TOTAL QUALITY MANAGEMENT

AWARENESS SESSION ON

SEVEN BASIC QUALITY TOOLS

Presented by -
Aditya vatsyayan
 AGENDA
• HISTORY OF 7QC TOOLS
• WHAT IS PROBLEM SOLVING
• PROBLEM SOLVING METHODOLOGY
• WHY TO USE 7 QC TOOLS FOR PROCESS IMPROVEMENTS
• WHAT IS THE USE OF 7QC TOOLS
• 7 QC TOOLS / PROBLEM SOLVING METHODOLOGY

1. CHECKSHEET
2. CAUSE AND EFFECT DIAGRAM (FISHBONE OR ISHIKAWA)
3. HISTOGRAM
4. PARETO DIAGRAM
5. SCATTER DIAGRAM
6. CONTROL CHART
7. FLOW CHARTS
 INTRODUCTION
7 QC Tools for Process Improvement are systematic and scientific
methods for problem solving and they are used for product and
process Improvement.
It is used to solve 90% of shop floor problems very easily and It
improves our workplace

From Where Did The 7QC Tools Come -

Primarily Kaoru Ishikawa Introduced the 7QC tools.
Ishikawa has known for the “Democratizing (Visual Aids /
Symbols) Statistics”
Good Visual Aids make statistical and quality control more
comprehensive
Dr. Kaoru Ishikawa was the professor at the Engineering College of
Tokyo University.
WHAT IS A PROBLEM
An Event where requirements (Customer / Internal) are not being met
“An Unforseen Event”
 WHAT IS THE CAUSE
ROOT CAUSE - Verified reason that accounts for the described Problem.
“cause which when eliminated, will prevent the re-occurance of the
problem”
 WHAT IS PROBLEM SOLVING
PROBLEM SOLVING - Elimination of the cause of a non confirmity,
Potential non confirmityor other undesirable condition in order to prevent
its occurance or re-currence
 TYPES OF CAUSES
COMMON CAUSE -
Variability inherent in the system
Typical Examples are Machine variation,
Material variation, Environment Variation.

SPECIAL CAUSE -
Veriability is not inherent in the System. A
Root Cause can be Determined and
Eliminated
Typical Examples are - operator
improperly set-up machine, Tool Worn out
 PROBLEMS
ACUTE PROBLEM -
•Problem may never have occured in the Past.
•Immediate action is required to solve the
problem

CHRONIC PROBLEM -
•Problem may not need immediate attention,
But happens often.
•Immediate action may not necessarily
required to solve the problem.
•Proble solving may be preventative or
improvement based.
 PROBLEM STATEMENT
Write the Statement Using the following SMART Rules
Specific
Measurable
Achievable
Realistic
Time Based
 7 Basic Quality Tools / Problem Solving Tools

1. Checksheet
2. Casue and Effect Diagram
3. Pareto Diagram
4. Control chart
5. Scatter Diagram
6. Histogram
7. Stratification
 1. CHECKSHEET -

What is a Checksheet ?
It is a systematic method of collecting , recording and presenting the relevent
data in a simple manner for analysis of the process.
It is also known a a “Tallys Sheet”
It can Collect Qualitative and Quantitative data also.

What is a Checksheet Used For ?

Data collection
Monitoring the manufacturing process performance.
It is also used for traceability purpose.
 1. CHECKSHEET -
5 Basic Types of Checksheets -
Dr. Kaoru Ishikawa identified Five different types of Checksheets -

i.Process Performance
ii.Defect Item
iii.Defect Location
iv.Task Conformation (Related to Traceability) etc...
v.Defect Cause
How Do I Make A Checksheet -

Five Easy Steps to Develop a checksheet -

i. Establish what information is needed

ii.Determine 5W and 2H
iii.Construction
iv.Testing
v.Take the final approval for use.
 Steps to Develop a Checksheet -

Step 1 - Establish What Information is needed

•Define what information is needed
•Sometimes this is known as record form, data form, etc...

Step 2 - Determine 5W and 2H

• What is the data needed?
•What type of data collection is required?
•Where the data should be collected from?
•Who has to collect the data?
•Frequency of data collection?
•Method of data measurement?
•How much data is esssential?
 Steps to Develop a Checksheet -
Step 3 - Construction of the sheet -
Checksheet has three Types of Information -
A.Title
B.Source Information
i.Name of the project
ii.Location of Data Collection
iii.
Date / Time
iv.Name of the person recording data.
C. Content information
Design the form. Set it up so that data can be recorded simply by making check marks or similar symbolsso that data donot have to be recopied for analysis.

Step 4 - Testing
Test the checksheet for a short interval of time so as to be sure it collects appropriate data and is easy to use.

Step 5 - Final Approval for Use

Standardize its use to assure consistency
Examples - Checksheet (Simple Tool)
 1. CAUSE AND EFFECT DIAGRAM

What is the Cause and Effect Diagram ?

It is a respresentation that represents the meaningful relationship between an effect and its
causes.
It is a very good tool for root cause analysis
Dr. Kaoru Ishikawa developed it in 1943 while consulting for Kawasaki SteelWorks
It is also know as Fishbone Diagram because it looks like a bone of a fish

When We can Use the Fishbone Diagram?

When identifying possible causes for an issue (trouble)
To identify all of the contributing root causes likely to be causing an issue.
Especially when the Team thinking tends to fall into ruts
 This tool is very helpful during Six Sigma Project.
 2. CAUSE AND EFFECT DIAGRAM

What is a Fishbone Diagram Used For ?

It is used for root Cause Analysis
Braistorming
To check the relation between cause and effect

How to make Fishbone Diagram?

