This program is aimed at training

candidates for Working Professionals

who want Up skilling in
Implementation of
“7QC”
 SEVEN QC TOOLS
* Check Sheets
* Pareto Diagram
* Cause and Effect Diagram.
* Stratification.
* Scatter Diagram.
* Histogram.
* Graphs and Control Charts.
 Check Sheet
What : An easy to understand form used to answer the question “ How often are
certain events happening?”

Why : Starts the process of translating “opinion” into “facts”

When : Gathering data in order to detect patterns.

Good point to start most problem solving cycles.
How :
•Team agrees as to exactly what event is being observed.
•Decide on the time period during which data will be collected. This could
range from hours to weeks.
•Design a form that is clear and easy to use making sure that all columns are
clearly labeled and that there is enough space to enter the data.
•Collect the data making sure that observations/ samples are as representative
as possible.
 Check sheet contd... Examples
Diagram type check sheet Frequency check sheet

SN Class Mean Value Tally Marks Total

1 950-955 952.5 IIII 4
2 955-960 957.5 IIII III 8
3 960-965 962.5 IIII IIII IIII 15
4 965-970 967.5 IIII IIII 10
Mark defect by 5 970-975 972.5 IIII I 6

Inspection check sheet

Part No: Process: Machine:

Sn Parameter Spec Sample No Judgement Remark
1 2 3 4 5
 Pareto Analysis
What: A bar chart that helps to prioritize actions by arranging
elements in descending order of occurrence. Sorts out the “vital
few” from the “trivial many”.
Why :
•To prioritize actions needed to solve complex problems.
•To separate important from non-important causes contributing
to a problem.
When :
•Many factors are impacting a problem.
•Attention needs to be directed only to the few factors that
account for most of the problem.
How:
•Define a problem and collect data on the factors that contribute to it.
•Historical records generally provide sufficient information.
•Classify the data by type, cost , percent, number of occurrences, or
whatever is appropriate for the situation.
•Arrange the data in descending order.
 Contd……. Pareto Analysis
How contd….

•Draw bar graph showing constituent ratio on vertical axis.

•Connect cumulative percentage of each bar graph to obtain Pareto curve.

Rejection details of Pinion

Defect Defect Qty % Cum
Code description Rej Contribution %age
A Drill Broken 70 46.60% 46.60%
B Serration Mismatch 45 30% 76.60%
C Runout more 25 16.60% 93.20%
D Dia U/S 6 4% 97.20%
E Dia O/S 4 2.80% 100%
Total 150
Contd… Pareto

75%
100%
n=150 50%

25%
Nos.

A B C D E
Defect Code
 Cause & Effect Diagram
What: A graphic tool used to represent the relationship between an
effect and the cause that influence it.
Why:
•Identifies various causes affecting a process.
•Helps groups in reaching a common understanding of a problem.
•Helps reduce incidence of subjective decision making.
When: Looking for all potential causes of problem.
How:
•Define the problem or effect clearly.
•Generate the potential cause of problem through brain storming.
•Construct the cause and effect diagram by:
*Place problem statement in a box on right hand side.
*Draw the major cause category boxes on the left hand side.
Commonly used categories are man, machine, method, material
and measurement.
* For each cause ask “ Why” and list responses as branches
off the major causes.
 How : Contd…..
*Identify likely root cause(s) and circle them.
*Collect data to verify the most likely root causes.

Man
Material

Quality characteristics

Measurement
Method
Machine
 Stratification
What: Stratification is a statistical technique of breaking down values
and numbers into meaningful categories or classification.
Why: To focus on corrective action or identify true causes.
When: To identify the cause of problem if they come from a particular
source.
•To analyze root cause in conjunction with other techniques
like pareto diagram histogram and graphs.
How: Regroup original data as per the source of data (eg. Machine
wise, shift-wise, model-wise, supplier-wise)
•If required collect data afresh after making the source from
which they come.
 Stratification ……..contd...
•Recreate histogram, pareto charts and graphs on classified data
Example:

Month Model A Mode B

Apr 10 50
May
90 8 32
Jun 80 15 65
Jul 10 50
Aug 70 8 42
Sep 7 28
60
Rej Nos

50 Mode B
Model A
40
30
20
10
0
Apr May Jun Jul Aug Sep
Month
 Scatter Diagram
What: A tool used to study the possible relationship between two
variables.
Why:
To test for possible causes and effect relationships.
Though it cannot prove that one variable causes the other, the
diagram does make it clear whether a relationship exists and shows
the strength of that relationship.
When:
There is a need to display what happens to one variable when another one
changes in order to test that the two variables are related.
How:
•Collect 50 to 100 paired samples of data believed to be related.
•Construct a data sheet.
•Draw the horizontal and vertical axis of the diagram.
•Label the axes.
Contd………….. Scatter diagram

How contd.….

