7 QC tools:

1. Check sheets
2.Pareto diagram
3.Cause & Effect Diagram
4.Control chart
5.Histogram
6.Stratification
7.Scatter plot
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

Check sheet
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. Variable data.
2. Attribute data.
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.

Product :
Manufacturing stage: Final inspection
Type of defect: Scar,incomplete
crack,misshapen.
Total no.inspected : 1525
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
 Defect Location Check Sheet
Defect Location Matrix For Blowholes (50 Defective Components)

1 2 3 4 A B C D
A 1 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 Cause Check Sheet.
Mon Tue Wed Thu Fri Sat
Equipment Operator
AM PM AM PM AM PM AM PM AM PM AM PM

ooo xx oo xx
1

ox
2 oo o
x xx

B
ooo
2
xxx

o Damage x Blowhole Poor finish Crack Others

Points to remembered while making check sheets

❖ Easy to use and understand.

❖ 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.

Pareto Diagram
 What is Pareto Diagram ?

Vilfredo Pareto

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.
Pareto Diagram:

➢ Pareto Diagram by Phenomena :

➢ Quality :Defects, faults, failures, Customer complaints, Customer

returns .

➢ Cost : Amount of loss , expenses.

➢ Delivery : Stock Shortages , Default in payments, Delay in Delivery.

➢ Safety : Accidents , mistakes , breakdowns.

➢ Pareto Diagram by Causes:

➢ Operator : Shift, Group, Age, Experience, Skill,

➢ Machine : Type , Model , Tools , Instruments , Software.

➢ Raw Material : Manufacturer , Plant , Lot , Kind.

12
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)
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.
 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 ………………………. IIII IIII 104

Gap IIII 4

Pinhole IIII IIII IIII IIII 20

Others IIII IIII IIII 14

Total 200
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 -

 Pareto Diagram by Defective Items:
Cumulative %
Defects 100
200 Vital Few 91 93 100
88
180 83 90

160 73 80

140 70
52
120 Trivial many 60

100 50

80 40

60 30

40 20

20 10

0 0
D B F A C E Others

A :Crack, B: Scratch, C: Stain, D: Strain, E: Gap, F: Pinhole.

Quality Live India

 Cause and Effect Diagram
Also called: cause-and-effect diagram, Ishikawa diagram

Man Machine

Characteristics

Material Method
Cause and effect diagram was introduced by

“Dr.K.Ishikawa”.

He used it in Kawasaki Iron Works in 1943.

The fishbone diagram identifies many possible causes for

an effect or problem. It can be used to structure a
brainstorming session.
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 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.
Quality Live India
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.

23
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

24
Line Graph :

709
700
662
Qty Produced

550

400 376
330
275 273
250
Jan'03 Feb Mar Apr May June
Month

Production details
25
Bar Chart / Graph :

10
9
8
7
7 6.3
6
Hrs

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

26
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.

27
Radar chart
Plant performance : 2001-2002

unit1
100% 100%

50%
unit5 unit2

0.85 80%
0%

unit4 60% unit3

90%

28
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

29
Control Chart
 What is Control Chart :
1) 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 line called “Upper & Lower limit”
2) Quality measured periodically is plotted on the chart and status of control
assessed.
3) 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.
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.
 X - R Chart to make control charts :
Procedure
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.
X - R Chart
x = x1 + x2 +……+ xn
1) Collect the data. n - Size of a sub group
2) Calculate x bar n

x = x1 + x2 +……+ xk
3) Calculate x double bar k - Number of subgroups
k
4) Calculate R

R = (Maximum value in a subgroup) -(Minimum Value in a subgroup)

5) Calculate R R = Rx1 + Rx2 +……+ Rn

6) Calculate the control lines

x Chart

Central line : CL = x, Upper control limit : UCL = x + A2R.

Lower control limit : LCL = x - A2R
7) Calculate the control lines
R Chart
Central line : CL = R, Upper control limit : UCL = D4R, Lower control limit : LCL = D3R
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
How to Read Control Charts :
1) Out of control limits.
Ten out of 11 consecutive
2) Run. Seven-point length of points occurring on one
run is abnormal. side is abnormal.

Run
38
How to Read Control Charts (contd.) :
3) Trend

Seven upward points Drastic downward trend

39
How to Read Control Charts (contd.) :
4) Approach to the control limits (2 out of 3 points)

3-sigma line
2-sigma line

2-sigma line
3-sigma line

40
How to Read Control Charts :

5) Approach to the central line.

3-sigma line
1.5-sigma line

41
How to Read Control Charts (contd.) :
6) Periodicity

42
Histogram
What is Histogram :

Histogram is a graphical representation of a

frequency distribution which is a summary of variation

in a product or process.
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
Histogram data sheet
1 104.1 11 104.5 21 104.4 31 104.4 41 104.6 Tally Data Sheet
2 104.4 12 104.3 22 104.5 32 104.3 42 104.4
104.1 - //
3 104.3 13 104.4 23 104.4 33 104.4 43 104.6
104.2 - ////
4 104.5 14 104.5 24 104.3 34 104.7 44 104.7 104.3 - //// //// //
5 104.4 15 104.4 25 104.2 35 104.2 45 104.3 104.4 - //// //// //// /
6 104.3 16 104.5 26 104.4 36 104.4 46 104.5 104.5 - //// ////
7 104.2 17 104.2 27 104.6 37 104.3 47 104.2
104.6 - ///
104.7 - //
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
Histogram

16

12

10

3
2 2

104.1 104.2 104.3 in104.4

mm 104.5 104.6 104.7
Interpretation of Histogram

Minimum Maximum Minimum Maximum

Limit Limit Limit Limit
1 4

2 5

6
3

48
Types of Histogram :

a) General type b) Comb type

c) Positively skew type d) Left–hand precipice type

49
Types of Histogram :

e) Plateau type f) Twin–peak type

g) Isolated–peak type
50
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.

51
Stratification
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.

• Defect based
• Machine based
• Worker based
• Shift based
• Production based
Types of Stratification :
A. Material Based :
48%
50

40

30
Defective %

20 16 % 15%

10

0
A B C
Supplier

Defective Quality - Supplier Wise.

Types of Stratification :
B. Quality Based :
50
48%

40
Quality Defective(Nos)

30

20 16% 18%
12%
10 6%

0
A B C D C
Type of Defect

Defects Data For Each Hour in a Shift

55
Types of Stratification :
C. Worker Based :
30

25 22%
No of Defective

20

15

10
5%
5 3%

0
A B C
Worker

Defective Assemblies
56
Types of Stratification :
D. Machine Based :
100
90
80
70
60 57%
Production %

50 43%
40
30
20
10
0
A B
Machine

Production Machine Wise

57
Types of Stratification :
E. Processing Based :
50

40
Power Consumption %

32%
30
25% 26%
20
12%
10 5%
0
A B C D E
Process Area

Power Consumption Process Area Wise

58
 Scatter Diagram
Scatter diagram is use for understanding between the two
variables, prepare by plotting paired for example Hardness &
Tensile strength, Age vs Weight or age vs height

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.
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

61
Examples of Scatter Diagram :

4.5
Overall rating of the Session

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)

62
Examples of Scatter Diagram :
Possibilities after plotting the points

a. Positive relationship

b. No correlation.

c. Negative correlation.

d. Positive and Negative correlation.

e. Negative and Positive correlation.

64
 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

65
Thank You