QCC & 7 QC Tools

QC Tools
Structure of Quality Circles

Top Management

Coordinator
Steering
Committee
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Members

• Small groups from the same work area

• Volunteers form a Quality Circles
• Active and enthusiastic participants
• Urge to solve any problem towards improvement
• Highly self motivated
• Having ambitions to become a top class leader
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Members - Role and Functions

• Actively attending all Quality Circle meetings

• Aiming at better performance in work area
• Making on going improvement for better performance
• Contributes ideas for problem solving
• Assist the leader in data gathering, recording, documenting and
interacting with other related areas
• Strive for highest standards of performance of Circle
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Leader / Dy Leader

• Person who directs the team

• Unanimously Chosen by the team
• Supervisor or change hand for any member
• Leader / Dy. leader can be on rotation - to give the
opportunities to every one in the team, in turn
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Leader / Dy Leader - Function & Role

• Responsible for the effectiveness of his circle

• Train the members with assistance of facilitator / coordinator
• Maintain a high degree of cohesiveness of his team
• To involve every member in the circle meetings / activities
• To bring about a consensus approach in problem solving
• To chalk out action plans and assign roles to members
• To interact with other functional areas in problem solving
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Facilitator

• Manager / Supervisor of the shop floor or dept or section

• Responsible for guiding and directing the activities of Quality
Circle
• Motivational and supporting factor for others in Quality Circles
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Facilitator - Role

• Attending Quality Circle meetings

• Assist the leader in training

• Reinforcing the leader’s skills

• Guide the circle to focus on their work related problems

• Coordinate & get the support from other functional area / dept

• Organising Mid-term and top management presentations/reviews

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Systematic Problem Solving

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Introduction

• Continuous Improvement Constantly and forever

• Creative methodology
• Systematically to decrease the cycle time
• Reduce the cost of the process
• Increase the Quality of the product
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P D C A Cycle

Plan

Do
Act

Check

Monitor &
Standardise
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Seven Steps in Problem Solving
Grasp the problem areas Select the theme

Decide on the attack objectives Establish the target

Decide & assign the organisation cooperation Plan the activity

structure

Analyse the present situation of the problem Analyse the main cause

Examine the improvement Plan Examine the improvement methods

Step-up the improvement activity Implement the improvement

Check & follow-up on the improvement results Confirm the effectiveness & maintain
the action
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Facts Based Decision

• Opinion to facts
o Opinions are the emotional side of facts
o Opinions - our own experience, conditioning
and values
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Facts Based Decision

• Conversion of Opinion to facts

• Who
• What
• When
• Where
• Why and
• How much 5W 1H
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Facts Based Decision

• What is the next step ?

o Collect data for each question about the
opinion
o Grouping of the data
o Comparing and collating
o Representing the data ( Graphs, Charts )
o Answer ->Solutions->Implement-> Results
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Facts Based Decision

Monitor &
Improve
Display &
Implement

Question
Analysis &
interpretation

Data
Collection
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What Is Data

• Data is a set of information

o About the Facts
o Collected about an event,
o Collected over a specified period
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Data Collection

• Why Collect Data ?

o Answer to questions
o Understanding the actual situation
o Analyse the past and present
o To control the Process
o Collect data for Regulating Data collection
o Prevention and to stop recurrence
o To take decision on Acceptance or
Rejection
o *****
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Data Collection

• Check List for Data collection

o Why is the data required?
o What questions are we trying to answer?
o Where will the data be collected from?
o When will be the best time?
o What time is available?
o Who is going to collect the data?
o How is it going to be collected
o How is it likely to be analysed
o *****
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7 QC Tools
• Check Sheet - Data Collection Tool
• Pareto
• Cause & Effect diagram Data analysis Tools

• Histogram
• Graphs & Control Charts
• Scatter Diagram Data Display &
• Stratification Monitoring Tools

o *****
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Check Sheet
A Check sheet Well defined format
collects data in for Collection and
a compiling data for
simple manner events as they
which meets “Occur”
the
objective
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Tool No. 1 Check Sheet

SMPS Wiring Harness length ( mm)

21.96 - 21.98 mm : //// //// ///
21.98 - 22.02 mm : //// //// //// //// //
22.02 - 22.04 mm : //// //// ////

QC tool for Data Collection

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Tool No. 1 Check Sheet

Typing Mistakes
Extra Letters : //// //// ///
Spelling : //// //// //// //// //
Wrong Numbers : //// //// ////

QC tool for Data Collection

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Check Sheet - Example
Keyboard Rejection in Final inspection :

Cabinet Aesthetics //// //// //// ….. //// = 150

Key tactility problem //// //// //// .… //// = 035
Key cap assy problem //// //// //// …. //// = 400
Label problem //// //// //// …. //// = 075
Wrong cap //// //// //// …. //// = 300
Key cap colour //// //// //// …. //// = 700
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Uses of Check Sheet

• To grasp the past and present situation

• To stratify
• To grasp the changes through time
• To grasp the improvement results
• To confirm the standards
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Check Sheet Points to Remember