• “Cause”is usually plotted on the horizontal axis and the “effect”

variable on the vertical axis.
• Plot the data on the diagram. If values repeat, circle that point.
 Interpretation

A. Randomly scattered points - B. Possible Positive correlation C. Strong positive correlation

No correlation

D. Possible negative correlation E. Strong Negative correlation

 Histogram
What: A bar chart that displays the variation within the process.
Also called a frequency distribution because the frequency of
occurrence of any given value is represented by the height of the bars.
Why:
•Allows one to quickly visualize what’s going on within a large
amount of data.
•Provides clues to causes of problems.
•Maybe be used to show the relationship between the engineering
tolerance and the capabilities of the process.
When:
•Capabilities studies are being performed.
•Analyzing the quality of incoming material.
How:
•Collect measurements(variable data)from a process or key characteristic.
Histogram…...
How…….contd..
•Thirty or more measurements are preferred.
•Construct check sheet to record the data.
•Find the range by subtracting the smallest measurements from the
largest.
•Using this guide determine the proper number of class intervals.

Observations No. of classes

25 to 50 5 to 8
51 to 100 6 to 11
101 to 250 9 to 13
251 and over 11 to 15

•Construct a frequency table. Tally the number of observations found

in each class.
 Histogram…...
How…….contd..
Class Class limits Tally Number of observations
1 0.51 to 5.50 IIII IIII 10
2 5.51 to 10.50 IIII IIII IIII IIII 20
3 10.51 to 15.50 IIII IIII IIII IIII IIII 25
4 15.51 to 20.50 IIII IIII IIII IIII 20
5 20.51 25.50 IIII IIII IIII 15
6 25.51 to 30 .50 IIII IIII 10

•Taking the class interval on horizontal axis, draw the height of the
bar corresponding to frequencies in interval on the vertical axis.
Histogram…...
How…….contd..
25

20

15

10

0.55 5.5 10.5 15.5 20.5 25.5 30.5

 Types of Histogram

General Type Comb Type Positively Skew Type

Isolated Peak Type

Left-hand Precipice Plateau Type Twin Peak Type

Type
 Normal Distribution
f(x)

x
•Frequency is the highest in the middle and becomes gradually lower towards the tail.
•It is symmetrical
It is denoted by N (µ, σ2)
µ : The centre of the distribution (the mean)
σ : The spread of the distribution(the standard deviation)
To obtain a probability in a normal distribution, we standardize by
transforming x to a variable
u= x-µ
σ
We then have a standard measure u, which is distributed as the standard
normal distribution N(0, 12). The normal distribution table gives probabilities in
the standard normal distribution.

µ±1σ :- 68.3% of area

µ±2σ :- 95.4% of area
µ±3σ :- 99.7% of area
 Process Capability Index
After Histogram shows that it follows normal distribution, a study of
process capability is often undertaken. This is to find out whether the process
can meet specifications or not
Both-sided specifications (SU and SL)

CP = SU - SL/6s

One-sided specification (SU or SL)

CP = SU - x /3s

Evaluation of process:

1) 1.33 < CP Satisfiable enough

2) 1.00 < CP < 1.33 Adequate

3) CP < 1.00 Inadequate

 Graphs
Graphs are among the simplest and best techniques to analyze and
display data for easy communication.
Various types of graphs generally used are shown below which are
self explanatory.

Bar chart Trend chart

Year Rej Cost Month Rej

Rejection %age
1996
80 50 Apr 0.8 0.2
Rej. cost

1997
60 45 May 0.6 0.6
1998 70 Jun 0.4 0.2 Rej
40
Jul 0.2
20 0.2
Aug 0.15
0 0
Sep 0.2
1996 1997 1998 Apr May Jun Jul Aug Sep
Year Month
 Graphs…contd…
Pie-chart
POWEROTHERS
RBS STRG.
STRG. 5.56%
ASSY.
4.92%
10.83%

R&P ASSY.
AXLE ASSY. 17.62%
28.67%

PROP.SHAFT
COLUMN
ASSY.
ASSY.
6.15%
26.25
 Control Charts
What: A control chart is A line graph used to display variation on
time ordered fashion. A centerline and control limits are placed on
the graph to help analyse the pattern of the data.
Why:
•To separate common causes from special causes of variation.
•To help assign causes of variation.

When : Measuring control characteristics.

Where: At the earliest possible point in the manufacturing process.

How :
•Define process parameter to be measured.
•Define wherein the process the control characteristics will be
measured.
•Select where control chart is to be used.
•Determine sample size and frequency.
•Take measurements.
•Plot measurements on graph.
 How contd…

•Plot measurements on graph.

•Connect dots.
•After 20 plot points calculate centre-line and control limits.
•Analyse pattern for special cause of variation.
 THANK YOU
(QUESTIONS AND QUERIES
ARE WELCOME)