#ATCoaching

By - Ankur Tyagi

7 Basic QC Tools
Definition of Problem

Current Objective
Situation

Gap
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7 Quality Control Tools – Bridging the Gap

Bridge

Problem Solution
Gap between the Bridging the Gap to
expectation and achieve the
current state objectives

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Benefits of Seven QC Tools

Simple Effective Systematic

When properly applied

Each tool has a
Anyone with basic data and utilised, 7QC tools
standardized
knowledge can use helps in finding the root
systematic approach to
these tools cause and completely
generate the outcome
eliminating the issue

Ankur Tyagi
1. Check sheet
Tool 1 - Check Sheet

Definition of Check Sheet:

In most of the analysis, Check sheet is the very First utilised of the QC Tools. A Check sheet is any plain sheet of
paper where the data & observations can be captured in a simple & structured manner.
ASQ provides a very simple definition on Check sheet: A check sheet is a structured, prepared form for collecting and
analysing data. This is a generic data collection and analysis tool that can be adapted for a wide variety of purposes.

Use of Check Sheet:

➢ To collect the data and observations.

➢ To quickly visualise the Frequency of observations in a numeric form
➢ To distinguish Facts from Opinions.

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Tool 1 - Check Sheet
Steps for preparing a Check sheet: Illustrations and Examples of Check sheet:

1. Understand the Problem / Gap.

2. Define & decide the event / process which has to be observed.
3. Define the data / observation to be collected.
4. Define Who (will collect the data), When (the data to be collected) and
How (the data to be collected.
Image Ref – asq.org
5. Define the type of data to be collected – Discrete / Categorical /
Continuous.
6. Design the Check sheet format
7. Train the members who will be entering the data.
8. Start using the Check sheet and take the feedback from the users and
Inspection Record
update the sheet of required
9. DO not forget to mention the “Format Number” to standardise the sheet.

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2. Flow Chart
Tool 2 – Flow Chart

Definition of Flow Chart:

➢ A Flow chart graphical visualization tool that illustrates the flow of a product or service and the relationship
between the activities across the Process Flow. It’s a very good tool for visualizing the actual process.
➢ A Flow chart can be of High level which is generally used to provide a Bird Eye View, also it can be a detailed one,
consisting the detailed activity flow and inventory display.
➢ A Flow chart utilises various shapes to display the step by step activity and these shapes are connected by
arrows to show the direction of flow.

Use of Flow Chart:

➢ To understand the sequence of activities in a process

➢ To document the how a job is being performed
➢ Quick visualization of how the product or service is flowing in the system and the activities being performed.
➢ Understanding how the activities are sequenced.

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Tool 2 – Flow Chart
Steps for preparing a Flow Chart: Illustrations and Examples of Flow Chart:

1. Identify the objective of developing the Flow Chart.

2. Understand the scope of the flow chart.
3. Brainstorm the activity list along with the sequence or if the process is
already existing, do Gemba and note down the activities and sequence of
flow of product / service.
4. Finalize the type of flow chart required as per the need (Macro level / Mini
Level / Micro Level)
5. Utilise the right shapes as assigned to individual activity and develop the
Flow Chart.
6. For existing process, validate the Flow Chart by cross verifying with
actuals process.

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Basic Symbols Used in a Flow Chart

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3. Histogram
Tool 3 – Histogram

Definition of Histogram:

➢ A histogram, also known as frequency plot is used to visualise the shape of the distribution of the data by
breaking the data into various intervals and plotting the frequencies of each interval.
➢ This is useful to see how often a particular reading occurred in a data set.

