7 QC/SPC TOOLS

SPC is comprised of 7 tools:

• Pareto diagram
• Histogram
• Cause and Effect Diagram
• Check sheet
• Process flow diagram
• Scatter diagram
• Control chart
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 Pareto Principle
• Alfredo Pareto (1848-1923) Italian Economist:
– Conducted studies of the distribution of wealth in
Europe.
– 20% of the population has 80% of the wealth
• Joseph Juran used the term “vital few from
the trivial many”. He noted that 20% of the
quality problems caused 80% of the dollar
loss.

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 Pareto 70
(64)
diagram 60

Percent from each cause

50

40
A pareto
diagram is a 30
graph that 20
ranks data (13)
(10)
10
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(3) (2) (2)
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order from left

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Causes of poor quality

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% Complaints Pareto diagram

5
 Pareto diagram
• Sometimes a pareto diagram has a
cumulative line.
• This line represents the sum of the data
as they are added together from left to
right.

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Pareto diagram
• The cumulative
percentage can be
computed (dotted
line).
• On the right, add a
vertical percent
scale equal in
length to the scale
on the left.
• Label this from 0%
to 100% .

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 Pareto diagram
Table 1. Example of a Tabulation of Causes of Ball Bond Lifting for
use in a Pareto Chart

Ball Lifting Cause Frequency Percent (%) Cum Percent (%)

Bonder Set-up Issues 19 38% 38%

Unetched Glass on Bond Pad 11 22% 60%
Foreign Contam on Bond Pad 9 18% 78%
Excessive Probe Damage 3 6% 84%
Silicon Dust on Bond Pad 2 4% 88%
Corrosion 1 2% 90%
Bond Pad Peel-off 1 2% 92%
Cratering 1 2% 94%
Resin Bleed-out 1 2% 96%
Others 2 4% 100%
Total 50 100% -

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 Table 1. Example of a
Tabulation of Causes of Ball
Bond Lifting for use in a
Pareto Chart

Ball Lifting Cause Frequency Percent (%) Cum Percent (%)

Bonder Set-up Issues 19 38% 38%

Unetched Glass on Bond Pad 11 22% 60%
Foreign Contam on Bond Pad 9 18% 78%
Excessive Probe Damage 3 6% 84%
Silicon Dust on Bond Pad 2 4% 88%
Corrosion 1 2% 90%
Bond Pad Peel-off 1 2% 92%
Cratering 1 2% 94%
Resin Bleed-out 1 2% 96%
Others 2 4% 100%
Total 50 100% -

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 Histogram

The histogram, graphically shows the process

capability and, if desired, the relationship to the
specifications and the nominal.
It also suggests the shape of the population and
indicates if there are any gaps in the data.
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Histogram

Data Range Frequency

0-10 1

10-20 3

20-30 6

30-40 4

40-50 2

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 Cause-and-Effect Diagrams

Show the relationships between a problem

and its possible causes.
Developed by Kaoru Ishikawa (1953)
Also known as …
– Fishbone diagrams
– Ishikawa diagrams

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Cause and Effect “Skeleton”

Materials Method

Quality
Problem

Man Machinet

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 Cause-and-Effect Diagrams
Measurement Man Machines

Faulty testing equipment Poor supervision Out of adjustment

Incorrect specifications Lack of concentration Tooling problems

Improper methods Inadequate training Old / worn

Quality
Inaccurate Problem
temperature Poor process
control Defective from vendor
design
Ineffective quality
Not to specifications management
Dust and
Dirt Material- Deficiencies
handling problems in product
design
Environment Materials Method

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 Cause-and-Effect Diagrams

• Advantages
– making the diagram is educational in itself
– diagram demonstrates knowledge of problem
solving team
– diagram results in active searches for causes
– diagram is a guide for data collection

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 Cause-and-Effect Diagrams

To construct the skeleton, remember:

• For manufacturing - the 4 M’s
man, method, machine, material
• For service applications
equipment, policies, procedures, people

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 Shifts

   

Defect Type

 

 

 

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COMPONENTS REPLACED BY LAB
TIME PERIOD: 22 Feb to 27 Feb 1998
REPAIR TECHNICIAN: Bob

TV SET MODEL 1013

Integrated Circuits ||||
Capacitors |||| |||| |||| |||| |||| ||
Resistors ||
Transformers ||||
Commands
CRT |

18
 Flowcharts
– Graphical description of how work is
done.
– Used to describe processes that are to
be improved.

"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.

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Flowcharts
Activity

Yes
Decision

No

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Flowcharts

21
Flow Diagrams

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Process Chart Symbols

Operations
Inspection

Transportation

Delay

Storage

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Flow Diagrams

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25
 Scatter Diagram

(a) Positive correlation (b) No correlation (c) Curvilinear relationship

The patterns described in (a) and (b) are easy to

understand; however, those described in (c) are
more difficult.
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 Control Charts

• Use run chart (time series plot) as a basis

– Examine the behavior of a variable over
time.

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Control Chart
27

24
UCL = 23.35
21
Number of defects

18 c = 12.67

15

12

6
LCL = 1.99
3

2 4 6 8 10 12 14 16
Sample number 28
Control Chart

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 SUMMARY
• SPC using statistical techniques to
 measure and analyze the variation in processes 
 to monitor product quality and
 maintain processes to fixed targets.
 
• Statistical quality control using statistical techniques for
 measuring and improving the quality of processes,
 sampling plans,
 experimental design,
 variation reduction,
 process capability analysis,
 process improvement plans.

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 SUMMARY
• A primary tool used for SPC is
 the control chart,
 a graphical representation of certain descriptive statistics for
specific quantitative measurements of the process. 
• These descriptive statistics are displayed in the control
chart in comparison to their "in-control" sampling
distributions. 
• The comparison detects any unusual variation in the
process, which could indicate a problem with the
process. 

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 SUMMARY - benefits
 Provides surveillance and feedback for keeping
processes in control
 Signals when a problem with the process has occurred
 Detects assignable causes of variation
 Reduces need for inspection
 Monitors process quality
 Provides mechanism to make process changes and track
effects of those changes
 Once a process is stable, provides process capability
analysis with comparison to the product tolerance

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