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7 Tools of Quality & Problem Solving: by MQS Office
7 Tools of Quality & Problem Solving: by MQS Office
&
PROBLEM SOLVING
By
MQS Office
AUTOMOTIVE SECTOR
Mahindra Quality System (A. S.)
Whose perspective should we look at?
products
processes
results
outcomes
benefits
Lens of customer
2. Intermediate customers
E.g. Retailer, Distributor, OEM
- Kaoru Ishikawa
The 7 QC Tools;
Flow chart
Check sheet
Q
Histogram
Pareto Diagram
Scatter diagram
The 7 QC Tools;
Check sheet
Histogram
Pareto Diagram
Scatter diagram
Control charts
Operation
Inspection
Transportation
Delay
Storage
Manufacturing
Accounting
Services
Restaurants
Real estate
The 7 QC Tools;
CHECK SHEET
Flow chart
Check sheet
Histogram
Pareto Diagram
Scatter diagram
Control charts
The 7 QC Tools;
HISTOGRAM
Flow chart
Check sheet
Histogram
Pareto Diagram
Scatter diagram
Control charts
What is a Histogram ?
TITLE: __________________________
‘X’ Axis
Constructing a Histogram
Constructing a Histogram
A B
Target Target
C D
Target Target
Mahindra Quality System (A. S.) 28
AUTOMOTIVE SECTOR
INTERPRETING HISTOGRAM
Benefits of Histogram
Histogram of C1
10
8
Frequency
0
12 14 16 18 20 22
C1
Descriptive Statistics: C1
Bin Frequency
Histogram 0 0
11.5 1
20 13 0
16
15 14.5 3
Frequency
12
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
The 7 QC Tools;
Flow chart
PARETO DIAGRAM
Check sheet 1
Histogram 2
Pareto Diagram 3
Scatter diagram
Control charts
2
Step 3: Label the vertical axis
3
Step 4: Label the Horizontal axis 4
2
Step 8: Add title, Legend and Date
3
Step 9: Analyze the Diagram 4
99% 100%
96% 100%
400 92%
90%
350
80%
74%
300 70%
ACCIDENT IN NO.
250 60%
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
300
Percent
60
200
40
100 20
0 0
Department r
-1 -2 -1 -2 IO
N
the
E E S S T O
A NC ANC IO
N
IO
N
RA
T T T
T EN T EN R A RA NIS
I
AI
N
AI
N EA EA M
M M OP OP AD
Count 128 102 82 76 20 16
Percent 30.2 24.1 19.3 17.9 4.7 3.8
Cum % 30.2 54.2 73.6 91.5 96.2 100.0
The 7 QC Tools;
Flow chart
CAUSE & EFFECT DIAGRAM
Check sheet
Histogram
Pareto Diagram
Scatter diagram
Control charts
Quality characteristic.
Negative (a problem)
POOR
MILEAGE -
5 KMPL
METHOD MACHINE
POOR
MILEAGE -
5 KMPL
PEOPLE MATERIAL
Use wrong
gears Under inflated
tyres
Rash Carburetor
Driving adjustment
POOR
MILEAGE -
Poor 5 KMPL
Improper
maintenance
lubrication
Poor Wrong
Driving habits fuel
PEOPLE MATERIAL
POOR
MILEAGE -
5 KMPL
PEOPLE MATERIAL
The 7 QC Tools;
SCATTER DIAGRAM
Flow chart
Check sheet
Histogram
Pareto Diagram
Scatter diagram
Control charts
To confirm a Hypothesis.
Line of Best Fit - Y Intercept Point at which line of best fit crosses Y axis
Moderate correlation
Weak correlation
(Tan 45 degree = 1)
The 7 QC Tools;
Check sheet
UCL
Histogram
X
Pareto Diagram
LCL
Cause & Effect
Scatter diagram
Control charts
UCL
LCL
The 7 QC Tools;
STRATIFICATION
Stratification
60
Parameter Y
50
Brain storming
40
30
20
10
1 2 3 4 5 6 7 8 9 10 11
Parameter X
What is Stratification ?
to be treated separately.
process.
Example:
Prevention cost
Appraisal cost
to 5 %
LCL
Benefits of Stratification
UCL
1 2 3 X
LCL
The 7 QC Tools;
GRAPHS & CHARTS
Stratification
Brain storming
1. Bar graph
2. Line graph
The 7 QC Tools;
BRAINSTORMING
Stratification
Brain storming
What is Brainstorming?
or solutions.
Benefits of Brainstorming
Creativity
Ground Rules
No discussion / No debate
Brainstorming sequence
80 • • 100%
PROCESS •
STEPS 60 • 75%
•
40 50%
DECISION
20 25%
A B C D E Other Check Sheet
STOP
Pareto Chart
Flow
Chart
IS IS NOT
WHAT?
Histogram
WHO?
WHERE?
WHEN?
HOW MUCH?
Capability Study
Is/Is Not Analysis Control Chart
Measurement
direction. work on a system based on basic guides of
Category
Surveys are used when a project to document
Brainstorming
wayisto give everyone a Probletunity.
The Nominal Group Technique [NGT] provides a
in the group an equal voice in understanding. There are no gray areas.
Average
*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.
Measurement
specific so that
Category
effective Example: Average
organization-wide “What would be the perfect
understanding and learning environment?”
Team Problem
Solving Process 3. Acquire and Analyse Data
7. Verify the Results
Draw Establish
Conclusions the Focus
Examine
the Current
DEFINE Situation
Standardise
the CONTROL MEASURE
Changes
Analyze
Act Plan the
ANALYZE Causes
Study
(Check) Do
IMPROVE
Study Act on
the the Causes
QC STORY
Results
DMAIC
PDSA/PDCA
The tools listed above are ideally utilized in reducing the process
Analysis
Improvement
Monitoring
Implementation