Use of Histogram:

➢ To visualise the data distribution, skewness and flatness

➢ Quick visualization of the Range of data along with the Central Tendency
➢ Quick Visual Identification of the concentration of the data points

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Tool 3 - Histogram
Steps for preparing a Histogram: Illustrations and Examples of Histogram:
➢ Data Collection.
➢ Determine the number of class intervals. Generally below
formulae are used:
2 to the k rule: 2k = n
Square Root Rule: k = SQRT(n)
Rice’s rule: k = 2 x n1/3
k – number of class interval
n – total number of observations.
➢ 3. Calculate the class interval –
➢ Total Range / number of class intervals
➢ Count the frequencies of the readings for each class interval
➢ Plot the Frequencies for each class interval on the graph

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4. Scatter Plot
Tool 4 – Scatter Plot
Definition of Scatter Plot:
➢ A scatter plot is a chart type that is normally used to observe and visually display the nature of relationship
between two continuous variables.
➢ Essentially, each of these data points looks “scattered” around the graph, giving this type of data visualization its
name.
➢ The relationships observed can either be positive or negative, non-linear or linear, and/or, strong or weak.
➢ By understanding such relationship, it becomes easy to control the output variable by varying the input variable.

Use of Scatter Plot:

➢ Quick visualization of the relationship between the two sets of variable data.
➢ A scatter plot can be useful for identifying other patterns in data and to segment the data into different parts.
➢ After brainstorming causes and effects using a fishbone diagram to determine objectively whether a particular
cause and effect are related.

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Tool 4 – Scatter Plot
Steps for preparing a Scatter Plot: Illustrations and Examples of Scatter Plot:
➢ Define the two continuous variables between which the
relationship is to be established. The one which is to be
controlled is called “Independent Variable” while the other one is
“Dependent Variable”
➢ Collect the pairs of data for the two variables across the range.
➢ Draw the dot plot with “Independent Variable” on X Axis and
corresponding readings of “Dependent Variable” on Y Axis.
➢ Analyse and understand the type of Relationship exists between
the two variables

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 Tool 4 – Scatter Plot
Types of Corelation in Scatter Plot Illustrations and Examples of Scatter Plot:
1. Strong Positive: The dependent Variable increases/decreases
with corresponding increase/decrease in the Independent
variable, most of the times and most points lies on a straight line.

2. Weak Positive: The dependent Variable increases/decreases

with corresponding increase/decrease in the Independent
variable, some of the times.

3. Strong Negative: The dependent Variable increases/decreases

in opposite to the decrease/increase in the Independent variable,
most of the times and most points lies on a straight line.

4. Weak Positive: The dependent Variable increases/decreases in

opposite to the decrease/increase in the Independent variable,
some of the times.

5. No Corelation: When there is no proper pattern of increasing or

decreasing of the dependent variable with corresponding Credits - Wikipedia
Independent variable, it is known as “No Corelation”

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5. Pareto Chart
Tool 5 – Pareto Chart
Definition of Pareto Chart:
➢ A Pareto chart is a bar graph, in which, the lengths of the bars represent count/frequency , and are arranged with
longest bars on the left and the shortest to the right.
➢ A Pareto chart is utilised to visually depicts which situations are more significant.
➢ It was created by JM Joran based upon the 80:20 principle given by Vilfredo Pareto, who interpreted that 80% of
world’s wealth is lying with 20% of individuals. In same way, Juran developed the principle that 80% of the
problems are a result of 20% of Causes. Resource allocation for problem solving can be done accordingly.
➢ Causes which are resulting into 80% problems are “Vital Few” and rest comes under category of “Trivial Many”.

Use of Pareto Chart:

➢ Prioritization the key few problems on which resources should be allocated to gain maximum output.
➢ Quickly understand the Contribution of each individual cause of the problem.

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Tool 5 – Pareto Chart
Steps for preparing a Pareto Chart: Illustrations and Examples of Pareto Chart:

1. Decide what categories (causes) you will use to group items.

2. Collect the data, recording the category each time.
3. Subtotal the measurements for each category.
4. Determine the appropriate scale for the measurements you have collected. The
maximum value will be the largest subtotal from step 5. Mark the scale on the
left side of the chart.
5. Construct and label bars for each category. Place the tallest at the far left, then
the next tallest to its right, and so on. If there are many categories with small
measurements, they can be grouped as “other.”
6. Calculate the percentage for each category: the subtotal for that category
divided by the total for all categories. Draw a right vertical axis and label it with
percentages. Be sure the two scales match. For example, the left measurement
that corresponds to one-half should be exactly opposite 50% on the right scale.
7. Calculate and draw cumulative sums: add the subtotals for the first and second
categories, and place a dot above the second bar indicating that sum.
8. To that sum add the subtotal for the third category, and place a dot above the
third bar for that new sum. Continue the process for all the bars. Connect the
dots, starting at the top of the first bar. The last dot should reach 100% on the
right scale.

