Professional Documents
Culture Documents
&
PROBLEM SOLVING
“Why do we need Quality ?”
2
Why do we need ‘Quality’ ?
3
Problem Solving Technique
Questionof Simple
Implementation
Problem Types
Problems
Known
C D
Solution
A B
Really Worth Unknown Known Require High
Solving & Level of Tech.
Challenging
Root Cause
4
Problem Solving Technique
Types of Problem Solvers
Self
Problem
Negating,
Solving
Despairing
Type
Type
5
Whose perspective should we look at?
products
processes
results
outcomes
benefits
Lens of customer
6
Who are Our Customers?
2. Intermediate customers
E.g. Retailer, Distributor, OEM
7
Why Do we need Quality Tools?
8
Problem solving - Methods & Tools
9
Problem solving - Methods & Tools
- Kaoru Ishikawa
10
7 QC TOOLS
The 7 QC Tools;
Flow chart
Check sheet
Histogram
Pareto Diagram
Q
Cause & Effect
Scatter diagram
11
7 QC TOOLS
The 7 QC Tools;
Check sheet
Histogram
Pareto Diagram
Scatter diagram
Control charts
12
FLOW CHARTS
13
FLOW CHARTS
14
FLOW CHARTS
15
FLOW CHARTS
FLOW CHART SYMBOLS
16
FLOW CHARTS
A BASIC FLOW CHART
17
FLOW CHARTS
MACRO MINI MICRO
NO NO
Is it Are
Type POD approv ed? Approval settings Correct
Ok?
YES
YES
End Distribute
End
End
18
FLOW CHARTS
19
FLOW CHARTS
20
FLOW CHART
21
7 QC TOOLS
The 7 QC Tools;
CHECK SHEET
Flow chart
Check sheet
Histogram
Pareto Diagram
Scatter diagram
Control charts
22
CHECK SHEET
23
CHECK SHEET
24
CHECK SHEET
25
CHECK SHEET
SAMPLE CHECK SHEET
26
CHECK SHEET
SAMPLE CHECK SHEET
27
CHECK SHEET
SAMPLE CHECK SHEET
28
CHECK SHEET
SAMPLE CHECK SHEET
29
7 QC TOOLS
The 7 QC Tools;
HISTOGRAM
Flow chart
Check sheet
Histogram
Pareto Diagram
Scatter diagram
Control charts
30
HISTOGRAM
What is a Histogram ?
31
HISTOGRAM
TITLE:
‘X’Axis
32
HISTOGRAM
33
HISTOGRAM
Constructing a Histogram
34
HISTOGRAM
Constructing a Histogram
35
BAR WIDTH & BOUNDARY
1. Find the range of the data set I.e., Highest value - lowest.
?
36
INTERPRETING HISTOGRAM
Location & Spread of Data
A B
Target Target
C D
Target Target
37
INTERPRETING HISTOGRAM
38
INTERPRETING HISTOGRAM
Common Histogram Shapes
39
INTERPRETING HISTOGRAM
40
INTERPRETING HISTOGRAM
41
INTERPRETING HISTOGRAM
42
HISTOGRAM
Benefits of Histogram
43
HISTOGRAM
• MS Excel
• Minitab software
2. Exercise on Histogram
44
HISTOGRAM
Histogram of C1
10
8
Frequency
0
12 14 16 18 20 22
C1
DescriptiveStatistics:C1
45
HISTOGRAM
Bin Frequency
Histogram 0 0
11.5 1
20 13 0
16
15 12 14.5 3
Frequenc y
8 9 16 12
10
5 17.5 8
5 3
1 19 16
0 0 0
0 20.5 9
0 11.5 13 14.5 16 17.5 19 20.5 22 23.5 22 5
Gap in mm 23.5 0
More 0
46
VISUALS
47
7 QC TOOLS
The 7 QC Tools;
Check sheet 1
Histogram 2
Pareto Diagram 3
Scatter diagram
Control charts
48
PARETO DIAGRAM
49
PARETO DIAGRAM
50
PARETO DIAGRAM
2
Step 3: Label the vertical axis
3
Step 4: Label the Horizontal axis 4
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PARETO DIAGRAM
2
Step 8: Add title, Legend and Date
3
Step 9: Analyze the Diagram 4
52
PARETO DIAGRAM
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PARETO DIAGRAM
A SAMPLE PARETO CHART
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PARETO DIAGRAM
• Minitab software
55
PARETO DIAGRAM
99% 100%
96% 100%
400 92%
90%
350
80%
74%
300 70%
60%
ACCIDENT IN NO.
250 54%
50%
200
40%
30%
150
128
30%
102
100
82 76 20%
50
10%
20
12
4
0 0%
MAINTENANCE - 1MAINTENANCE - 2OPEARATIONS - 1OPEARATIONS - 2 ADMINISTRATION TRAINING SAFETY
DEPARTMENT
56
PARETO DIAGRAM
300
Percent
60
200
40
100 20
0 0
Department
57
7 QC TOOLS
The 7 QC Tools;
Flow chart
CAUSE & EFFECT DIAGRAM
Check sheet
Histogram
Pareto Diagram
Scatter diagram
Control charts
58
CAUSE & EFFECT DIAGRAM
Quality characteristic.
