7 QC Tools
7 QC Tools
Training Module
7QC tools
Developed by Innovation Cell
Types
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Pareto Diagram
Cause & Effect diagram
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Check sheet
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7 QC TOOLS
Check sheet
Check sheets are forms used for
standardizing checking results of work verifying and collecting data
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Discrete value such as no. Of recording errors, no. of Item sold & Rejections etc.
Measured Data
Counted Data
Check Sheet
Ordered Data
1st, 2nd Order Very Good, Good, No Good - Type
Primary Data
YES / NO or / X - Type
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No. of defects
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Pareto Vilfredo Pareto was an Italian engineer in the 19th Century who studied the number of people in various income classes & declared 20% of the people own 80% of the countrys wealth;
7 QC TOOLS Pareto Principle Pareto principle holds good to the present day in various applications A few causes lead to many defects; many causes lead to few defects.
The few causes that lead to many defects are the vital few.
The many causes that lead to few defects are the trivial many.
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STEP 1
8
9 10 11
Stores
Personnel Materials Finance
5
8 66 15
12
13 14
4
6 4
Pareto
STEP 2
Department
Materials Marketing Plant Maintenance Finance Service Production Engineering Personnel Information Systems Stores Research & Development
11
12 13 14
Others
Quality Factory production Manufacturing Planning
4
2 2 1 200
STEP 3
Sl.No
1 2 3 4 5
Nos.
66 45 20 15 12
Relative %
33.0 22.5 10.0 7.5 6.0
6
7 8 9 10 11 12 13 14
Production Engineering
Personnel Information Systems Stores Research & Development Others Quality Factory production Manufacturing Planning
10
8 6 5 4 4 2 2 1 200
5.0
4.0 3.0 2.5 2.0 2.0 1.0 1.0 0.5
STEP 4
Sl.No
1 2 3 4 5
Nos.
66 45 20 15 12
Relative %
33.0 22.5 10.0 7.5 6.0
Cumulative %
33.0 55.5 65.5 73.0 79.0
6
7 8 9 10 11 12 13 14
Production Engineering
Personnel Information Systems Stores Research & Development Others Quality Factory production Manufacturing Planning
10
8 6 5 4 4 2 2 1 200
5.0
4.0 3.0 2.5 2.0 2.0 1.0 1.0 0.5 100
84.0
88.0 91.0 93.5 95.5 97.5 98.5 99.5 100.0
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Sl.No
1 2 3 4 5
Department
Materials Marketing Plant Maintenance Finance Service
Nos.
66 45 20 15 12
Relative %
33.0 22.5 10.0 7.5 6.0
Cumulative %
33.0 55.5 65.5 73.0 79.0
VITAL FEW
10
8
6
7 8 9 10 11 12 13 14
Production Engineering
Personnel Information Systems Stores Others Quality Factory production Manufacturing Planning
5.0
4.0 3.0 2.5 2.0 2.0 1.0 1.0 0.5 100
84.0
88.0 91.0 93.5 95.5 97.5 98.5 99.5 100.0
TRIVIAL MANY
6 5 4 4 2 2 1 200
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Sl.No
1 2 3
Department
Materials Marketing Plant Maintenance
Nos.
66 45 20
Relative %
33.0 22.5 10.0
Cumulative %
33.0 55.5 65.5
4
5
Finance
Others
15
60 200
7.5
27 100
73.0
100
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Vital Few
70 %
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Why pareto ?
To Clearly prioritise the magnitude of the problem. To identify the vital few and trivial many problems.
