Tools TRG Module ACT Advance Cluster

7 QC tools
Property of ACT ( ACMA Centre for Slide No. 1

Technology ) 2007
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Seven QC Tools
Scatter Diagram
Stratification
Histogram
Graph and Control Chart
Cause and Effect Diagram
Pareto Diagram
Check Sheet

Technology ) 2007

Sl.No Tools Function
Check Sheet / To Collect the data in a simple manner and to
1
Data Sheet prevent omitting the checks
To pick up the important few problems from
2 Pareto Daigram
the trivial many.
Cause and Effect To reorganise the factors (causes) which are
3
Diagram influencing the problem
Presentation of data in a pictorial form for
Graph and Control
4 better understanding and see if the process
Chart
is under stable conditions.
To see the distribution pattern compared
5 Histogram
against the standard values.
To segregate data according to contributing
6 Stratification
sources.(Suppliers,machines,operators etc)
7 Scatter Diagram To see relation between two sets of data

Technology ) 2007

Check Sheet
Solder Bath Temperature
Checked by : Raised by :
Take reading of temperature nearest to degree.
Time Temp (0C) Time Temp (0C)
0800 60 1300 61
0900 62 1400 58
1000 59 1500 63
1100 58 1600 63
1200 59 1700 59
Note : Power failure from 12.00 to 12.15 Hours

Technology ) 2007

What is Check Sheet ?
A Check sheet is a paper form on which item to be
checked have been printed already so that data can be
collected easily and concisely. Its main purposes are
two-fold :
1) To make data-gathering easy ;
2) To arrange data automatically so that they can be
used easily later on
Two Types of Data :

1. Measurement data or Variable data.
2. Attribute data.
Technology ) 2007

Check sheets are of following types :
a) Check sheet for production process distribution.
b) Defective item check sheet.
c) Defect location check sheet.
d) Defect cause check sheet.

Technology ) 2007

Check Sheet for Production Process Distribution:
Checks
Deviation F
5 10 15 requency
-10 20
-9
Specification -8
-7
-6
-5 1
-4 2
-3 4
-2 6
-1 9
8.300 0 11
1 8
2 7
3 3
4 2
5 1
6 1
7
Specification 8
9
10
Total 55

Technology ) 2007

Defective Item Check Sheet:
Product :
Date :
Manufacturing stage: Final inspection
Section :
Type of defect: Scar,incomplete
Inspector’s name :
crack,misshapen.
Lot no :
Total no.inspected : 1525
Order no :
Remarks : All items inspected.
Type Checks Subtotal
Surface scars IIII IIII IIII II 17
Cracks IIII IIII I 11
Incomplete IIII IIII IIII IIII IIII I 26
Mishappen III 3
Others IIII 5
Total : 62
Total rejects 42
Technology ) 2007

Defect Location Check Sheet
A B C D
1 4
2 3 1
A 1
B 12 15 2
C 10 11
3
D 1
From the location matrix it is

4
clear that most of the blow holes
are occupied in the segment B2,B3,C2 & C3.
Defect Location Matrix For Blowholes (50 Defective Components)

Technology ) 2007

Defect Cause Check Sheet.
Mon Tue Wed Thu Fri Sat
Equipment Operator
AM PM AM PM AM PM AM PM AM PM AM PM
oo ox ooo oo xxxx oo
x xxx xx
1
ooo xx oo xx
A
2 oo xxx
1 oo xx
B
2 xx oo
o Damage x Blowhole Poor finish Crack Others

Technology ) 2007

Points to remembered while making check sheets
 Easy to use and understand.

 Information should be true and accurate.
 Decide objective by involving all the members.
 Use 5W and 1H principle.

 Who will collect the data ?
 When will the data be collected ?
 Where will the data be collected ?
 How will data be collected ?

 Check sheets should be displayed on visible area.

Technology ) 2007

Benefits of Check Sheets
Data Collection have the following benefits :
• Right decision can be made.
• Errors due to subjective feeling or personal bias are avoided.
• Agreement on decisions necessary rather than different or
subjective opinion.
• Measurement understandable to all.
• Assessments of magnitude of improvements.
• Discovery of causes affecting quality and productivity .

