7 TOOLS QUALITY

BASIC
 Where did the Basic Se7en
comes from?
“KAORU ISHIKAWA”

• Known for “Democratizing Statistic”

• Good Visual Aids make statistical and quality control more

comprehendible (most important).

• The Basic Se7en Tools made statistical analysis less complicated

for the average person
1. FLOWCHART
 What is a Flowchart?

A diagram that uses graphic symbols to

depict the nature and flow of the steps in a
process.
 BENEFITS OF USING FLOWCHART

01 02 03
Promote Process Tool For Training Identify Problem
Understanding
Because of the way they Problem areas
Explaining the steps visually lay out the become more visible. It is
pictorially. People may sequence of process easy to spot opportunities
have differing ideas about steps, Flowcharts can be for simplifying your
how a process works. A very helpful in training process by analyzing
Flowchart can help you employees to perform the decision points,
gain agreement about the process according to redundant steps, and
sequence of steps standardized procedures. rework loops.

“Draw a flowchart for whatever you do. Until you do, you do not know what you are
doing, you only just have a job.”

-- Dr. W. Edwards Deming

 1 • Start with the big picture
Understanding process at broad level rather than
focusing on finite detail.

2 • Observe the new/current process

A good way to start Flowcharting a process is to walk
through the new or current process, observing it in
actual operation.
Keys to 3 • Record process steps
Success Gather necessary information from the process (voice
of process).

4 • Arrange the sequence of steps

Map the process and arrange exactly as you
observed the steps.

5 • Draw the process

Draw process diagram or workflow as you observed,
recorded, and arranged the sequence of steps
 Examine Each Examine Each
Decision Activity
Symbol Symbol
Can this step be Does the step help
eliminated? Or is build a key quality
there any other characteristic into
option? the end product?

Interpretation
Steps 1 2 3 4
Examine Each Examine Each
Process Step Rework Loop
Bottlenecks? Weak Can it be shortened
links? Poorly defined or eliminated?
steps? Cost-added-
only steps?
Flowchart Mulai

(example)
1
Perubahan atau
Kondisi Abnormal

2
Informasikan ke
Dept. Quality

3
Verifikasi Proses
“Management of dan Produk
4
Change” Lakukan
Perbaikan

Verifikasi NG
Produk?

OK

Informasi
ke
Pelanggan?

Ya Tidak

5 7
Berkoordinasi Lanjutkan Proses
dengan Pelanggan Produksi Massal

6
Tahapan Kontrol
Pengajuan Proses
Perubahan

Selesai
PROS

Provide Visual
Clarity Provide Better
Analysis
The biggest and most
important benefits of With the help of
flowchart is that they Solve Problem flowchart you and your
give you ability to team can better analyze Improve
clearly visualize a every problem or Communication
A Flowchart will split
process and its every process.
bigger problem into
steps. smaller, easily Because a flowchart
understandable step splits everything in
and parts. And if think clear and easy to follow
about it, it makes total steps, everyone will be
sense. able to understand it.
CONS
It’s Harder to
Make Edit
That’s because every time you
have to make edit to a step, you
might have to go back to the
pervious one and maybe redraw
the entire flowchart.
It Can be Quite
Complex
When a process is more complex,
you risk the flowchart to become
messy and overcomplicated.
When this happens, management
and other members might have
harder time to understanding th e
process.
Reproduction
Might be Hassle
It cannot be typed out. You have
to use programs such as Microsoft
office that allows you to insert
shapes, lines, and colors. This
means that initial flowchart can’t
be reproduced by other.
2. CHECKSHEET
 What is a Check sheet?

Check Sheet is a form (document) used to

collect data in real time at the location
where the data is generated. The data it
captures can be quantitative or qualitative.
 WHAT IS A CHECKSHEET?

01 02 03
Data Collection Data Event Record Data Support

Check sheets are Check sheets are Check sheets can be

data collection designed to answer used either to support
the question How conclusions concerning
forms constructed to
a process on its own or
record specific often does this may be a step in the
information about a event occur and process of assembling
process in a under what the data to support
organized manner. conditions? one of the other
improvement tools
CHECKSHEET KEY POINT
Simple
Keep the form simple to use and
easy to understand; (the easier
you make the sheet to use, the
more likely you will get the data
you need)
Informative
Include only information that you
intend to use. Seek for
improvement.
Effective
Pilot or test the Check Sheet form
before you use it on a full-scale
basis – Make changes to it if
necessary
3. PARETO CHART
 Pareto Principle

• Vilfredo Pareto (1848-1923) – Italian economist

- 20% of the population has 80% of wealth.