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1. STRUCTURED
IN THIS METHOD EVERY PERSON IN A GROUP MUST GIVE AN IDEA AS THEIR TURN ARISES IN THE ROTATION OR PASS UNTIL THE NEXT ROUND. IT OFTEN FORCES EVEN SHY PEOPLE TO PARTICIPATE AND ALSO CREATE A CERTAIN AMOUNT OF PRESSURE TO CONTRIBUTE. 2. UNSTRUCTURED IN THIS METHOD, GROUP MEMBERS SIMPLY GIVE IDEAS AS THEY COME TO MIND. IT TENDS TO CREATE MORE RELAXED ATMOSPHERE BUT ALSO RISKS DOMINATION. THUMB RULE : 5 15 MINUTRES WORKS WELL
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BRAIN STORMING BRAIN STORMING IS A TECHNIQUE TO OBTAIN CREATIVE IDEAS FROM A GROUP OF PERSONS IN A SHORTEST POSSIABLE TIME ON AN EFFECT. BRAIN STORMING PLAYS AN IMPORTANT ROLE TO BUILD A CAUSE AND EFFECT DIAGRAM
WHY
TO IDENTIFY THE PROBLEM - TO IDENYIFY THE CAUSES TO FIND SOLUTION - TO PREVENT PROBLEM
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BRAIN STROOMING SESSION
Let all the members speak freely and give ideas Encourage wild ideas
TO IDENTIFY THE PROBLEM TO IDENTIFY CRITICAL CAUSES TO FIND THE SOLUTION TO PREVENT THE PROBLEM
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EFFECT IS WHAT? HAPPENS CAUSE IS WHY? IT HAPPENS
EFFECT = RESULT OR OUTCOME CAUSE = REASON(S) OR FACTOR(S) CONTRIBUTING TO THE EFFECT THE ANALYSIS OF WHY? FOR WHAT? IS CAUSE AND EFFECT DIAGRAM
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The cause and effect diagram was developed by Dr.K.ISHIKAWA to represent the relationship between EFFECT or PROBLEM and all the possible CAUSES influencing it.
For every EFFECT there are likely to be several CAUSES.
The major causes can be summarized generally under four categories known as 4MsMAN,MACHINE,MATERIAL & METHOD, OR 4Ps PLANT,POLICY,PEOPLE,PROCEDURE
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EFFECT
A Result or an outcome.
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METHOD
Sub cause
MATERIAL
Sub-sub cause
MAN
MACHINE
CAUSES
EFFECT
The EFFECT or PROBLEM is stated on the right side of the diagram and the major INFLUENCES or CAUSES are listed to the left.
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METHOD
Sub cause
MATERIAL
Sub-sub cause
PROBLEM
MAN
MACHINE
CAUSES
EFFECT
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Non-standard HANDLING COPYING PAPER Not using specified quality of paper Over consumption Paper shortage No communication Serviced by unauthorized persons Improper service No periodical service No stabilizer Power Limited machines High fluctuation
Not understanding the defect Party removed codes/ communicating defects Paper jam Wrong paper not cleared usage properly Lack of Paper with stables Untrained personnel knowledge handling the machine Supply from various sources Nominated persons Non-standard not handling Dust accumulation Location No cleaning Heavy usage Frequent changes
MACHINE
PROCESS CONSUMABLES
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Material
Man
Improper
Assembly
Missing
Worn out
SQ. Drive
missing
Not provided
Needle
Pinion Broken
Hammering
Speedometer
Method
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Cause and Effect Diagram Or Ishikawa Diagram Or Fishbone Diagram It gives the relationship between Effect or Problem and all the possible cause influencing it. For every effect, there are likely to be several causes. Normally, causes are analyzed under 4 categories such 4 ms Man, Machine, Material and Method Or 4 P Plant, Process, Procedure and People
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Cost Stratification Beeorr Guard
S tr a ti fi c a ti o n
cost RS. 2.80 cost RS. 0.80 can be serviced to old customers simple assembly can be serviced at a high cost of Rs. 141/- to old customers high rate of handling damages
Casting
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Effect
Causes
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Effect
Causes
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7 QC TOOLS Definition
Stratification is nothing but the act of dividing data to the fine tune, in order to make sure of the significance of the assured factors, to the grass root level.
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Case study
Sales %
208
Numbers
75
54
50 25 0 < 5000 5000 - 100001 - > 25000 200001 - 150001 10000 15000 25000 20000
20 4 21 1 2 1 1 1 1
Magazine Value
Total Inventory
Components
Work in process
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Histogram is an important diagnostic tool which gives a Birds eye-view of the variation in a data set. It is nothing but a frequency distribution chart. Histogram helps to actually judge the changes in quality characteristic of a group and the dispersion manner against the mid-value. The Pareto Diagram deals only with characteristic of a procut or service such as type of defects, problem, etc. However, a histogram takes measurement data and reveals the amount of variation.
