FISHBONE DIAGRAM

CHECK SHEET &

CHECK LISTS

FLOW CHART

THE 7 Quality Control

Tools for Process
Improvements

CONTROL &
RUN CHARTS
2

HISTOGRAM

SCATTER DIAGRAM

PARETO CHART

The
Basic
Seven
Quality
Control
tools

Known for Democratizing Statistics

Made statistical analysis less complicated
for the average person
Have good Visual Aids make statistical
and quality control more comprehendible.

Where did
the Basic Kaoru Ishikawa,a professor of
Seven
engineering at Tokyo University
come
and the father of quality circles.
from?

FLOW
CHART
A diagram that uses graphic symbols to depict the
nature
and flow of the steps in a process.

" Draw a flowchart for

whatever you do. Until
you do, you do not know
what you are doing, you
just have a job.
-- Dr. W. Edwards Deming

Promote
process
understanding

Benefits
of Using
Flowchart
s
7

Identify
problem areas
and
improvement
opportunities

Provide tool
for training

Symbols used in flow

charts

Start or stop
The beginning and the endpoints in the sequence

START/ STOP

PROCESS

Process

DECISON

Decision

INPUT/OUPUT

An istruction or a command
Its either yes or no

Input or output

An input is a data received, an output is a signal

or data sent

Connector
A jump from one point in the sequence to
another
Direction of flow
Connects the symbol, the arrow shows the
direction of flow of instructions.

THE
LEVELS
OF FLOW
CHART

MICRO LEVEL
It provides detailed
picture of the
process, taking in to
account each action.
MINI LEVEL
It falls between the
macro level and
more detailed micro
level flowchart
where it focuses on
one part of macfro
level flow chart
MACRO LEVEL
It represents a bog
picture of the process.
It generally has less
that six steps

KEY TO SUCCES

Start with the big picture

Observe the current
process
Record process step
Arrange the sequence
Draw the flowchart
10

 Determine who is involved

INTERPRETIN
G YOUR
FLOW CHART

Form theories about root cause

Identify ways to simplify and refine
Determine how to implement changes
Locate cost-added-only steps
Provide training

11

INTEPRETATION
STEPS
Bottlenecks?
Weak links?
Poorly defined
steps? Costadded-only
1.Examine
steps?
each process
step

12

2. Examine
each decision
symbol
Can this be
eliminated?

Can it be
shortened or
eliminated?
3. Examine
each rework
loop

4. Examine
each activity
symbol
Does the
step add
value for the
end-user?

CAUSE AND
EFFECT
DIAGRAM
.

A graphic tool that helps identify, sort and display

possible causes of a problem or quality
characteristics.

Helps determine root

causes

Benefits
of Using
Cause and
Effect
Diagram
14

Encourages group
participation
Uses an orderly, easy-toread format
Indicates possible causes of
variation
Increases process
knowledge
Identifies areas for
collecting data

Cause
Cause A
A

Cause
Cause B
B

Basic
Layout of
Cause and
Effect
Diagram

EFFECT
EFFECT

Cause
Cause C
C
15

Cause
Cause D
D

Fishbone
Diagram
Procedure

16

STEP 1: IDENTIFY
AND DEFINE THE
EFFECT

Decide on the effect to examine

Use operational definitions
Phase effect as
Positive (an objective) or
Negative (a problem)

Fishbone
Diagram
Procedure

STEP 2:

Fill in the Effect Box and Draw the

Spine

POOR GAS
MILEAGE

17

Fishbone
Diagram
Procedure

STEP 3:

METHODS

Fill in the Effect Box and Draw the

Spine

MACHINERY

POOR
GAS
MILEAGE

18

PEOPLE

MATERIALS

Fishbone
Diagram
Procedure

STEP 4:

METHODS

Identify causes influencing the effect

MACHINERY
Underrated tires
Use wrong gears

Drive too fast

Poor maintenance

Calibration
adjustments
Improper lubrication
Poor driving
habits

19

PEOPLE

MATERIALS

POOR
GAS
MILEAGE
Wrong octane gas

YES
YES

STEP 5:

Fishbone
Diagram
Procedure

METHODS

Analyze the diagram

MACHINERY
Underrated tires
Use wrong gears

Drive too fast

Poor maintenance

Calibration
adjustments
Improper lubrication
Poor driving
habits

20

PEOPLE

MATERIALS

POOR
GAS
MILEAGE
Wrong octane gas

YES
YES

STEP 5:

Fishbone
Diagram
Procedure

METHODS

Analyze the diagram

MACHINERY
Underrated tires
Use wrong gears

Drive too fast

Poor maintenance

Calibration
adjustments
Improper lubrication
Poor driving
habits

21

PEOPLE

MATERIALS

POOR
GAS
MILEAGE
Wrong octane gas

CHECK SHEET
.

A structured, prepared form for collecting and

analyzing data. This is a generic tool that can be
adapted for a wide variety of purposes

When data can be observed and collected repeatedly

by the same person or at the same location.

WHEN TO
USE A
CHECK
SHEET

23

When collecting data on the frequency or patterns of

events, problems, defects, defect location, defect
causes, etc.

When collecting data from a production process.

CHECK SHEET
PROCEDURE

24

Design the
form. Set it
up so that
data can be
recorded
Decide what
simply by
event or
Decide when
making
problem will data will be
check marks
be observed.
collected
or Xs or
Develop
and for how
similar
operational
long.
symbols and
definitions.
so that data
do not have
to be
recopied for
analysis.

