7QC TOOLS - New 7 Quality Control Tools with detailed explanation

New 7 Quality Control Tools with detailed explanation

1. The Basic Seven (B7) The Basic Seven (B7)
Tools of QualityTools of Quality
"As much as 95% of quality related problems in the factory can be solved "As much as 95% of quality related problems in the factory can be solved
with seven fundamental quantitative tools." - Kaoru Ishikawawith seven fundamental quantitative tools." - Kaoru Ishikawa

2. What are the Basic What are the Basic
Seven Tools of Quality?Seven Tools of Quality?
•Fishbone DiagramsFishbone Diagrams
•HistogramsHistograms
•Pareto AnalysisPareto Analysis
•FlowchartsFlowcharts
•Scatter PlotsScatter Plots
•Run ChartsRun Charts
•Control ChartsControl Charts

3. Where did the Basic Where did the Basic
Seven come from?Seven come from?
Kaoru IshikawaKaoru Ishikawa
•Known for “Democratizing Statistics”Known for “Democratizing Statistics”
•The Basic Seven Tools made statistical The Basic Seven Tools made statistical
analysis less complicated for the average analysis less complicated for the average
personperson
•Good Visual Aids make statistical and Good Visual Aids make statistical and
quality control more comprehendible.quality control more comprehendible.

4. The Basic Seven (B7) The Basic Seven (B7)
Tools of QualityTools of Quality
Fishbone DiagramsFishbone Diagrams
•No statistics involvedNo statistics involved
•Maps out a process/problemMaps out a process/problem
•Makes improvement easierMakes improvement easier
•Looks like a “Fish Skeleton”Looks like a “Fish Skeleton”

5. Constructing a Fishbone Constructing a Fishbone
DiagramDiagram
•Step 1 - Identify the ProblemStep 1 - Identify the Problem
•Step 2 - Draw “spine” and “bones”Step 2 - Draw “spine” and “bones”
Example: Example: High Inventory Shrinkage at local Drug High Inventory Shrinkage at local Drug
StoreStore
Shrinkage

6. Constructing a Fishbone Constructing a Fishbone
DiagramDiagram
•Step 3 - Identify different areas where Step 3 - Identify different areas where
problems may arise fromproblems may arise from
Ex. : Ex. : High Inventory Shrinkage at local Drug StoreHigh Inventory Shrinkage at local Drug Store
Shrinkage
employees
shoplifters

7. Constructing a Fishbone Constructing a Fishbone
DiagramDiagram
•Step 4 - Identify what these specific Step 4 - Identify what these specific
causes could becauses could be
Ex. : Ex. : High Inventory Shrinkage at local Drug StoreHigh Inventory Shrinkage at local Drug Store
Shrinkage
shoplifters
Anti-theft tags poorly designed
Expensive merchandise out
in the open
No security/ surveillance

8. Constructing a Fishbone Constructing a Fishbone
DiagramDiagram
•Ex. : Ex. : High Inventory Shrinkage at local Drug StoreHigh Inventory Shrinkage at local Drug Store
Shrinkage
shoplifters
Anti-theft tags poorly designed
Expensive merchandise out in the open
No security/ surveillance
employees
attitude
new trainee
training
benefits practices

9. Constructing a Fishbone Constructing a Fishbone
DiagramDiagram
•Step 5 – Use the finished diagram to Step 5 – Use the finished diagram to
brainstorm solutions to the main problems.brainstorm solutions to the main problems.

10. The Basic Seven (B7) The Basic Seven (B7)
Tools of QualityTools of Quality
HistogramsHistograms
•Bar chartBar chart
•Used to graphically represent groups Used to graphically represent groups
of dataof data

11. ConstructingConstructing a Histogram a Histogram
From a set of data computeFrom a set of data compute
•sumsum
•mean (x)mean (x)
•MaxMax
•MinMin
•Range (max-min)Range (max-min)

12. ConstructingConstructing a Histogram a Histogram
•Use range to estimate beginning Use range to estimate beginning
and end and end
•Calculate the width of each Calculate the width of each
column by dividing the range by column by dividing the range by
the number of columnsthe number of columns
Range
# of Columns
= Width