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CAUSE & EFFECT DIAGRAM
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CAUSE & EFFECT DIAGRAM
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CAUSE & EFFECT DIAGRAM
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CAUSE & EFFECT DIAGRAM
Negative (a problem)
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CAUSE & EFFECT DIAGRAM
STEP 2 - Fill in the Effect Box & draw the spline
POOR
MILEAGE -
5 KMPL
64
CAUSE & EFFECT DIAGRAM
STEP 3 - Identify main categories
METHOD MACHINE
POOR
MILEAGE -
5 KMPL
PEOPLE MATERIAL
65
CAUSE & EFFECT DIAGRAM
STEP 4 - Identify Causes influencing the factors
METHOD MACHINE
Use wrong
gears Under inflated
tyres
Rash Carburetor
Driving adjustment
POOR
MILEAGE -
Poor 5 KMPL
Improper
maintenance
lubrication
Poor W rong
Driving habits fuel
PEOPLE MATERIAL
66
CAUSE & EFFECT DIAGRAM
STEP 5 - Add detailed levels & Analyze the diagram
METHOD MACHINE
POOR
MILEAGE -
5 KMPL
PEOPLE MATERIAL
67
CAUSE & EFFECT DIAGRAM
68
CAUSE & EFFECT DIAGRAM
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CAUSE & EFFECT DIAGRAM
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CAUSE & EFFECT DIAGRAM
• Minitab software
71
CAUSE & EFFECT DIAGRAM
No interest Relativ es
Low Income
So ciety O ffice
72
7 QC TOOLS
The 7 QC Tools;
SCATTER DIAGRAM
Flow chart
Check sheet
Histogram
Pareto Diagram
Scatter diagram
Control charts
73
SCATTER DIAGRAM
74
SCATTER DIAGRAM
To confirm a Hypothesis.
75
SCATTER DIAGRAM
INTERPRETATION OF SCATTER DIAGRAM
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SCATTER DIAGRAM
77
SCATTER DIAGRAM
78
SCATTER DIAGRAM
SCATTER PLOT STATISTICS:
Stdev of X and Y values Indicates spread of data around the mean. Line
Line of Best Fit - Y Intercept Point at which line of best fit crosses Y axis
79
SCATTER DIAGRAM
INTERPRETATION OF SCATTER DIAGRAM
Strong correlation
Moderate correlation
W eak correlation
(Tan 45 degree = 1)
80
SCATTER DIAGRAM
81
SCATTER DIAGRAM
• Minitab software
82
7 QC TOOLS
The 7 QC Tools;
Flow chart CONTROL CHARTS
Histogram
X
Pareto Diagram
LCL
Cause & Effect
Scatter diagram
Control charts
83
CONTROL CHARTS
UCL
LCL
84
CONTROL CHARTS
85
CONTROL CHARTS
86
CONTROL CHARTS
• MS Excel
• Minitab software
87
VISUALS
88
OTHER QC TOOLS
89
7 QC TOOLS
The 7 QC Tools;
STRATIFICATION
Stratification
60
Paramet er Y
50
Brain storming
40
30
20
10
1 2 3 4 5 6 7 8 9 10 11
Paramet er X
90
STRATIFICATION
What is Stratification ?
to be treated separately.
91
STRATIFICATION
process.
92
STRATIFICATION
Example:
Appraisal cost
to 5 %
93
STRATIFICATION
LCL
94
STRATIFICATION
Benefits of Stratification
Unknown strands of data can be identified.
UCL
1 2 3 X
LCL
95
7 QC TOOLS
The 7 QC Tools;
GRAPHS & CHARTS
Stratification
Brain storming
96
GRAPHS & CHARTS
1. Bar graph
2. Line graph
97
GRAPHS & CHARTS
• MS Excel worksheet
98
VISUALS
99
7 QC TOOLS
The 7 QC Tools;
BRAINSTORMING
Stratification
Brain storming
100
BRAINSTORMING
What is Brainstorming?
or solutions.
101
BRAINSTORMING
Benefits of Brainstorming
Creativity
102
BRAINSTORMING
Ground Rules
No discussion / No debate
103
BRAINSTORMING
Brainstorming sequence
104
BRAINSTORMING
1. A Demo on Brainstorming:
• Go to Brainstorming video.
2. Exercise on Brainstorming
105
VISUALS
106
DEFINING THE PROBLEM
START
80 • • 100%
PROCESS •
STEPS 60 • 75%
•
40 50%
DECISION
20 25%
STOP A B C D E Other Check Sheet
Pareto Chart
Flow
Chart
IS IS NOT
W HAT?
Histogram
WHO?
WHERE?
WHEN?
HOW MUCH?
Capability Study
Is/Is Not Analysis Control Chart
107
P roject Bulletin Board A Quality Tool Belt P r oblem
RED I TEMS REQUI RE ACTI ON WI THI N 30 DAYS. Cause Cause
1.
2.
Completed Items move to the
S t a t e m e nt
Suc c es s ful Projec ts Board.
