Seven Quality Tools.ppt

WORK BOOK WORK BOOK PRESENTATIONPRESENTATION

Seven Quality ToolsSeven Quality Tools

PRESENTED BY: - MOHIT BANSAL0821002764

• After World War II the Japanese adopted After World War II the Japanese adopted 'quality' as a philosophy for economic 'quality' as a philosophy for economic recovery and, in line with this traditional recovery and, in line with this traditional approach, sought seven tools to approach, sought seven tools to accomplish the economic rejuvenation. accomplish the economic rejuvenation. The seven tools chosen were: The seven tools chosen were:

Seven Quality ToolsSeven Quality Tools

Seven Quality ToolsSeven Quality Tools•The Seven ToolsThe Seven Tools

– HistogramsHistograms– Pareto ChartsPareto Charts– Cause and Effect DiagramsCause and Effect Diagrams– Run ChartsRun Charts– Scatter DiagramsScatter Diagrams– Flow ChartsFlow Charts– Control ChartsControl Charts

Ishikawa’s Basic Tools of Ishikawa’s Basic Tools of QualityQuality

• Kaoru Ishikawa developed seven basic Kaoru Ishikawa developed seven basic visual tools of quality so that the average visual tools of quality so that the average person could analyze and interpret data.person could analyze and interpret data.

• These tools have been used worldwide by These tools have been used worldwide by companies, managers of all levels and companies, managers of all levels and employees.employees.

HistogramsHistograms

• Histogram DefinedHistogram Defined– A histogram is a bar graph that shows A histogram is a bar graph that shows

frequency data.frequency data.– Histograms provide the easiest way to Histograms provide the easiest way to

evaluate the distribution of data.evaluate the distribution of data.

HistogramsHistograms

• Creating a HistogramCreating a Histogram– Collect data and sort it into categories.Collect data and sort it into categories.– Then label the data as the independent set or Then label the data as the independent set or

the dependent set.the dependent set.• The characteristic you grouped the data by would The characteristic you grouped the data by would

be the independent variable.be the independent variable.• The frequency of that set would be the dependent The frequency of that set would be the dependent

variable.variable.– Each mark on either axis should be in equal Each mark on either axis should be in equal

increments. increments. – For each category, find the related frequency For each category, find the related frequency

and make the horizontal marks to show that and make the horizontal marks to show that frequency.frequency.

HistogramsHistograms

• Examples of How Histograms Can Be Examples of How Histograms Can Be UsedUsed– Histograms can be used to determine Histograms can be used to determine

distribution of sales.distribution of sales.– Say for instance a company wanted to Say for instance a company wanted to

measure the revenues of other measure the revenues of other companies and wanted to compare companies and wanted to compare numbers.numbers.

Pareto ChartsPareto Charts• Pareto Chart DefinedPareto Chart Defined

– Pareto charts are used to identify and prioritize Pareto charts are used to identify and prioritize problems to be solved.problems to be solved.

– They are actually histograms aided by the They are actually histograms aided by the 80/20 rule adapted by Joseph Juran.80/20 rule adapted by Joseph Juran.• Remember the 80/20 rule states that approximately Remember the 80/20 rule states that approximately

80% of the problems are created by approximately 80% of the problems are created by approximately 20% of the causes.20% of the causes.

Pareto ChartsPareto Charts

• Constructing a Pareto ChartConstructing a Pareto Chart– First, information must be selected based First, information must be selected based

on types or classifications of defects that on types or classifications of defects that occur as a result of a process.occur as a result of a process.

– The data must be collected and classified The data must be collected and classified into categories.into categories.

– Then a histogram or frequency chart is Then a histogram or frequency chart is constructed showing the number of constructed showing the number of occurrences.occurrences.

Pareto ChartsPareto Charts

• An Example of How a Pareto Chart Can Be An Example of How a Pareto Chart Can Be UsedUsed– Pareto Charts are used when products are suffering from Pareto Charts are used when products are suffering from

different defects but the defects are occurring at a different defects but the defects are occurring at a different frequency, or only a few account for most of different frequency, or only a few account for most of the defects present, or different defects incur different the defects present, or different defects incur different costs. What we see from that is a product line may costs. What we see from that is a product line may experience a range of defects. The manufacturer could experience a range of defects. The manufacturer could concentrate on reducing the defects which make up a concentrate on reducing the defects which make up a bigger percentage of all the defects or focus on bigger percentage of all the defects or focus on eliminating the defect that causes monetary loss. eliminating the defect that causes monetary loss.