13. Acme Pizza ExampleAcme Pizza Example
•Let’s say the owner wants a Let’s say the owner wants a
distribution of Acme’s Thursday distribution of Acme’s Thursday
Night SalesNight Sales
Data Set from last Thursday(slices)Data Set from last Thursday(slices)
0 2 1 2 2 4 1 3 1 2 1 2 2 4 3 4 1 4 3 2 2 3 2 1 2 2 1 2 2 1 4 2 0 2 1 2 2 4 1 3 1 2 1 2 2 4 3 4 1 4 3 2 2 3 2 1 2 2 1 2 2 1 4 2
2 1 2 1 2 2 1 2 1 2 1 2 1 2 1 2 1 2 2 2 1 2 1 2 1 1 2 2 2 3 1 4 2 1 2 1 2 2 1 2 1 2 1 2 1 2 1 2 1 2 2 2 1 2 1 2 1 1 2 2 2 3 1 4
2 2 3 2 2 2 1 2 3 2 2 4 2 2 4 4 1 2 2 2 3 2 2 1 2 2 4 2 1 2 4 2 2 2 3 2 2 2 1 2 3 2 2 4 2 2 4 4 1 2 2 2 3 2 2 1 2 2 4 2 1 2 4 2
1 7 2 1 2 2 3 1 2 1 1 2 1 2 2 2 1 2 2 1 2 1 2 2 2 4 2 41 7 2 1 2 2 3 1 2 1 1 2 1 2 2 2 1 2 2 1 2 1 2 2 2 4 2 4

14. Acme Pizza ExampleAcme Pizza Example
Mean = 2.032258 Mean = 2.032258
Max = 7 Max = 7
Min = 0 Min = 0
Range = 7 Range = 7
QuestionQuestion
For 7 columns what would the width For 7 columns what would the width
be?be?
Range/Columns=7/7=1 slice

15. Acme Pizza ExampleAcme Pizza Example
33
65
8
12
0 0 1
0
10
20
30
40
50
60
70
1 2 3 4 5 6 7
Slices of Pizza
#
t
i
m
e
s
o
r
d
e
r
e
d
Histogram

16. Constructing a HistogramConstructing a Histogram
How is this helpful to Acme?How is this helpful to Acme?
•2 slices of pizza most common order 2 slices of pizza most common order
placedplaced
•Distribution of sales useful for Distribution of sales useful for
forecasting next Thursday’s late forecasting next Thursday’s late
night demandnight demand
If you were an Acme manager how If you were an Acme manager how
could you apply this information?could you apply this information?

17. The Basic Seven (B7) The Basic Seven (B7)
Tools of QualityTools of Quality
Pareto AnalysisPareto Analysis
•Very similar to HistogramsVery similar to Histograms
•Use of the 80/20 ruleUse of the 80/20 rule
•Use of percentages to show Use of percentages to show
importanceimportance

18. Acme Pizza (part 2)Acme Pizza (part 2)
SlicesSlices FrequencyFrequency %%
00 11 .3.3
11 33 33 13.09 13.09
22 65 65 25.79 25.79
33 88 3.17 3.17
44 12 12 4.76 4.76
55 00 00
66 00 00
77 11 .3 .3

19. Acme Pizza (part 2)Acme Pizza (part 2)
•The completed Pareto Analysis results in the The completed Pareto Analysis results in the
following graph:following graph:
0
10
20
30
40
50
60
70
1 2 3 4 5 6 7
Slices of Pizza
#
t
i
m
e
s
o
r
d
e
r
e
d
2143756

20. Acme Pizza (part 2)Acme Pizza (part 2)
Critical ThinkingCritical Thinking
•How does the Pareto Analysis How does the Pareto Analysis
differ from the Histogram?differ from the Histogram?
•How can this be a useful tool to How can this be a useful tool to
the Acme boss?the Acme boss?

21. The Basic Seven (B7) The Basic Seven (B7)
Tools of QualityTools of Quality
FlowchartsFlowcharts
•A graphical picture of a PROCESSA graphical picture of a PROCESS
Process Decision
The process flow

22. FlowchartsFlowcharts
Don’t Forget to:Don’t Forget to:
•Define symbols before beginningDefine symbols before beginning
•Stay consistentStay consistent
•Check that process is accurateCheck that process is accurate

23. Acme Pizza Example Acme Pizza Example
(Flowchart)(Flowchart)
WindowWindow Take CustomerTake Customer Money?Money?
(start)(start) Order Order
Get PizzaGet Pizza
LockupLockup
Put More inPut More in
OvenOven 2 Pies 2 Pies
Available?Available?