Technology ) 2007

Pareto Diagram
250 100
100
96.75
91.53
200 85.28 80
156
150 60
105
100 50.98 40
50 20
20 16
9
0 0
Cold oil shot Damage Chip off Bad app
shut
Types of Defects

Technology ) 2007

What is Pareto Diagram ?
Pareto diagrams are presentation technique used to
show facts and they help us to separate the “vital few”.
Pareto diagram was first thought out by an Italian economist,
Pareto (1848 - 1923), when he used it as a method for national
income analysis to show that a large proportion of the wealth
was centered around a small minority of people.
After that, an American Quality Control Authority, Mr.Juran used
it in the field of Quality Control.

Technology ) 2007

Steps to make the pareto diagrams :
1) Decide what problems are to be investigated and how to collect the

data.
2) Design a data tally sheet listing the items,with space to record their
totals.
3) Fill out the tally sheet and calculate the totals (Example-1)
4) Make the pareto diagram data sheet listing the items, their individual
totals,cumulative totals,percentages of overall total, and cumulative
percentages (Example-2)

Technology ) 2007

Steps to make the pareto diagrams (contd.) :
1) Draw two vertical axes and a horizontal axis.
2) Construct a bar diagram.
3) Draw the cumulative curve (Pareto curve).
4) Write any necessary items on the diagram.
a) Items concerning the diagram.
b) Items concerning the data.
5) Arrange the items in the order of quantity,and fill out the data sheet.

Technology ) 2007

Data Tally Sheet - Example -1
Type of Defect Tally Total
Crack IIII IIII 10
Scratch IIII IIII IIII IIII …………. IIII II 42
Stain IIII I 6
Strain IIII IIII IIII IIII I I I .I

……………………… IIII 104
Gap IIII 4
Pinhole IIII IIII IIII IIII 20
Others IIII IIII IIII 14
Total 200

Technology ) 2007

Data Sheet for Pareto Diagram - Example - 2
Type of Number of Cumulative Percentage of Cumulative
Defect Defect Total Overall Total Percentage
Strain 104 104 52 52
Scratch 42 146 21 73
Pinhole 20 166 10 83
Crack 10 176 5 88
Stain 6 182 3 91
Gap 4 186 2 93
Others 14 200 7 100
Total 200 - 100 -

Technology ) 2007

Parteo Diagram by Defective Items:
100
200 April 1 - June 30 93 100
88 91
180 83 90
160 80
73
140 70
120
52 60
100 50
80 104 40
60 30
42
40 20
20
20 10 6 4 14 10
0 0
D B F A C E Others
A :Crack, B: Scratch, C: Stain, D: Strain, E: Gap, F: Pinhole.

(Number of Units Investigated : 5,000)
Technology ) 2007

Cause and Effect Diagram
Man Machine
Characteristics
Material Method

Technology ) 2007

What is Cause and Effect Diagram ?
Any defect in a component, a product or service could be
due to one or more causes.To find out the relationship between
the causes and effect, a diagram is drawn systematically by
mapping out all the probable causes influencing the effect.
Cause
This is and effect
called diagram
a “Cause andwas introduced
Effect by “Dr.K.Ishikawa”.
Diagram”
He used it in Kawasaki Iron Works in 1943.

Since final diagram looks like a fish bone it is also called as
Fish Bone Diagram.

Technology ) 2007

Format of a Cause and Effect Diagram
Main Cause Main Cause Level 2
A Cause
Level 3
Cause Level 1
Cause
Characteristics
Main Cause Main Cause
Above diagram depicts the basic format of Cause and Effect diagram.
There is a hierarchical relationship of the effect to the main causes and
their subsequent relationship to the sub-causes.

Technology ) 2007

Procedure for Making Cause-and-effect Diagrams
for Identifying Causes:
1) Determine the quality characteristics.
2) Choose one quality characteristics and write it on the right-
hand side of a sheet of paper, draw in the backbone form
left to right, and enclose the characteristic in a square. Next,
write the primary causes which affect the quality characteristics
as big bones also enclosed by squares.