Credits - ASQ

Ankur Tyagi
6. Control Chart
Tool 6 – Control Chart
Definition of Control Chart:

➢ A control chart is a time series chart of a process characteristic which is used to understand if the process is in
state of control and stable over the time.
➢ A control chart always has a central line for the average (X Bar), an upper line for the upper control limit (UCL),
and a lower line for the lower control limit (LCL). These lines are determined from historical data.
➢ By comparing the current data with the Historical LCL/UCL, the conclusion can be drawn on stability of process.
➢ Control Chart can be plotted both for Variable data (X Bar, R Bar, S Bar, I-MR Charts) and Attribute data (p, np. C,
u charts).

Use of Control Chart:

➢ To understand if the process is in state of control and is stable.

➢ To identify if there are any special cause exist in the process.

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Tool 6 – Control Chart
Steps for preparing a Control Chart: Illustrations and Examples of Control Chart:

1. Choose the appropriate control chart for your data.

2. Determine the appropriate time period for collecting and plotting data.
X Bar
3. Collect data, construct your chart and analyse the data.
4. Look for "out-of-control signals" on the control chart. When one is identified, mark
it on the chart and investigate the cause. Document how you investigated, what
you learned, the cause and how it was corrected.
5. Continue to plot data as they are generated. As each new data point is plotted,
check for new out-of-control signals.
6. When you start a new control chart, the process may be out of control. If so, the
control limits calculated from the first 20 points are conditional limits. When you
have at least 20 sequential points from a period when the process is operating in
control, recalculate control limits.

Credits - ASQ

Ankur Tyagi
2. Ishikawa Diagram
Tool 7 – Ishikawa Diagram
Definition of Ishikawa Diagram:
➢ Ishikawa diagrams are structured diagrams which visually represents Cause and Effect relationship.
➢ This tool was popularized in the 1960s by the Japanese great, Kaoru Ishikawa.
➢ The fishbone diagram identifies many probable causes for an effect or problem. It can be used to structure a
brainstorming session and is also known as - Fishbone diagram, Herringbone diagram, Cause-and-Effect diagram.
➢ It immediately sorts ideas into useful categories – Man, Machine, Material, Method, Measurement, Mother Nature.
➢ It is called Fishbone because of its shape - The defect is shown as the fish's head, with the causes extending to the
left as fishbones; the ribs branch off the backbone for major causes, with sub-branches for root-causes.

Use of Ishikawa Diagram:

➢ To brainstorm and identify the possible causes of an effect or problem.

➢ To develop structured approach for root cause analysis, utilising the knowledge and experience of CFT.

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Tool 7 – Ishikawa Diagram
Steps for preparing a Ishikawa Diagram: Illustrations and Examples of Ishikawa Diagram:

1. Define the problem statement (effect). Write it at the centre right

of the flipchart or whiteboard. Draw a box around it and draw a
horizontal arrow running to it. This is like Mouth of a Fish. X Bar
2. Brainstorm the major categories of causes of the problem under
the generic 6M categories - Man, Machine, Method, Material,
Measurement and Mother Nature (Environment)
3. Write the categories of causes as branches from the main arrow.
4. Brainstorm all the possible causes of the problem. Ask “What
could be the reason of this problem?" As each idea is given, the
facilitator writes it as a branch from the appropriate category.
Causes can be written in several places if they relate to several
categories.
5. Continue to ask “What could be the reason of this problem?"
about each cause and generate deeper levels of causes. Layers
of branches indicate causal relationships.
6. When the group runs out of ideas, focus attention to places on
the chart where ideas are few.

Credits - ASQ

Ankur Tyagi