TOTAL QUALITY MANAGEMENT

SEVEN QUALITY CONTROL TOOLS

By: Syed Shahwar Hasan

 Seven QC Tools
1) Cause-and-effect diagram
2) Check Sheet
3) Histogram
4) Pareto Chart
5) Scatter Diagram
6) Flowchart / Run Chart / Stratification
7) Control Chart / SPC
 Dr.Kaoru Ishikawa,
Professor at Tokyo University & Father of Q C in Japan.

• CAUSE ANALYSIS TOOLS are Cause

and Effect diagram, Pareto analysis & Scatter
diagram.
• EVALUATION AND DECISION
MAKING TOOLS are decision matrix
and multivoting
• DATA COLLECTION AND ANALYSIS
TOOLS are check sheet, control charts, DOE,
scatter diagram, stratification, histogram,
survey.
• IDEA CREATION TOOLS are
Brainstorming, Benchmarking, Affinity
diagram, Normal group technique.
• PROJECT PLANNING AND
IMPLEMENTATION TOOLS are Gantt
chart and PDCA Cycle.
 Cause-and-effect diagram
(also called Ishikawa or fishbone chart )

DESCRIPTION
• The fishbone diagram identifies many possible
causes for an effect or problem. It can be used
to structure a brainstorming session. It
immediately sorts ideas into useful categories.
WHEN TO USE
• When identifying possible causes for a problem.
• Especially when a team’s thinking tends to fall
into ruts
 PROCEDURE
• MATERISLS REQUIRED: Flipchart (or) White Board, Marking
Pens.

• Agree on a problem statement (effect). Write it at the

center right of the flipchart or whiteboard. Draw a box
around it and draw a horizontal arrow running to it.
• Brainstorm the major categories of causes of the problem.
If this is difficult use generic headings:
– Methods (SOP)
– Machines (Equipments / Tools)
– Man (Manpower)
– Materials (Inventory)
– Measurement
– Environment
• Write the categories of causes as branches from the
main arrow.

• Brainstorm all the possible causes of the problem. Ask:

“Why does this happen?” As each idea is given, the
facilitator writes it as a branch from the appropriate
category. Causes can be written in several places if they
relate to several categories.

• 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.

• When the group runs out of ideas, focus attention to

places on the chart where ideas are few.
• Example
• This fishbone diagram was drawn by
a manufacturing team to try to
understand the source of periodic
iron contamination. The team used
the six generic headings to prompt
ideas. Layers of branches show
thorough thinking about the causes of
the problem.
• For example, under the heading “Machines,” the
idea “materials of construction” shows four kinds
of equipment and then several specific machine
numbers.

• Note that some ideas appear in two different

places. “Calibration” shows up under “Methods”
as a factor in the analytical procedure, and also
under “Measurement” as a cause of lab error.
“Iron tools” can be considered a “Methods”
problem when taking samples or a “Manpower”
problem with maintenance personnel
 CHECK SHEET (or) DEFECT
CONCENTRATION DIAGRAM

DESCRIPTION
• A check sheet is a structured, prepared
form for collecting and analyzing data.
This is a generic tool that can be
adapted for a wide variety of purposes
WHEN TO USE
• When data can be observed and
collected repeatedly by the same
person or at the same location.
• When collecting data on the frequency
or patterns of events, problems,
defects, defect location, defect causes,
etc.
• When collecting data from a production
process.
PROCEDURE
• Decide what event or problem will be observed.
Develop operational definitions.
• Decide when data will be collected and for how
long.
• Design the form. Set it up so that data can be
recorded simply by making check marks or Xs
or similar symbols and so that data do not have
to be recopied for analysis.
• Label all spaces on the form.
• Test the check sheet for a short trial period to
be sure it collects the appropriate data and is
easy to use.
• Each time the targeted event or problem occurs,
record data on the check sheet.
EXAMPLE

• The figure below shows a check

sheet used to collect data on
telephone interruptions. The tick
marks were added as data was
collected over several weeks.
Histogram

• Histogram: The most commonly

used graph for showing frequency
distributions, or how often each
different value in a set of data occurs
WHEN TO USE
• The data are numerical values.
• To see the shape of the data’s distribution,
especially when determining whether the output
of a process is distributed approximately
normally.
• Analyzing whether a process can meet the
customer’s requirements.
• Analyzing what the output from a supplier’s
process looks like.
• Whether a process change has occurred from one
time period to another.
• To determine whether the outputs of two or more
processes are different.
• To communicate the distribution of data quickly
and easily to others.
 Histogram Shapes and
Meaning
• Normal. A common pattern is the bell-
shaped curve known as the “normal
distribution.” In a normal distribution,
points are as likely to occur on one side of
the average as on the other.
 • Skewed. The skewed distribution is
asymmetrical because a natural limit
prevents outcomes on one side. The
distribution’s peak is off center toward the
limit and a tail stretches away from it.