Technology ) 2007

Procedure for Making Cause-and-effect Diagrams
for Identifying Causes – (contd):
3) Write the causes (Secondary causes) which affect the big
bones (primary causes) as medium-sized bones and write the
causes (tertiary causes) which affect the medium-sized bones
as small bones.
4) Assign an importance to each factor and mark the particularly
important factor that seem to have a significant effect on the
quality characteristics.
5) Record any necessary information.

Technology ) 2007

Example of Cause-and-Effect Diagram :
Health Spirit Encouragement
Pride
Relaxation
Fighting spirit
Rest
Nutrition Calories Patience Devotion
Amusement Calmness
Meal Carefulness
Time
C
Quantity
Sleep Concentration
omposure
Depth Defeat in a
Confidence
Theory Information Po sports match
Schedule
Study of wer
Planning opponent Speed
Motion Exercise
A Q
nalysis Cooperatio uality
Common Rules Observation n Quantity
Advice
sense Judgement of situation Function
Teamwork Form
Strategy Experience of matches Model Repetition

Techniqure Slide No. 25

Example of Cause-and-Effect Diagram :
MAN MACHINE
Milling Depth
under size
Wrong assembly
M/c condition
New operator not ok
Valve Plate
High variation Projecting out
Importance not in the process of cyl.head in
known to operator 94 dia cylinder
head
Hole location not taken
assembly
during assembly
Gap less at WHY?
suction side
No Poka yoke Hole position shifted
In adequate Valve plate outer

In adequate
dimension oversize
Fixture design design Improper
METHOD MATERIAL blanking
Technology ) 2007

Points to remembered.
1) Once Cause and Effect diagram is made, check for its

completeness. If required get reviewed from the experts.
2) A good Cause and Effect diagram gives an excellent
understanding of a complex problem in a simple way.
3) Cause and Effect diagram is not an answer of the problem.
4) Main cause to be found out by collecting data or on collective
experience.
5) Less educated persons and with poor knowledge about process
can be benefited by this.

Technology ) 2007

Graph and Control Chart
UCL
C/L
LCL

Technology ) 2007

What is Graph :
Graph is a pictorial representation of data which is easily
understandable at a glance. It is a visual representation of
data made up of points, lines, letters, words, numbers,
shades etc.

Technology ) 2007

Types of Graphs :
1) Line graph
2) Bar chart / graph
3) Pie chart or Circle graph
4) Radar chart
5) Compound graphs - bar and line
6) Gantt chart

Technology ) 2007

Line Graph :
709
700
662
550
400 376
330
275 273
250
Jan'03 Feb Mar Apr May June
Month
Production details
Technology ) 2007

Bar Chart / Graph :
10
9
8
7
7 6.3
6
5
4 4
4 3.4
3
3
2
1
0
Jan'01 Feb'01 Mar'01 Apr'01 May'01 Jun'01
HMC Machine Breakdown

Technology ) 2007

Pie chart or Circle graph :
Unwanted - 61
Tags removed - 59
Easy to CLI - 855 Leakage - 845
Tags removed - 850 Tags removed - 825
Electrical - 332 Missing - 385

Tags removed - 325 Tags removed - 380
Loose - 393
Damage & Broken - 340 Tags removed - 390
Tags removed - 334
Classification of abnormality tags.

Technology ) 2007

Radar chart
Plant performance : 2001-2002
unit1
100% 100%
50%
unit5 unit2
0.85 80%
0%
unit4 60% unit3

90%

Technology ) 2007

Compound graph - Bar and Line
10 9.25
9 8.75 Frequency
8
7 7
7
Hours
6
4.75 5
5
4 4 4.75
4
3 3 3.5
3
2
1
0
Jan'01 Feb'01 Mar'01 Apr'01 May'01 Jun'01
HMC Machine Breakdown

Technology ) 2007

Gantt chart

Technology ) 2007

What is Control Chart :
1) Control chart is a graphical device to aid in process control.
2) It consist of a graph with a central line denoting the target value
control limit” and “Limit control limit” and two limit lines on either side
of the central
3) Quality line called
measured “Upper
periodically is plotted on the chart and status of
control assessed.
4) The control chart was first proposed by Dr.Walter A Shewhart, an
engineer in the Bell Telephone Laboratories,USA with a view
to eliminate abnormal variation.