• Collect meaning full data

• Act on the data as quickly as possible
• Understand the actual situation
• Regulate and modify the process
• Collect consistently for comparison

QC tool for Data Collection

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QC Tools No. 2 Pareto Diagram

1600 100 100
98

93
90
1400
84
80

1200

70
66
1000
60

700
800 50

42
40
600

400
30
300
400

20
150
200 75
35 10

0 0

P1 P2 P3 P4 P5 P6

Freq Cum %
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Tool No.2 Pareto Diagram

Helps to give direct attention & effort to important problems

Helps to determine Priorities
Helps to find “Vital few” and “Trivial many”

Invented by Mr. Wilfred Pareto in 1848 - 1923

QC tools for Priority fixing & Analysis

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Tool No.2 Pareto Example
Keyboard Rejection in Final inspection :

Cabinet Aesthetics 150 4

Key tactility problem 035 What Next
Key cap assy problem 400 6
Label problem 075
Wrong cap 300
2 Prioritise
Key cap colour 700 5 problems for
3 analysis
1
Draw the graph
 QC Tools Pareto Diagram - Key Board Rejection

Vital Few

Cumulative %
Trivial Many
Problem Frequency

Problem Code
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Uses - Pareto Diagarm

• Use Pareto to focus on the Principal aspect of a

problem
• Helps to select specific causes to make effective
improvement
• To confirm the improvement results
• It helps us to monitor and check the effectiveness of
the improvement activity implemented
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Cause & Effect Diagram

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Tool No. 3 - Cause & Effect Diagram

• Systematic relationship between a fixed result and

the related causes.
• Group thinking process to investigate the root cause
• Also called as “ Fish bone diagram ”

or “Ishikawa” diagram
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Tool No. 3 - Cause & Effect Diagram

• Every effect there are likely to be several major causes

Media
Machine
Material

Effect

Methods
Measure Man
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Tool No. 3 - Cause & Effect Diagram

• Every effect there are likely to be several major causes

Price
Promotion
Product

Good
Sales

Process
People
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Tool No. 3 - Cause & Effect Diagram

• Successful person

Conviction
Courage
Commitment

Successfu
l
Person
Courtesy
Character
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Recap

Structure of QCC

Facts based decision

Data Collection
Check Sheet
1600 100
100
1400 93 98 90
84

Pareto
1200 80
70
1000 66 60
800700 50
42
600 400 40
400 300 30
150 20
200 75 3510
0 0
P1 P2 P3 P4 P5 P6
FreqCum %

Cause & Effect Diagram

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Now…..

Histogram

Graphs / Control Charts

Scatter Diagram
Stratification

Brainstorming Ideas
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Tool No. 4 - Histogram

• Examines what is the quality of a group

• Shows the dispersion shape in a graphical form

• Helps to identify the changes in quality characteristics

• Bell Shaped curve
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Tool No. 4 - Histogram
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Tool No. 4 - Histogram
Printer carriage rail dia in mm

Graph
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Type of Histograms
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Tool No. 5 Graphs & Control Charts

• What is a Graph
o Diagrammatic representation of Analysis of a data
o Easy to understand by all
o Shows the current situation
o Gives the lightening effect for the data
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Tool No. 5 Graphs & Control Charts

Product performance
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Types of Graphs

• Bar Graph • Line Graph

• PIE or Circle Graphs

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Tool No. 6 Scatter Diagram

• Graphical Representation of relation between two

data

• Helps to find the level of relation and distribution

pattern of two sets of data
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Scatter Diagram

Examples
Heights Vs Weights
Time Vs Production qty
Production Qty Vs Failure

Torque Vs Breakage
Sales Vs Profit
Salary Vs Expenses
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Tool No. 7 Stratification

• Method of grouping data

• To identify the sources of defects
• To identify the sources of variation
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QC Tools QC Story - Journey Towards Problem solving
QC Tools QC Story - Journey towards of Problem solving
QC Tools QC Story - Journey towards Problem solving

PROBLEM ANALYSIS CAUSE & EFFECT DIAGRAM

26 % 24 %
2
4
QX Series Sales
Others
IT Order (15% ) Other Order (21
Postponment %) Postponment

QX 235 Non Slow rampup of Qx

Supply in OND 30 235 in Cnl (34%)
%
Variance in No. of
Price correction / DMP ( 13900 Nos)
TO BE ANALYSED Roll out not done
SEPARATELY
( 15 % )
New Prod Launch
delay ( 50% )
Wrong Target
Setting ( 12 % ) Mumbai Cnl Mgt
HD Sales in Issue ( 23 % )
OEM 3 MSP 245 in DLR 1
Cnl
21 % 29 %
QC Tools QC Story - Journey towards Problem solving
QC Tools 7 QC Tools

• Check Sheet - Data Collection Tool

• Pareto
• Cause & Effect diagram
Data analysis Tools
• Histogram
• Graphs & Control Charts
• Scatter Diagram
• Stratification Data Display &
Monitoring Tools
o *****
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What Next ?
Fear about the Problems U can sit and Enjoy the life - If

U are working together to

solve any Problem
THANKS