANCE”

Method :-
Data collection after implementation , compared with the data collected before solving the
 problem.. Collect fresh data using control
problem control chart and watc
watch
h process trends. Analyse the result,

discuss and incorporate the changes needed

STEP -11 “ REGULAR IMPLE

IMPLEMENT
MENTA
ATION”

Method :-
Once validity is checked and improvement observed with data , regular
implementation can be effected

STEP -12 “ FOLLOW UP/ REVIEW”

Method :-
Implement evaluation procedure, use Data collection, control chart and Bar Graph , have six
monthly report for evaluation.
Make modifications if necessary