• Adapted by Joseph Juran

Remember the 80/20 rules state that
Approximately 80% of the problem are created
by approximately 20% of the causes.
 What is Pareto Chart?

• A bar chart arranged in descending order of

height from left to right

• Bars on left relatively more important than

those on right

• Seperates the “vital view” from the “trivial

many” (Pareto Principle)
 Why use is Pareto Chart?

• Breaks big problem into smaller pieces

• Identifies most significant factors
• Shows where to focus efforts
• Allows better use of limited resources
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PROS

Improvement Decision
Effectiveness Making
Helps and provides a Identify which
better explanation adjustments influence
regarding defects that the greatest positive
are needed to resolved outcome.
first. One can also Solve Problem Documentation helps in
decide and plan about preparing for any Improve Skill
correct and important Helps in solving issues additional changes.
measures or actions for regarding problem- With help of Pareto
improvement solving and decision chart, skills of
effectively. making, time individuals are also
management i.e. be at increased in better
work on time or ways like problem-
personal, change solving skills, decision-
management, etc. making skills, etc.
CONS

Limited features Limited data

for root-cause
One of main disadvantages is that
root cause analysis cannot be done
by itself in Pareto analysis. There is
a requirement of tool i.e. root
cause analysis tool for determining
or identify root causes or major
causes of defect.
representative
It does not represent severity of
defect or any problem. It only
shows qualitative data.
.
Past Data
Pareto analysis only focuses on
past data where damaged has
already happened.
4. CAUSE-EFFECT
DIAGRAM
 What is cause and effect
diagram?

A graphic tool that helps to identify, sort,

and display possible causes of a problem or
quality characteristic.
 Benefits of Using a Cause-Effect
Diagram

• Helps determine root causes

• Encourages group participation
• Uses an orderly, easy-to-read format
• Indicates possible causes of variation
• Increases process knowledge
• Identifies areas for collecting data
 CAUSE-EFFECT or FISHBONE
Environment Machine Man
Lack of Personnel not
Poor lighting Lack of regular trained properly
supervision
maintenance
Poor working Training record not
area layout Old Machinery completed/updated
Lack of
Concentration Trainer not
Messy available
Spare part
work area Full Exhausted
not available Interpersonal
Inadequete Storage Issue
workspace Spare part used
not standard
High
Reject
Rate
Lack of control Supplied material
below standard
WI/SOP Outdated
SOP Unclear
Worn-out
material

Inappropriate
Storage

Methode Material
5. CONTROL CHART
 What is a Control Chart?

A statistical tool to distinguish between

process variation resulting from common
causes and variation resulting from special
causes.
 Why use Control Chart?

• Monitor process variation over time.

• Differentiate between special cause and
common cause variation.
• Assess effectiveness of changes.
• Communicate process performance.
6. HISTOGRAM
 What is Histogram?

• A bar graph that shows distribution of data

• A snapshot of data taken from a process
 When a Histogram used?

• Summarize large data sets graphically

• Compare measurements to specifications
• Communicate information to the team
• Assist in decision making
7. SCATTER
DIAGRAM
 What is a Scatter Diagram?

Is a tool for analyzing relationships between

two variables for determining how closely
the two variables are related.
 Where could we use Scatter
Diagram?

• Used during analysis phase to understand the

behavior of a process and how pair of variable
change to relative to one another (correlation).
• Used to provide an input to cause and effect
analysis.
• To find out how much the behavior of the process
has changed after improvement.
Scatter Diagram – What is it for?

• To understand the behaviour of a process

• To determine if there is a relationship between two
factors
• To visually demonstrate the correlation between two
related factors.
• To determine where there may be cause and effect
relationship.
Scatter Diagram – How do we
use it?
 “Measurement is the first step that leads to
control and eventually to improvement. If you
can’t measure something, you can’t
understand it. If you can’t understand it, you
can’t control it. If you can’t control it, you
can’t improve it.”

- H. James Harrington -
THANK YOU