3.
Brainstorming
3.
P u r p o se & Vi si o n IN TERRELATIONSHIP
C O L UM N C H A RT
Cause Cause Im agine er ing
STRATEGIC PLAN FO R C E FI E LD A NA LY SI S
D riving R est ra in
Number Fo r c es Fo
EFFECT
Measurement
P re se n t Organi zati on
1. Average
2. D 4 2 2 4 12
3.
4.
_ _ _ _ _ _ _ _ _ _ _ _ __ _ _ __ _ _ __ _ __
Lower Control Limit [LCL]
NGT
Time
C HECKLIST 3
C onsensogram Stratification Capacity Matrix
Date RUN CHART
Understanding
Total 2 Aim or Capac ity Breakdow n
M easurement
100 %
Knowledge
Res ult
Application
A Alone
Analysis
1
Category 1 Data Data
90 %
Measuremen
0
Category 2 Data Data 80 % A and B Combined Average
t
Category 4 Data Data ETC.
P ie C hart Time
Time
.
Q uality I mprovemen t Story Board Parking
1. D escri b
e t he OFI ident if iedi nt he
Bal dri ge Assess ment.
2.a. Identi fy the teammemberswho wil l
address t he i ss ue.
3. Col lect data regardi
current si tuat ion. CORRELATION CHART H I ST O GRA M A ffinity Diagram Ganntt Chart Lot
b. Est abl i shoperati on
al def init ionst o b
e used.
PROJECT +
STEPS Time What is goingwell? What needs improvement
1.
Factor 1
Frequency
Name Role
Proc es s Delighted John Team Leader
Why?
Category
St ep Customers Mary Coach
Bob Teacher
D e c is ion Do
Bill Secretary
The Plan-Do-Study-Act [PDSA] Cycle Systems Progress Pilot Project Five Whys? Survey Results In Percent Jane Driver
Wayne Student
St op
Quality Improvement Story Board
1. Describe the OFI identified in 2.a. Identify the team members who will 3. Collect data regarding the
the Baldrige Assessment.* address the issue . Define the Team current situation. Use any or all of
the following:
Team M emb ers
Name Role
STRATEGICPLAN M ary
Bob
Coach
Teach er
S u san Cu stod ian
Bill S ecretary
Jan e Driver
RUN CHART
BA R C H A RT
Wayn e S tu d en t
Measurement
b. Establish operational definitions t o be used.
Category
Average
B
P r oblem
Survey Results In Percent Time
SURVEY S t a t e m e nt
Total
A 1 3 1 1 6
1. xxxxxxxxxx
B 3 4 4 2
2. xxxxxxxxxx
C
C HECKLIST
3. xxxxxxxxxx 2 1 3
D Date Total
4
O p era tio n al
Category 1 Data Data
D e f i ni ti on s
Category 2 Data Data
*Use BOTH the Building Bullet Book and the Baldrige Category 4 Data Data
Feedback Report along with the annual Baldrige Survey Results
to identify OFIs.
6. Report results.
4. Identify causes for the current 5. Develop a plan for improve ment and
situation. how suc c ess will be measured.
FO R C E FI E LD A NA LY SI S
D riving R est ra in
Fo r c es Fo
Cause Cause
Affinity Diagram
Measurement
Category
Average
C4 C5 C6
⚫ Analyse x’s
Run 1 2 3 4 5 6 7
⚫ Map the Process 1 1 1 1 1 1 1 1
⚫ Determine Process 2 1 1 1 2 2 2 2
⚫ Identify Customer 3 1 2 2 1 1 2 2
Stability 4 1 2 2 2 2 1 1
Requirements 5
6
2
2
1
1
2
2
1
2
2
1
1
2
2
1
⚫ Determine Process 7 2 2 1 1 2 2 1
8 2 2 1 2 1 1 2
Capability
xx
x
xx x
15 20 25 30 35 x x
x
⚫ Identify Priorities x
⚫ Set Targets for
⚫ Update Project File
Measures x
110
THE IMPROVEMENT CYCLE
Improve Control
⚫ Characterise x’s ⚫ Control Critical x’s
y
.. .. . 10.2 Upper Control Limit
. .. .. . 10.0
y=f(x1,x2,..) 9.6
1 5 10 15 20
y
Q
⚫ Set Tolerances for x’s ⚫ Validate Control
⚫ Verify Improvement Plan
LSL USL
⚫ Close Project
15 20 25 30 35
111
PDCA LOOP IN ACTION
Team Problem
Solving Process 3. Acquire and Analyse Data
7. Verify the Results
112
PDCA LOOP IN ACTION
Draw Establish
Conclusions the Focus
Examine
the Current
DEFINE Situation
Standardise
the CONT ROL M EASURE
Changes Analyze
Act Plan the
ANALYZE Causes
Study
(Check) Do
IMPROVE
Study Act on
the the Causes
QC STORY
Results
DMAIC
PDSA/PDCA
113
SUMMARY
The tools listed above are ideally utilized in reducing the process
• Analysis
• Improvement
• Monitoring
• Implementation
114