Technology ) 2007

Two Types of Variations :
1. Chance Causes.
2. Assignable Causes.
1. Chance Causes :
Which are uncontrollable and comprising very small
differences in raw materials in the same batch or machines,
actual conditions etc.

2. Assignable Causes :
Such as different settings of a machine, different raw
material batches, changes in operators, operator errors etc.

Technology ) 2007

Types of Control Chart
Characteristic Value Name
x - R Chart (average value and range)

Continuous value
x chart (measured value)
pn chart (number of defective units)
p chart (fraction defective)

Discrete value
c chart (number of defects)
u chart (number of defects per unit)

Technology ) 2007

Types of Control Chart :
x - R Chart
1) It is used for controlling and analyzing a process using
continuous values of product quality such as length, weight or
concentration and this provides the larger amount of information on the
process.
2) x represents an average value of a subgroup and R represents the
range of the subgroup.
3) An R chart is used usually in combination with an x chart to
control the variation within a subgroup.

Technology ) 2007

Procedure to make control charts :
x - R Chart
1) Collect the data.
2) Calculate x
x = x1 + x2 +……+ xn
n - Size of a sub group
n
3) Calculate x
x = x1 + x2 +……+ xk
k - Number of subgroups
k
Technology ) 2007

Procedure to make control charts (contd.) :
x - R Chart
4) Calculate R
R = (Maximum value in a subgroup) -(Minimum Value in a subgroup)
5) Calculate R
R = Rx1 + Rx2 +……+ Rn

Technology ) 2007

x - R Chart
6) Calculate the control lines
x Chart
Central line :
CL = x
Upper control limit :
UCL = x +
A2R.
Lower control limit :
UCL = x - A2R
Technology ) 2007

x - R Chart
7) Calculate the control lines
R Chart
Central line :
CL = R
Upper control limit :
UCL = D4R.
Lower control limit :
LCL = D3R

Technology ) 2007

Procedure to make control charts(contd.) :
8) List of Coefficients for x - R Chart.
Size of Subgroup x Chart R Chart

n
A2 D3 D4 d2
2 1.88 --- 3.267 1.128
3 1.023 --- 2.575 1.693
4 0.729 --- 2.282 2.059

5 0.577 --- 2.115 2.326
6 0.483 --- 2.004 2.534

Technology ) 2007

Procedure to make control charts(contd.) :
x - R Chart
9) Plot the points.
10) Draw the control lines.
11) Write the necessary items.

Technology ) 2007

Examples of Control Chart :
UCL
C/L
LCL
Control Chart for Controlled State
UCL
C/L
LCL
Control Chart for Uncontrolled State
Technology ) 2007

Examples of Control Chart :
Average chart (X)
READINGS
52.043 USL
LSL
52.039
Xdbar
52.035 UCL XBAR
LCL XBAR
52.031
1 3 5 7 9 11 13 15 17 19 21 23 25
Samples

Technology ) 2007

How to Read Control Charts :
1) Out of control limits.

Ten out of 11 consecutive
2) Run. points occurring on one
Seven-point length of
run is abnormal. side is abnormal.
Run
Technology ) 2007

How to Read Control Charts (contd.) :
3) Trend
Seven upward points Drastic downward trend

Technology ) 2007

4) Approach to the control limits (2 out of 3 points)
3-sigma line
2-sigma line
2-sigma line
3-sigma line

Technology ) 2007

How to Read Control Charts :
5) Approach to the central line.
3-sigma line
1.5-sigma line

Technology ) 2007

6) Periodicity

Technology ) 2007

Histogram
40
38
35 34
30
25
20
15
9.9
10 9
4 4 4.5
5
2.5 2.5
0
0
0 3.3 3.35 3.4 3.45 3.5 3.55 3.6 3.65 3.7

Technology ) 2007

What is Histogram :
Histogram is a graphical representation of a
frequency distribution which is a summary of variation
in a product or process.