Label all
spaces on
the form.

Test the
Each time
check sheet
the targeted
for a short
event or
trial period
problem
to be sure it
occurs,
collects the
record data
appropriate
on the check
data and is
sheet.
easy to use.

CHECK SHEET

25

The figure below shows a check sheet used to

collect data on telephone interruptions. The tick
marks were added as data was collected over
several weeks.

SCATTER
DIAGRAM
.

Used to study and identify the possible relationships between

the changes observed in two different sets of variables

When to
Use a
Scatter
Diagram

When you have

paired numerical
data.

When your
dependent
variable may
have multiple
values for each
value of your
independent
variable.

When trying to
determine
whether the two
variables are
related.

The relationship between two variables is called a

Correlation

Interpretin
g Scatter
Diagrams

A line of best-fit is a line which helps us to identify

the type of correlation (positive, negative, no
correlation) & make predictions
The line of best fit is drawn so that the points are
evenly distributed on either side of the line
The closer the dots to the line, the stronger the
correlation
1.
2.
3.

Remember:
The line of best fit is a STRAIGHT LINE
It DOES NOT have to pass through the
origin
It DOES NOT have to go through each point

Correlatio
n can be
STRONG
or WEAK

Strong Positive
Correlation

Weak Positive
Correlation

All the points lie

close to the line of
best fit

The points are well

spread out from the
line of best fit but still
follow the trend

PARETO CHART
.

Bar chart arrange in descending order from left to

right.
Bars on left relatively important than those on right
Separates the vital fiew from the trivial many

VILFREDO PARETO(1848-1923)
-Italian economist

PARETO
PRINCIPL
E

80/20 rule states that:

Approximately 80% of the
problems are created by
approximately 20% of the
causes
Adapted by Joseph Juran.

 When analysing data about the frequency

of problens or causes in a process

Why use
a Pareto
Chart

When there are many problems or causes

and you want to focus on the most
significant

When analysing broad causes by looking

at their specific components

When communicating with others about

your data

Step 1: Arranged
the values from
highest to lowest
and find the total
frequency.
Constructing
a Pareto
Chart
Step 3: Make a
pareto diagram
33

Step 2: Find the

percentage and
cumulative
percentage

PARETO
CHART

34

At Costco store #156 we are looking at the frequency

of identified problems that result in customers being
stopped, and delayed at the exit, due to discrepancies
between their receipt and what the checker verifies
as being in the basket. Six basic error categories have
been ..identified at this particular store by the team
responsible for working this.
MISTAKE TYPE

NUMBER OF OCCURENCES

Double Charge

157

Bottom of basket

210

Item not charged

330

Wrong item charged

102

Coupon Error

56

Item hidden

95

PARET
O
CHART

35

HISTOGRAM
.

A bar graph that shows the distribution of data.

A snapshot of data taken from a process

Summarize large
data sets
graphically

Assist in decision
making

Compare
WHEN ARE
measurements to
HISTOGRAMS specifications
USED
Communicate
information to the
team

Step 1

Use thehistogram worksheetto set up the

histogram.

Step 3
Draw x- and y-axes on graph paper.
Mark and label the y-axis for counting
data values.

HOW TO
CONSTRUC
TA
HISTOGRA
M

Step
2

Collect at least 50 consecutive data points

from a process

Step 4

For each data point, mark off one count above

the appropriate bar with an X or by shading
that portion of the bar.

Chart Title
4.3

Interpretin
g
Histograms

2.4

Chart Title
4.3

2.4

3
2

Most of the
data were on
the target
with a very
little
variation
from it
Although some
data were on
target many
others were
dispersed away
from the target

Chart Title
4.3
2

Interpretin
g
Histograms

2.4

Chart Title

The data were

off target and
widely
dispersed

4.3

2.4

Even when most

of the data were
close together,
they were
located of the
target by a
significant
amount

3
2

Typical Histogram
Shapes and What
They Mean

Typical Histogram
Shapes and What
They Mean

CONTROL
CHARTS

.A statistical tool used to distinguish between process

variation resulting from common causes and
variation resulting from special causes.

Control charts
are designed
to prevent two
common
mistakes:

44

1) adjusting the process when it should be

left alone; and
2) ignoring the process when it may need to
be adjusted.

ELEMENTS
OF A
CONTROL
CHART

A control chart begins with

a time series graph.

A central line (X) is added

as a visual reference for
detecting shifts or trends
this is also referred to as
the process location

Upper and lower control

limits (UCL and LCL) are
computed from available
data and placed equidistant
from the central line. This is
also referred to as process
dispersion.

Control limits (CLs) ensure time is not wasted looking for

unnecessary trouble the goal of any process improvement
practitioner should be to only take action when warranted.
Control limits are calculated by:
1.Estimating thestandard deviation of the sample data
2.Multiplying that number by three
3.Adding (3 x ? to the average) for the UCL and subtracting (3
x ? from the average) for the LCL
Mathematically, the calculation of contorl limits looks like:

46

CONTROL
CHART
TYPES

47

Control
charts for
variables
data

Control
charts for
attributes
data

REFERENCE
S

48

THANK YOU FOR BEING

ATTENTIVE

CAMPANG, KAYSE E
DIEGO, MARA J.
MARIANO, MAELEN T.

49