Quality Tools Quality Tools Problem Solving
Oct 20, 2014
Quality ToolsQuality ToolsProblem Solving
Munif Ahmad/Introduction To Management/ Quality Improvement
Quality Control ToolsQuality Control Tools• Pareto chart• Histogram • Process flow diagram• Check sheet• Scatter diagram• Control chart
• Run chart
• Cause and effect diagram
Munif Ahmad/Introduction To Management/ Quality Improvement
Pareto chartPareto chart
7 Quality Tools7 Quality Tools
28
16
12 12
64 3
0
5
10
15
20
25
30
LooseThreads
Stitchingflaws
Buttonproblems
Materialflaws
% C
om
pla
ints
Munif Ahmad/Introduction To Management/ Quality Improvement
Pareto Pareto Chart Chart
Per
cent
fro
m e
ach
caus
e
Causes of poor quality
Mac
hine
cal
ibra
tions
Defec
tive
parts
Wro
ng d
imen
sions
Poor D
esig
n
Ope
rato
r erro
rsDef
ectiv
e m
ater
ials
Surfa
ce a
bras
ions
0
10
20
30
40
50
60
70(64)
(13)(10)
(6)(3) (2) (2)
Munif Ahmad/Introduction To Management/ Quality Improvement
HistogramHistogram
0
5
10
15
20
25
Category
Fre
qu
ency
7 Quality Tools7 Quality Tools
Munif Ahmad/Introduction To Management/ Quality Improvement
HistogramHistogram
0
510152025303540
1 2 6 13 10 16 19 17 12 16 20 17 13 5 6 2 1
Munif Ahmad/Introduction To Management/ Quality Improvement
FlowchartsFlowcharts Flowcharts
• Graphical description of how work is done.• Used to describe processes that are to be
improved.
7 Quality Tools7 Quality Tools
Munif Ahmad/Introduction To Management/ Quality Improvement
Flow DiagramsFlow Diagrams
" Draw a flowchart for whatever you do. Until you do, you do not know what you are doing, you just have a job.”
-- Dr. W. Edwards Deming.
Munif Ahmad/Introduction To Management/ Quality Improvement
FlowchartFlowchart
Activity
DecisionYesYes
NoNo
7 Quality Tools7 Quality Tools
Munif Ahmad/Introduction To Management/ Quality Improvement
FlowchartFlowchart
Munif Ahmad/Introduction To Management/ Quality Improvement
Flow DiagramsFlow Diagrams
Munif Ahmad/Introduction To Management/ Quality Improvement
Flow DiagramsFlow Diagrams
Process Chart SymbolsProcess Chart Symbols
Operations
Inspection
Transportation
Delay
Storage
Munif Ahmad/Introduction To Management/ Quality Improvement
Munif Ahmad/Introduction To Management/ Quality Improvement
Process ChartProcess ChartS
tep
Op
erat
ion
Tra
nsp
ort
Insp
ect
Del
ayS
tora
ge
Dis
tan
ce(f
eet)
Tim
e(m
in)Description
ofprocess
1
2
3
4
5
6
7
8
9
10
11
Unload apples from truck
Move to inspection station
Weigh, inspect, sort
Move to storage
Wait until needed
Move to peeler
Apples peeled and cored
Soak in water until needed
Place in conveyor
Move to mixing area
Weigh, inspect, sort
TotalPage 1 0f 3 480
30
5
20
15
360
30
20
190 ft
20 ft
20 ft
50 ft
100 ft
Date: 9-30-00
Analyst: TLR
Location: Graves Mountain
Process: Apple Sauce
Munif Ahmad/Introduction To Management/ Quality Improvement
Munif Ahmad/Introduction To Management/ Quality Improvement
Check SheetCheck SheetCheck SheetCheck Sheet
ShiftsShifts
De
fect
Typ
eD
efe
ct T
ype
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Munif Ahmad/Introduction To Management/ Quality Improvement
Check SheetCheck Sheet
COMPONENTS REPLACED BY BSB LABTIME PERIOD: 22 Feb to 27 Feb 2011REPAIR TECHNICIAN: Hj. Ottman Bin Hj Ghani
TV SET MODEL 1013
Integrated Circuits ||||
Capacitors |||| |||| |||| |||| |||| ||
Resistors ||
Transformers ||||
CommandsCRT |
Munif Ahmad/Introduction To Management/ Quality Improvement
Cause-and-Effect DiagramsCause-and-Effect DiagramsCause-and-Effect DiagramsCause-and-Effect Diagrams Show the relationships between a
problem and its possible causes. Developed by Kaoru Ishikawa (1953) Also known as …
• Fishbone diagrams• Ishikawa diagrams
7 Quality Tools7 Quality Tools
Munif Ahmad/Introduction To Management/ Quality Improvement
Cause and Effect Cause and Effect “Skeleton”“Skeleton”Cause and Effect Cause and Effect “Skeleton”“Skeleton”
QualityProblem
Materials
EquipmentPeople
Procedures
7 Quality Tools7 Quality Tools
Munif Ahmad/Introduction To Management/ Quality Improvement
Fishbone Diagram Fishbone Diagram
QualityProblem
MachinesMeasurement Human
ProcessEnvironment Materials
Faulty testing equipment
Incorrect specifications
Improper methods
Poor supervision
Lack of concentration
Inadequate training
Out of adjustment
Tooling problems
Old / worn
Defective from vendor
Not to specifications
Material-handling problems
Deficienciesin product design
Ineffective qualitymanagement
Poor process design
Inaccuratetemperature control
Dust and Dirt
Munif Ahmad/Introduction To Management/ Quality Improvement
Cause and effect diagramsCause and effect diagrams Advantages
• making the diagram is educational in itself• diagram demonstrates knowledge of
problem solving team• diagram results in active searches for
causes• diagram is a guide for data collection
Munif Ahmad/Introduction To Management/ Quality Improvement
Cause and effect diagramsCause and effect diagrams
To construct the skeleton, remember: For Manufacturing - the 4 M’s
man, method, machine, material For Service applications
equipment, policies, procedures, people
Munif Ahmad/Introduction To Management/ Quality Improvement
Scatter DiagramScatter Diagram
.
Munif Ahmad/Introduction To Management/ Quality Improvement
Run ChartsRun Charts Run Charts (time series plot)
• Examine the behavior of a variable over time.
• Basis for Control Charts