Technology ) 2007

Steps to construct the Histogram :
1) Collect 100 reading.
2) Find out lowest and highest value of reading row wise.
3) Find out lowest and highest from all the rows.
4) Compute the range . R = Max - Min.
5) Follow standard table for no of classes.

No of Observations No of Classes ( k )
< 50 6
51 - 100 7
101 - 200 8
201 - 500 9
501 - 1000 10
Technology ) 2007

Graph to Determine K
20
18
16
14
k 12
10
0
1 2 3 4 5 678 10 20 50 200 500 1,000
n n - Numbers of Measurements.
Technology ) 2007

Steps to construct the Histogram :
1) Calculate the approximate width of class with the help of
formula ( R + W ) / K
Where “ R “ is the range. “ W “ is accuracy in the observation
and “ K “ is no.of classes.Make the frequency table and then
draw the histogram.
 Note
1) Classes should be continuous.i.e 1-5,5-10,10-15 etc.
2) All classes should have same width.

Technology ) 2007

Histogram data sheet
1 104.1 11 104.5 21 104.4 31 104.4 41 104.6
2 104.4 12 104.3 22 104.5 32 104.3 42 104.4
3 104.3 13 104.4 23 104.4 33 104.4 43 104.6
4 104.5 14 104.5 24 104.3 34 104.7 44 104.7
5 104.4 15 104.4 25 104.2 35 104.2 45 104.3
6 104.3 16 104.5 26 104.4 36 104.4 46 104.5
7 104.2 17 104.2 27 104.6 37 104.3 47 104.2
8 104.5 18 104.4 28 104.4 38 104.5 48 104.5
9 104.3 19 104.3 29 104.3 39 104.4 49 104.4
10 104.5 20 104.4 30 104.1 40 104.3 50 104.3

Technology ) 2007

Tally Data Sheet
104.1 - //
104.2 - ////
104.3 - //// //// //
104.4 - //// //// //// /
104.5 - //// ////
104.6 - ///
104.7 - //
Technology ) 2007

Examples of Histogram :
20
16
15
12
10
10
5
5 3
2 2
0
104.1 104.2 104.3 104.4 104.5 104.6 104.7
in mm

Technology ) 2007

Interpretation of Histogram
Minimum Maximum Minimum Maximum

Limit Limit Limit Limit
1 4
2 5
6
3

Technology ) 2007

Types of Histogram :
a) General type b) Comb type
c) Positively skew type d) Left-hand precipice type

Technology ) 2007

Types of Histogram :
e) Plateau type f) Twin-peak type
g) Isolated-peak type
Technology ) 2007

Uses of Histogram :
1) To know the pattern of variation.
2) To assess states of control
3) To assess conformance to specifications
4) To assess spread or variation with reference to specification.
5) To assess process capability.
6) To get clues for bringing process under control - whether to shift

mean or to reduce variation or both.
7) To get clues for possible assignable causes for observed variation -

mixture of lots, suppliers, instruments /measurements errors, bias of
written results etc.

Technology ) 2007

Stratification
50 48%
40
30
20 16% 18%
12%
10 6%
0
A B C D E
Types of Defect

Technology ) 2007

What is Stratification :
Stratification is the process of separation of data into
categories. It is normally done for identifying the categories
contributing to the problem tackled.

Technology ) 2007

Types of Stratification :
A. Material Based :
48%
50
40
30
20 16 % 15%
10
0
A B C
Supplier
Defective Quality - Supplier Wise.
Technology ) 2007

B. Quality Based :
50
48%
40
30
20 16% 18%
12%
10 6%
0
A B C D C
Type of Defect
Defects Data For Each Hour in a Shift
Technology ) 2007

C. Worker Based :
30
25 22%
20
15
10
5%
5
3%
0
A B C
Worker
Defective Assemblies
Technology ) 2007

D. Machine Based :
100
90
80
70
60 57%
50 43%
40
30
20
10
0
A B
Machine
Production Machine Wise
Technology ) 2007

E. Processing Based :
50
40
32%
30
25% 26%
20
12%
10 5%
0
A B C D E
Process Area
Power Consumption Process Area Wise
Technology ) 2007

