Seven Quality Tools

Seven Quality Tools

• The Seven Tools

– Histograms, Pareto Charts, Cause and Effect
Diagrams, Run Charts, Scatter Diagrams,
Stratification, Control Charts
 Histogram

• Histogram Defined
– A histogram is a bar graph that shows
frequency data.
– Histograms provide the easiest way to evaluate
the distribution of data.
 Histogram (2)

• Creating a Histogram
– Collect data and sort it into categories.
– Then label the data as the independent set or the
dependent set.
• The characteristic you grouped the data by would be the
independent variable.
• The frequency of that set would be the dependent variable.
– Each mark on either axis should be in equal increments.
– For each category, find the related frequency and make
the horizontal marks to show that frequency.
 Histogram (3)
• Examples of How Histograms Can Be Used
– Histograms can be used to determine
distribution of sales.
– Say for instance a company wanted to measure
the revenues of other companies and wanted
to compare numbers.
Contoh Pembuatan Histogram
Contoh Pembuatan Histogram
Contoh Pembuatan Histogram
Lembar Data Histogram
Histogram
Histogram Dan Spesifikasi
Stratifikasi Histogram
Stratifikasi
Cara Stratifikasi dan Analisisnya
Contoh Stratifikasi
Contoh Stratifikasi
Data Sheet
Data Sheet
Contoh 1: Kompetensi karyawan
Contoh Data Sheet
Contoh 2: Temperatur ruangan
Contoh Data Sheet
Contoh 3: Cacat fuel tank
Contoh Data Sheet
 Pareto Chart
• Pareto Chart Defined
– Pareto charts are used to identify and prioritize
problems to be solved.
– They are actually histograms aided by the 80/20 rule
adapted by Joseph Juran.
• Remember the 80/20 rule states that approximately 80% of
the problems are created by approximately 20% of the causes.
 Pareto Chart (2)
• Constructing a Pareto Chart
– First, information must be selected based on
types or classifications of defects that occur as
a result of a process.
– The data must be collected and classified into
categories.
– Then a histogram or frequency chart is
constructed showing the number of
occurrences.
 Example of Pareto Chart
• An Example of How a Pareto Chart Can Be Used
– Pareto Charts are used when products are suffering from different
defects but the defects are occurring at a different frequency, or
only a few account for most of the defects present, or different
defects incur different costs. What we see from that is a product
line may experience a range of defects. The manufacturer could
concentrate on reducing the defects which make up a bigger
percentage of all the defects or focus on eliminating the defect
that causes monetary loss.
Example of Pareto Chart
 Cause and Effect Diagram
• Cause and Effect Diagram Defined
– The cause and effect diagram is also called the Ishikawa diagram
or the fishbone diagram.
– It is a tool for discovering all the possible causes for a particular
effect.
– The major purpose of this diagram is to act as a first step in
problem solving by creating a list of possible causes.
 Cause and Effect Diagram
• Constructing a Cause and Effect Diagram
– First, clearly identify and define the problem or effect for which
the causes must be identified. Place the problem or effect at the
right or the head of the diagram.
– Identify all the broad areas of the problem.
– Write in all the detailed possible causes in each of the broad
areas.
– Each cause identified should be looked upon for further more
specific causes.
– View the diagram and evaluate the main causes.
– Set goals and take action on the main causes.
Example of CEDAC
 Scatter Diagrams
• Scatter Diagrams Defined
– Scatter Diagrams are used to study and identify
the possible relationship between the changes
observed in two different sets of variables.
 Scatter Diagrams
• Constructing a Scatter Diagram
– First, collect two pieces of data and create a summary
table of the data.
– Draw a diagram labeling the horizontal and vertical
axes.
• It is common that the “cause” variable be labeled on the X axis and
the “effect” variable be labeled on the Y axis.
– Plot the data pairs on the diagram.
– Interpret the scatter diagram for direction and
strength.
 Scatter Diagram

• An Example of When a Scatter Diagram Can Be

Used
– A scatter diagram can be used to identify the
relationship between the production speed of an
operation and the number of defective parts made.
– Displaying the direction of the relationship will
determine whether increasing the assembly line speed
will increase or decrease the number of defective parts
made. Also, the strength of the relationship between
the assembly line speed and the number of defective
parts produced is determined.
 Run Chart
• Run Charts Defined
– Run charts are used to analyze processes
according to time or order.
 Run Chart
• Creating a Run Chart
– Gathering Data
• Some type of process or operation must be available to take
measurements for analysis.
– Organizing Data
• Data must be divided into two sets of values X and Y. X values represent
time and values of Y represent the measurements taken from the
manufacturing process or operation.
– Charting Data
• Plot the Y values versus the X values.
– Interpreting Data
• Interpret the data and draw any conclusions that will be beneficial to the
process or operation.
 Run Chart

• An Example of Using a Run Chart

– An organization’s desire is to have their product arrive
to their customers on time, but they have noticed that
it doesn’t take the same amount of time each day of
the week. They decided to monitor the amount of
time it takes to deliver their product over the next few
weeks.
 Control Chart

• Control Charts Defined

– Control charts are used to determine whether
a process will produce a product or service
with consistent measurable properties.
 Control Chart (2)