Step 1 - State the undesirable effect or Problem
 First of all we will mention the undesirable effect or problemand draw the
backbone and a line
Then define a problem statement (effect)
Write it at the centre-right of the chart
 2. CAUSE AND EFFECT DIAGRAM
How to make Fishbone Diagram?
Step 1 - State the undesirable effect or Problem
 First of all we will mention the undesirable effect or problemand draw the
backbone and a line
Then define a problem statement (effect)
Write it at the centre-right of the chart
 2. CAUSE AND EFFECT DIAGRAM

How to make Fishbone Diagram?

Step 2 - Identify the Main Cause group
In this we will brainstorm the major categories of causes that are related to the problem.
For the Manufacturing industry it is 6'M'

i.Man
ii.Machine
iii.Material
iv.Method
v.Measurement
vi.Mother Nature / Environment
 2. CAUSE AND EFFECT DIAGRAM

How to make Fishbone Diagram?

Step 3 - Arrange Causes and Sub-causes as relevant
Write the categories of causes as branches from the main arrow
Brainstorm all the possible origins of the problem
Ask : “Why does this Happen?” As each idea is given, the facilitatorwrites it as a branch from
the appropriate category.

Study all probable causes which are related to poor mileage of the car.
•Carburator Adjustment
•Underinflated tire
•Poor driving Habbit
•Improper Lubrication
•Gear shifting is not in sequence
•wrong fuel mixture
 2. CAUSE AND EFFECT DIAGRAM

How to make Fishbone Diagram?

Step 4 - Identify Potential Root cause(s)
Again ask “why does this happen?” about each cause. Write sub-causes branching off the
causes. Continue to ask “Why?” and generate deeper levels of causes. Layers of
branches indicate causal relationships.
After validation of all probable causes we will get the actual reason contributing to the
problem.
 2. CAUSE AND EFFECT DIAGRAM

Benefits of Cause and Effect Diagram -

1. Helps to determine the root cause.
2. Increase Process knowledge
3. Encourage group participation
4. A good tool for Brainstorming
5. Identifies areas for collecting data.
 TOOL 3 - HISTOGRAM
What is a Histogram Graph ?
It is a type of bar chart representing frequency distribution of data from a process.
Only one parameter can be used for cosntructing this chart
The parameter must be a variable data
This tool is used in the DMAIC methodology

What is a Histogram used for ?

It is used for showing large data set graphically
Problem forecasting
study the variation in on-going process

Key concept of Histogram -

Data always have a variation
variation has a pattern
patterns can be seen easily when summarised pictorially.
TOOL 3 - HISTOGRAM
How to make Histogram ?
Total Seven steps are followed for making
the Histogram
1.Data collection
2.Compute the Range
3.Determine the number of intervals
4.Determine the interval width
5.summarize the record
6.contruct the graph
7.Analyze the chart Pattern
TOOL 3 - HISTOGRAM
Analyze the Graph -
Interpritation of the graph -
1.Central tendency
2.Process Variation
3.Histogram shape
4.Process Capability (comparison with the specification)
TOOL 4 - RUN CHART / RUN CHARTS
What is a Control Chart ?
It is a statistical tool used to differentiate between process variation resulting from a common cause and special cause.
It is used to study the variation over the time.
Control charts measures variation and shows it graphically and hence it is easy to decide whether the process is in acceptable limits
or not.

Use of Control Charts -

•It is used to predict the performance of the manufacturing process
•Find out Special causes within the process
•Identify the trend of the process
TOOL 4 - RUN CHART / RUN CHARTS
Excersise -
Ramayana, (Sanskrit: “Rama’s Journey”) shorter of the two great epic poems of India, the other being the
Mahaharata (“Great Epic of the Bharata Dynasty”). The Ramayna was composed in Sanskrit, probably not
before 300 bce, by the poet Valmiki and in its present form consists of some 24,000 couplets divided into
seven books.
Rama is the hero of the Ramayna epic, an incarnation of the God Vishn. The eldest and favourite son of
Dasatha, King of Ayohya, he is a virtuous prince and is much loved by the peopl.
Sita is Rma's wife and daughter of King Janaka of Mithila. Sta is the epitome of womanly purity and virtue.
Lakshman is Rma's younger brother. Completely loyal to Rama, he chooses to go with Rama and Sta
when they are exiled from Ayodhya.
TOOL 4 - RUN CHART / RUN CHARTS
Excersise -
Ramayana, (Sanskrit: “Rama’s Journey”) shorter of the two great epic poems of India, the other being the
Mahaharata (“Great Epic of the Bharata Dynasty”). The Ramayna was composed in Sanskrit, probably not
before 300 bce, by the poet Valmiki and in its present form consists of some 24,000 couplets divided into
seven books.
Rama is the hero of the Ramayna epic, an incarnation of the God Vishn. The eldest and favourite son of
Dasatha, King of Ayohya, he is a virtuous prince and is much loved by the peopl.
Sita is Rma's wife and daughter of King Janaka of Mithila. Sta is the epitome of womanly purity and virtue.
Lakshman is Rma's younger brother. Completely loyal to Rama, he chooses to go with Rama and Sta
when they are exiled from Ayodhya.
TOOL 4 - RUN CHART / RUN CHARTS
How Do I Make A Control Chart -
1. Collect the Data
2. Calculate the sub-group average
3. Determine the overall average
4. calculate the Range
5. Compute the average of the Range.
6. Calculate the control limit
7. Plot the data in the graph
8. Interpret the graph
TOOL 4 - RUN CHART / RUN CHARTS
Step 7. Plot the Graph -
Vertical axis : X-Barand R values
Horizontal axis - Sub-group number
Draw the central line - X Double bar and R Bar
Draw all control limits UCL and LCL
Plot the X-Bar and R Values and join the points

Step 8 - Interpret the Graph

•Process Stability
•Process Capability