Scatter Diagram
4.5
4.4
4.3
4.2
4.1
4.0 y axis
4 430 x axis
3.9
3.8
3.7
3.6
3.5
3.4
100 150 200 250 300 350 400 450 500 550 600 650
Average Experience of Training Team (in days)

Technology ) 2007

What is Scatter Diagram :
Scatter diagram is a graphical representation of
relationship between two variables. It can be between a Cause
and Effect and between causes.
In 1837 J.F.W.Herswchal,an Englishman, used scatter diagram.
In 1950s Dr.K.Ishikawa popularized the use of scatter diagram.

Technology ) 2007

Steps to draw Scatter Diagram :
1) Collect paired data (x,y)
2) Find the maximum and minimum values for

both the x and y.
3) Plot the data.
4) Enter all necessary items.

Technology ) 2007

The horizontal (x axis) and vertical (y axis) lines of the diagram:
The measurement scales generally increase as you move up

the vertical axis and to the right on the horizontal axis.
4.5
4.4
4.3 Dependent variable (“effect”)
4.2
4.1
4.0
3.9 * Looking for relationships

3.8 not cause & effect
3.7 Independent variable (“cause”)

3.6
3.5
150 200 250 300 350 400 450 500 550 600 650

Technology ) 2007

Examples of Scatter Diagram :
4.5
4.4
4.3
4.2
4.0 y axis
4.1 430 x axis
4
3.9
3.8
3.7
3.6
3.5
3.4
100 150 200 250 300 350 400 450 500 550 600 650
Average Experience of Training Team (in days)

Technology ) 2007

Possibilities after plotting the points
a. Positive relationship
b. No correlation.
c. Negative correlation.
d. Positive and Negative correlation.
e. Negative and Positive correlation.

Technology ) 2007

n = 30 r = 0.9 n = 30 r = 0.6 n = 30 r = 0.0
y y y
6 6 6
4 4 4
2 2 2
0 0 0
0 2 4 6 x 0 2 4 6 x 0 2 4 6 x
Positive Correlation Positive Correlation No Correlation

May Be Present
n = 30 r = 0.9 n = 30 r = 0.6
y y
6 6
4 4
2 2
0 0
0 2 4 6 x 0 2 4 6 x
Negative Correlation Negative Correlation May Be Present

Technology ) 2007

The Journey is Never Ending

Technology ) 2007

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7 QC tools

Property of ACT ( ACMA Centre for Slide No. 1

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Graph and Control Chart

Cause and Effect Diagram

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7 Scatter Diagram To see relation between two sets of data

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Two Types of Data :

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a) Check sheet for production process distribution.

b) Defective item check sheet.

c) Defect location check sheet.

d) Defect cause check sheet.

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Incomplete IIII IIII IIII IIII IIII I 26

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From the location matrix it is

Defect Location Matrix For Blowholes (50 Defective Components)

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o Damage x Blowhole Poor finish Crack Others

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 Easy to use and understand.

 Decide objective by involving all the members.

 Use 5W and 1H principle.

 When will the data be collected ?

 Where will the data be collected ?

 How will data be collected ?

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• Right decision can be made.

• Errors due to subjective feeling or personal bias are avoided.

• Agreement on decisions necessary rather than different or

• Measurement understandable to all.

• Assessments of magnitude of improvements.

• Discovery of causes affecting quality and productivity .

Property of ACT ( ACMA Centre for Slide No. 12

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Property of ACT ( ACMA Centre for Slide No. 13

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show facts and they help us to separate the “vital few”.

Pareto diagram was first thought out by an Italian economist,

Pareto (1848 - 1923), when he used it as a method for national

income analysis to show that a large proportion of the wealth

was centered around a small minority of people.

After that, an American Quality Control Authority, Mr.Juran used

it in the field of Quality Control.

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1) Decide what problems are to be investigated and how to collect the

totals,cumulative totals,percentages of overall total, and cumulative

Property of ACT ( ACMA Centre for Slide No. 15

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2) Construct a bar diagram.

3) Draw the cumulative curve (Pareto curve).