UNIT – III

TQM TOOLS
AND
TECHNIQUES I
 SEVEN TOOLS OF QUALITY

(1) Flow chart

(2) Check sheet,
(3) Histogram,
(4) Pareto chart,
(5) Cause-and-effect diagram,
(6) Scatter diagram,
(7) Control chart
Relation between 7 QC tools and PDCA
(1) Flowchart
 (2) Check sheet

 Systematic way of collecting and recording data.

 Also called ‘Tally sheets’.
 Used to indicate frequency of certain occurrence.
 Can be used even by shop floor personnel.
 Facilitate quick decisions from the data collected.
 format is tailored to suit each situation/application.
 Counts are marked as ‌| , ‌|| , ||| , |||| and |||| in
groups of five. Totals can be quickly calculated.
 Can be used to analyze types of defects, causes of
defects, nature of complaints, etc.
 Example: Check sheet for customer complaints.

Nature of complaint Frequency

Delayed delivery |||| || 07

Missing items ||| 03

Damaged items |||| |||| || 12

Invoice errors |||| 04

TOTAL 26
 (3) Histogram

 Type of bar graph showing frequency distribution.

 Shows the variation in a process.
 Consists of a set of rectangles that represent the
frequency of observed values in each category.
 Range of values (of a variable) is divided into a
number of groups, called class intervals or cells.
 Above is shown on the x-axis while their
frequencies of occurrence are shown on y-axis.
 The width of all cells are equal.
 The shape of the histogram can indicate whether the
frequency distribution is normal, skewed, peaked, flat, etc.

 Frequency tables, check sheets can be converted into

histograms.
(4) Pareto Diagram
(5) Cause and Effect Diagram
 (3) Scatter Diagram
 Helps to analyze cause-and-effect relationship between two
variables.
 Independent variable is plotted on the x-axis and the
dependent, response variable on the y-axis.
 Data is plotted as a cloud of points.
 Density and the direction of the cloud indicate how the two
variables influence each other.
 Various possibilities being: positive correlation, negative
correlation, no correlation, etc.
 Advantage of scatter diagram is that once the exercise is
carried out, it is possible to extrapolate the results for any
given situation.
 Eg. Level of training vs No. of errors
Equipment age vs No. of breakdowns
Work experience vs No. of accidents
 (4) Control Charts
 Run chart’ is a chart that plots data pertaining to a
variable or characteristic over time.
 Control chart – type of run chart – used in Statistical
Quality Control (SQC) to monitor the quality of a
process continuously.
 Developed by Walter A. Shewhart in 1924 to identify
common cause & special cause variations in a process.

 Graph consists of three horizontal lines: central line,

Upper Control Limit , & Lower Control Limit.
 Random samples from a process are drawn at specific
intervals, the sample serial number is shown on the x-
axis while the quality characteristic being measured is
plotted on the y-axis.
 (4) Control Charts
 Central line is set at the mean value while the UCL
and LCL are set at ±3 sigma limits above and below
the mean.

 If all readings fall between the UCL and LCL, the

process is inferred to be in control and if the
readings fall beyond the limits, the process is
deemed to be out of control.

 Various types of control charts are:

X-chart and R-chart (for variables)
p-chart, np-chart, c-chart, and u-chart (for attributes)
NEW SEVEN MANAGEMENT TOOLS

(1) Affinity Diagram

(2) Relationship Diagram
(3) Tree Diagram
(4) Matrix Diagram
(5) Matrix Data Analysis
(6) Decision Tree (PDPC)
(7) Arrow Diagram (PERT)
Affinity Diagram
Relationship Diagram
Tree Diagram
Matrix Diagram
Matrix Data Analysis Diagram
Process Decision Programme Chart
/Decision Tree
Arrow Diagram
Six Sigma
Six Sigma Process
Six Sigma Organization
Advantages of Six Sigma Process
Benchmarking
Benchmarking
Benchmarking
Steps in Benchmarking Process
Benefits of Benchmarking
Failure Mode Effect Analysis
(FMEA)
Types of FMEA
Benefits of FMEA
Stages of FMEA
FMEA Procedure