Material
People
Machine methods
Environment
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CASE STUDY
STEP 1
Period Material UOM Thickness : wk no. 15 to 20 : ms flange collar : mm : 9 mm + 1.5 mm
Collect data
9.9 9.8 9.7 10.2 9.9 9.3 9.0 10.0 9.5 9.6 10.3 9.5 9.9 9.9 9.3 9.8 9.4 10.1 10.7 10.2 9.5 9.7 9.7 9.4 9.6 9.5 10.4 10.2 10.2 10.1 9.6 9.8 9.3 9.2 9.7 9.4 10.6 10.1 9.7 9.8 9.3 9.8 9.4 10.1 9.9 9.7 10.0 9.8 10.1 10.3 10.3 9.9 9.9 9.7 9.7 9.8 9.8 9.4 9.5 10.1 9.5 10.1 9.7 10.1 9.9 9.2 9.6 10.2 9.3 9.6 N = 125 9.6 9.8 9.9 10.0 9.8 9.9 9.8 9.6 10.0 10.2 9.8 10.0 9.7 9.5 10.1 10.0 10.4 9.8 9.5 9.5 9.6 10.3 10.1 9.5 10.0 9.7 9.7 10.7
9.9 9.9 10.1 10.2 9.8 9.8 9.3 10.0 9.8 9.8 9.7 10.0 9.7 9.6
9.8 9.6 10.0 10.7 9.4 9.4 9.7 9.8 9.3 9.3 10.0 9.7 10.7
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CASE STUDY
STEP 2
9.9 9.8 9.7 10.2 9.9 9.3 9.0 10.0 9.5 9.6 10.3 9.5 9.9 9.9
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CASE STUDY Divide the R in to No. Of Classes, referred to as K 125 data points would be broken down in to 7 12 classes. Method - 1 No.of data points Under 50 50 100 100 250 Over 250 No. of classes 57 6 10 7 12 10 - 20 Method 2 No. Of Classes K =N where, N = No. Of sample For example, if N = 125
STEP 4
K =125 = 11
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CASE STUDY
STEP 3
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CASE STUDY
STEP 5
Determine the class width H R K 1.7 = 0.17 10 Can be rounded off to 0.20 (Range) = H (# of classes)
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CASE STUDY
STEP 6
For simple determination of class boundaries, take the smallest individual measurement in the data set. Use this number or round to the next appropriate lowest number. This will be lower end point for our first class boundary.
In our example this would be 9.0. Now take this number and add the class width to it, 9.00 + 0.20. But it is essential to fix class boundaries in such way that every observed reading will fit in to one and only class. Therefore, we may choose the class boundaries with one decimal place more than the observed readings. For example, if the observations are in one decimal, the class boundaries will be in two decimals and so on. For our case study, it will be 8.95 + 0.20 = 9.15 Finally, consecutively add the class width, to the lowest class boundary until the correct number of classes, approximately 10 and containing the range of all our numbers is obtained.
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CASE STUDY
STEP 7
Class Class Midpoint # Boundaries 1 2 3 4 5 6 7 8 9 10 8.95-9.15 9.15-9.35 9.35-9.55 9.55-9.75 9.75-9.95 9.95-10.5 10.5-10.35 10.35-10.55 10.55-10.75 10.75-10.95 9.05 9.25 9.45 9.65 9.85 10.05 10.25 10.45 10.65 10.85
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CASE STUDY
STEP 8
Construct Histogram
35 30
Frequency
USL
Thickness in mm
The specification for the thickness characteristic is 7.5 to 10.5, with a target of 9. The above Histogram indicates the process is targeted high and that 3% may be above the upper specification limit.