• Steps Used in Developing Process Control Charts

– Identify critical operations in the process where
inspection might be needed.
– Identify critical product characteristics.
– Determine whether the critical product characteristic is
a variable or an attribute.
– Select the appropriate process control chart.
– Establish the control limits and use the chart to
monitor and improve.
– Update the limits.
 Example

• An Example of When to Use a Control Chart

– Counting the number of defective products or
services
• Do you count the number of defects in a given
product or service?
• Is the number of units checked or tested constant?
Case Study: Restaurant for bussines travelers
A restaurant caters to business
travelers and has a self service
buffet

Restaurant or Cafetaria beside the

highway…..
 Case Study

Some foods are prepared in the buffet

 Case Study

A restaurant caters to business travelers and has a

self service buffet. Interested in customer
satisfaction, the manager construct a survey,
distributes it to customer over a three-month period,
and summarizes the result in a Pareto chart (see
Figure 4-17). The Pareto chart indicates that the
restaurant’s major problem is that customers have to
wait too long to be seated. A team of employees is
formed to work on this problem.
 Pareto Chart
• A Room to drafty
• B Table not clean
• C No dietetic sweetener provided
70
• D Had to wait for seats
60 • E Buffet table not well organized
• F Missing utensils at place setting
50
• G No ashtray on table
40 • H Had to wait long time for coffee
D
30 E

20 B

10 A
H
F C G
 Step 1. Define the project
With the survey as the background, his team undertakes the
first step. The problem is that customer wait too long to be
seated. They should not have to wait at all. The problem is
important because customers have complained, and this is
supported by the Pareto chart constructed from the survey
data. Most of the customers are business travelers who want
either a speedy breakfast or a chance to conduct business
during breakfast.
 Step 1. Define the project
Decreasing the wait to be seated will increase the restaurant’s
ability to respond to these key quality characteristics progress
can be measured by the percent of customers each day who
have to wait in excess of, say, one minute to be seated. The team
develops an operational definition of “waiting to be seated” to
answer such questions as : When does the wait start? When
does it end? How is it measured?
Restaurant floor
 It’s time for discussion
Work in group and try to explain the next
step to solve the problem!
Step 2. Study the current situation

The team collects baseline data and plots it (see

Figure 4-18). At the same time, the team develops a
flowchart of seating a party. The team members feel
that a floor diagram might be helpful, so they
produce one (see Figure 4-19). The variables they
identify as potentially affecting the problem are the
day of the week, size of the party, reason for waiting,
and time of the morning. Data relating to these
variables are collected.
Run Chart of Current Situation
 Analysis current situation
From the baseline data, the team learns that the percent of people
served who have to wait is higher early in the week and decreases
during the week, with only a small percent waiting on the
weekends. This is reasonable, since the restaurant‘s clientele
primarily consists of business travelers. The size of the party does
not appear to be factor, because parties of all sizes wait in
approximately the same proportions
 Analysis current situation
A histogram of the number of people waiting by the time of the
morning reveals nothing surprising : more people wait during the
busy hours than during the slow hours (see Figure 4-20). The
reason for waiting , however , is interesting. Most people wait
because a table is not available or because they have seating
preference (as opposed to be hostess not being around to seat
customers waiting for friends to join them)
Histogram
At this point, it would be easy for
the team to jump to the solution
of putting more staff on early in
the week and during busy hours in
the morning-but analyzing causes
is not done until the next step.
 Need of additional information
The team decides additional information is needed on why tables
are not available and how seating preferences affect waiting. After
data are collected, it learns that tables are generally unavailable
because they are not cleared (as opposed to being occupied) and
that most of the people who have a seating preference wait for a
table in the nonsmoking area.
 Step 4.Analyze the potential causes
A cause-and –effect diagram is constructed showing why
tables are not cleared quickly, with particular emphasis
on identifying root causes (see Figure 4-21). This diagram,
together with rest of the data the team has gathered,
leads the team to conclude that the most likely cause is
the distance from the tables to the kitchen, particularly in
the nonsmoking area.
CEDAC
 Step 4. Implement solution
The team develops a possible solution. Since the team
has not been able to verify the cause by controlling
the variables, it chooses a solution that can be easily
tested: set up temporary workstations in the
nonsmoking area. No other changes are made. The
team continues to collect data on the percent of
people waiting for longer than one minute to be
seated.
 Step 5. Check the result

After a month, the team analyzes the data

collected in step four. As Figure 4-22 shows,
the improvement is dramatic.
Step 6. Standardized the improvement

The temporary workstations are replaced with

permanent ones
 Step 7. Establish future plans
The team decides that the next highest bar in the pareto
chart of customer complaints-the buffet table being not
well organized-should be addressed.
 It is time for homework

• Silakan ambil contoh salah satu aktivitas yang

anda laksanakan pada kurun waktu ......
September – ....... Oktober 20...... Selanjutnya
anda diminta untuk melakukan deskripsi
tentang aktivitas tersebut serta kriteria kualitas
yang menyertainya.
• Lakukan perbaikan kualitas aktivitas yang
mungkin dapat dilaksanakan.
• Tuliskan hasil anda tersebut pada kertas A4
maksimal 2 halaman, 1 spasi dan dikumpulkan
saat kuliah Manjemen Mutu Industri tanggal .....
Oktober 20.......