These distributions are called right- or
left-skewed according to the direction of the tail.
• Double-peaked or bimodal. The bimodal
distribution looks like the back of a two-
humped camel. The outcomes of two
processes with different distributions are
combined in one set of data. A two-shift
operation might be bimodal.
• Plateau. The plateau might be called a
“multimodal distribution.” Several
processes with normal distributions are
combined. Because there are many peaks
close together, the top of the distribution
resembles a plateau.
• Dog food. The dog food distribution is
missing something—results near the
average. If a customer receives this kind
of distribution, someone else is receiving
a heart cut, and the customer is left with
the “dog food,” the odds and ends left
over after the master’s meal
 Pareto Chart (or) Pareto diagram
(or) Pareto analysis
• A Pareto chart is a bar graph. The
lengths of the bars represent
frequency or cost (time or money),
and are arranged with longest bars
on the left and the shortest to the
right.
 When to Use
When analyzing data about the frequency of
problems or causes in a process.
 When there are many problems or causes and
you want to focus on the most significant.
 When analyzing broad causes by looking at
their specific components.
When communicating with others about your
data.
PARETO DIAGRAM
To identify the ‘VITAL FEW FROM TRIVIAL
MANY’ and to concentrate on the vital few for
improvement.
A Pareto diagram indicates which problem we
should solve first in eliminating defects and
improving the operation.

 The Pareto 80 / 20 rule

80 % of the problems are produced by 20 %
of the causes.
 Scatter Diagram (or) Scatter plot
(or) X–Y graph
• The scatter diagram graphs pairs of
numerical data, with one variable on each
axis, to look for a relationship between
them. If the variables are correlated, the
points will fall along a line or curve. The
better the correlation, the tighter the points
will hug the line.
When to Use
• When you have paired numerical data.
• When your dependent variable may have
multiple values for each value of your
independent variable.
• When trying to determine whether the two
variables are related, such as when trying
to identify potential root causes of
problems.
• After brainstorming causes and effects
using a fishbone diagram, to determine
objectively whether a particular cause and
effect are related.
Stratification (or) Flowchart (or)
Run chart
• Stratification is a technique used
in combination with other data
analysis tools. When data from a
variety of sources or categories
have been lumped together, the
meaning of the data can be
impossible to see
 When to Use
• Before collecting data.
• When data come from several sources
or conditions, such as shifts, days of
the week, suppliers or population
groups.
• When data analysis may require
separating different sources or
conditions.
 EXAMPLE
• The ZZ-400 manufacturing team drew a
scatter diagram to test whether product purity
and iron contamination were related, but the
plot did not demonstrate a relationship. Then
a team member realized that the data came
from three different reactors. The team
member redrew the diagram, using a
different symbol for each reactor’s data
Benefit from stratification.

• Always consider before collecting data

whether stratification might be needed during
analysis. Plan to collect stratification
information. After the data are collected it
might be too late.

• On your graph or chart, include a legend that

identifies the marks or colors used.
 Control Chart / Statistical process
control
VARIATIONS
• Different types of control charts can be
used, depending upon the type of data. The
two broadest groupings are for variable data
and attribute data.
• Variable data are measured on a continuous
scale. For example: time, weight, distance or
temperature can be measured in fractions or
decimals. The possibility of measuring to
greater precision defines variable data.
• Attribute data are counted and
cannot have fractions or decimals.
Attribute data arise when you are
determining only the presence or
absence of something: success or
failure, accept or reject, correct or
not correct. For example, a report
can have four errors or five errors,
but it cannot have four and a half
errors.
 Variables charts
– X and R chart (also called averages and range
chart)
– X and s chart
– chart of individuals (also called X chart, X-R
chart, IX-MR chart, Xm R chart, moving range
chart)
– moving average–moving range chart (also
called MA–MR chart)
– target charts (also called difference charts,
deviation charts and nominal charts)
– CUSUM (also called cumulative sum chart)
– EWMA (also called exponentially weighted
moving average chart)
– multivariate chart (also called Hotelling T2)
 Attributes charts

– p chart (also called proportion chart)

– np chart
– c chart (also called count chart)
– u chart