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# Of Responses
10
63
64
65 66
67
68
69
70 71
Minutes
Histogram-Manufacturing Print Density
8 6 4 2 0 0.6 0.7 0.8 0.9 0.1 1.1 1.2 1.3 1.4 Block density of print
Frequency
Height (inches)
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Interpretation Tips
No. Of classes (bars in the graph) determine how much of a pattern will be visible. Some processes are naturally skewed; dont expect every distribution to follow a bell shaped curve. Get suspicious of the accuracy of the data if the classes suddenly stop at one point (such as a specification limit) without some previous decline in number. Always look for twin peaks indicating that the data is coming from two or more different sources, e.g., shifts machines, etc.,
Scatter diagram
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Scatter diagram
7 QC TOOLS In actual practice, it is often essential to study the relation of two corresponding variables.
For example, to what extent will the dimension of a machined part be varied by the change in the speed of a lathe?
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To study the relation of two variables such as the speed of the lathe & the dimension of the part we can use what is called a Scatter diagram.
7 QC TOOLS The two variables we will deal with are: a) A quality characteristic & a factor affecting it,
7 QC TOOLS Step 1 Collect paired data (x,y) between which you want to study the relations & arrange the data in a table. It is desirable to have at least 30 pairs of data.
7 QC TOOLS Step 2 Find the maximum & minimum values for both x & y. Decide the scales of horizontal & vertical axes so that both the lengths become approximately equal, then the diagram will be easier to read. Keep the number of unit graduations between 3 to 10 for each axis & use round numbers to make it easier to read.
Step 4
Enter all necessary items. Make sure that the following items are included so that anyone besides the maker of the diagram can understand at a glance:
7 QC TOOLS Example A manufacturer of plastic tanks who made them using the blow moulding process encountered problems with defective tanks that had thin tank walls. It was suspected that the variation in air pressure, which varied from day to day, was the cause of the defective thin walls. The table shows data on blowing pressure & percent defective. Let us draw a scatter diagram using this data according to the steps given previously.
Data of blowing air pressure & percent defective of plastic tank Date Air pressure Percent (kgf/cm2) Defective Oct-01 8.6 0.889 2 8.9 0.884 3 8.8 0.874 4 8.8 0.891 5 8.4 0.874 6 8.7 0.886 7 9.2 0.911 8 8.6 0.912 9 9.2 0.895 10 8.7 0.896 11 8.4 0.894 12 8.2 0.864 13 9.2 0.922 14 8.7 0.909 15 9.4 0.905 16 8.7 0.892 17 8.5 0.877 18 9.2 0.885 19 8.5 0.866 20 8.3 0.896 21 8.7 0.896 22 9.3 0.928 23 8.9 0.886 24 8.9 0.908 25 8.3 0.881 26 8.7 0.882 27 8.9 0.904 28 8.7 0.912 29 9.1 0.925 30 8.7 0.872
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Step 1
As seen in the table, we have 30 pairs of data. Step 2
In this example, let blowing air pressure be indicated by X (horizontal axis), & percent defective by Y (vertical axis).
Then,
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We mark off the horizontal axis in 0.5(kgf/cm2) intervals, from 8.0 to 9.5 (kgf/cm2) and the vertical axis in0.01(%) intervals, from 0.85 to 0.93(%) Step 3 Plot the data.
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0.93 0.92 0.91 0.9 0.89 0.88 0.87 0.86 0.85 8 8.5 9 9.5
Step 4
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Enter the time interval of the sample obtained (oct.1 oct 30) number of samples (n = 30), horizontal axis (blowing air pressure [kgf/cm2]), vertical axis (percent defective [%]), and title of diagram (scatter diagram of blowing air pressure & percent defective).
0.93 0.92 0.91 0.9 0.89 0.88 0.87 0.86 0.85 8 8.5 9 9.5
n=30
7 QC TOOLS How to read scatter diagrams You can grasp the correlation between pairs of data just by looking at the shape of a scatter diagram. 5 examples are given below
35 30 25 20 15 10 5 0 0 5 10 15 20
350 300 250 200 150 100 50 0 0 100 200 300 400
Series1
Series1
Positive correlation
Negative correlation
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40 30 20 10 0 0 5 10 15 20 Series1
500 400 300 200 100 0 0 100 200 300 400 Series1
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700 600 500 400 300 200 100 0 0 100 200 300 400
Series1
No correlation
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Thank you