TimeTime
to close?to close?
Take to CustomerTake to Customer
no
yes
no
yes
no
yes

24. How can we use the flowchart to How can we use the flowchart to
analyze improvement ideas from analyze improvement ideas from
the Histogram?the Histogram?
WindowWindow Take CustomerTake Customer Money?Money?
(start)(start) Order Order
Get PizzaGet Pizza
LockupLockup
Put More inPut More in
OvenOven 2 Pies 2 Pies
Available?Available?

TimeTime
to close?to close?
Take to CustomerTake to Customer
no
yes
no
yes
no
yes

25. Want some practice?Want some practice?
Make a flowchart for:Make a flowchart for:
•Taking a showerTaking a shower
•Cooking dinnerCooking dinner
•Driving a carDriving a car
•Having a partyHaving a party
•Creating a FlowchartCreating a Flowchart
Any other processes you can think of?Any other processes you can think of?

26. The Basic Seven (B7) The Basic Seven (B7)
Tools of QualityTools of Quality
Scatter PlotsScatter Plots
•2 Dimensional X/Y plots2 Dimensional X/Y plots
•Used to show relationship Used to show relationship
between independent(x) and between independent(x) and
dependent(y) variablesdependent(y) variables

27. Acme Pizza Acme Pizza
(Scatter Diagram)(Scatter Diagram)
Minutes CookingMinutes Cooking Defective Pies Defective Pies
1010 11
4545 88
3030 55
7575 20 20
6060 14 14
2020 44
2525 66
In this simple example, you can find the existing In this simple example, you can find the existing
relationship without much difficulty but…relationship without much difficulty but…

28. Scatter DiagramsScatter Diagrams
0
5
10
15
20
25
0 20 40 60 80
•Easier to see direct
relationship
Time Cooking (minutes)
D
e
f
e
c
t
i
v
e
P
i
z
z
a
s

29. Scatter DiagramsScatter Diagrams
As a quality toolAs a quality tool
•What does this tell Acme What does this tell Acme
management about their management about their
processes?processes?
•Improvements?Improvements?
0
5
10
15
20
25
0 20 40 60 80
Time Cooking (minutes)
D
e
f
e
c
t
i
v
e
P
i
z
z
a
s

30. The Basic Seven (B7) The Basic Seven (B7)
Tools of QualityTools of Quality
Run chartsRun charts
•Time-based (x-axis)Time-based (x-axis)
•CyclicalCyclical
•Look for patternsLook for patterns

31. Run ChartsRun Charts
8 9 10 11 12 1 2 3 48 9 10 11 12 1 2 3 48 9 10 11 12 1 2 3 4
PM- AM PM- AM PM- AM
Thursday
Week 1
Thursday
Week 2
Thursday
Week 3
5
1
0

1
5

2
0

2
5

3
0

3
5
4
0

4
5

5
0

5
5

6
0

6
5
7
0

7
5

8
0

8
5

9
0

9
5
1
0
0
Slices/hour
Time

32. The Basic Seven (B7) The Basic Seven (B7)
Tools of QualityTools of Quality
Control ChartsControl Charts
•Deviation from MeanDeviation from Mean
•Upper and Lower Spec’sUpper and Lower Spec’s
•RangeRange

33. Control ChartsControl Charts
Upper LimitUpper Limit
Lower LimitLower Limit
Unacceptable
deviation
X

34. Control ChartsControl Charts
Acme Pizza Management wants to get
in on the control chart action
•Average Diameter = 16 inches
•Upper Limit = 17 inches
•Lower Limit = 15 inches

35. Acme example Acme example
Control ChartsControl Charts
Upper LimitUpper Limit
17 inches17 inches
Lower LimitLower Limit
15 Inches15 Inches
Small Pie
X16 inches=

36. Acme example #50Acme example #50
Control ChartsControl Charts
•Pies within specifications were
acceptable
•One abnormally small pie is
“uncommon”
•Should be examined for quality control

37. SummarySummary
•Basic Seven Tools of QualityBasic Seven Tools of Quality
•Measuring dataMeasuring data
•Quality AnalysisQuality Analysis
•““Democratized statistics”Democratized statistics”