• Actual chart is on the next slideActual chart is on the next slide

Pareto ChartsPareto Charts

Cause and Effect DiagramsCause and Effect Diagrams

• Cause and Effect Diagram DefinedCause and Effect Diagram Defined– The cause and effect diagram is also called the Ishikawa The cause and effect diagram is also called the Ishikawa

diagram or the fishbone diagram.diagram or the fishbone diagram.– It is a tool for discovering all the possible causes for a It is a tool for discovering all the possible causes for a

particular effect.particular effect.– The major purpose of this diagram is to act as a first The major purpose of this diagram is to act as a first

step in problem solving by creating a list of possible step in problem solving by creating a list of possible causes.causes.

Cause and Effect DiagramsCause and Effect Diagrams

• Constructing a Cause and Effect DiagramConstructing a Cause and Effect Diagram– First, clearly identify and define the problem or effect for First, clearly identify and define the problem or effect for

which the causes must be identified. Place the problem which the causes must be identified. Place the problem or effect at the right or the head of the diagram.or effect at the right or the head of the diagram.

– Identify all the broad areas of the problem.Identify all the broad areas of the problem.– Write in all the detailed possible causes in each of the Write in all the detailed possible causes in each of the

broad areas.broad areas.– Each cause identified should be looked upon for further Each cause identified should be looked upon for further

more specific causes.more specific causes.– View the diagram and evaluate the main causes.View the diagram and evaluate the main causes.– Set goals and take action on the main causes.Set goals and take action on the main causes.

Cause and Effect DiagramsCause and Effect Diagrams

• An Example of When a Cause and An Example of When a Cause and Effect Diagram Can Be UsedEffect Diagram Can Be Used– This diagram can be used to detect the This diagram can be used to detect the

problem of incorrect deliveriesproblem of incorrect deliveries– When a production team is about to launch a When a production team is about to launch a

new product, the factors that will affect the new product, the factors that will affect the final product must be recognized. The final product must be recognized. The fishbone diagram can depict problems before fishbone diagram can depict problems before they have a chance to begin.they have a chance to begin.

Cause and Effect DiagramsCause and Effect Diagrams

Diagram of the Incorrect Deliveries Example:Diagram of the Incorrect Deliveries Example:

Scatter DiagramsScatter Diagrams

• Scatter Diagrams DefinedScatter Diagrams Defined– Scatter Diagrams are used to study and Scatter Diagrams are used to study and

identify the possible relationship identify the possible relationship between the changes observed in two between the changes observed in two different sets of variables.different sets of variables.

Scatter DiagramsScatter Diagrams• Constructing a Scatter DiagramConstructing a Scatter Diagram

– First, collect two pieces of data and create a First, collect two pieces of data and create a summary table of the data.summary table of the data.

– Draw a diagram labeling the horizontal and Draw a diagram labeling the horizontal and vertical axes. vertical axes. • It is common that the “cause” variable be labeled on the X It is common that the “cause” variable be labeled on the X

axis and the “effect” variable be labeled on the Y axis.axis and the “effect” variable be labeled on the Y axis.– Plot the data pairs on the diagram.Plot the data pairs on the diagram.– Interpret the scatter diagram for direction and Interpret the scatter diagram for direction and

strength.strength.

Scatter DiagramsScatter Diagrams

• An Example of When a Scatter An Example of When a Scatter Diagram Can Be UsedDiagram Can Be Used– A scatter diagram can be used to A scatter diagram can be used to

identify the relationship between the identify the relationship between the production speed of an operation and production speed of an operation and the number of defective parts made. the number of defective parts made.

Scatter DiagramsScatter Diagrams

• An Example of When a Scatter Diagram Can Be An Example of When a Scatter Diagram Can Be Used (cont.)Used (cont.)– Displaying the direction of the relationship will Displaying the direction of the relationship will

determine whether increasing the assembly line speed determine whether increasing the assembly line speed will increase or decrease the number of defective parts will increase or decrease the number of defective parts made. Also, the strength of the relationship between made. Also, the strength of the relationship between the assembly line speed and the number of defective the assembly line speed and the number of defective parts produced is determined.parts produced is determined.

Flow ChartsFlow Charts

• Flow Charts DefinedFlow Charts Defined– A flow chart is a pictorial representation A flow chart is a pictorial representation

showing all of the steps of a process.showing all of the steps of a process.

Flow ChartsFlow Charts

• Creating a Flow ChartCreating a Flow Chart– First, familiarize the participants with the flow First, familiarize the participants with the flow

chart symbols.chart symbols.– Draw the process flow chart and fill it out in Draw the process flow chart and fill it out in

detail about each element.detail about each element.– Analyze the flow chart. Determine which steps Analyze the flow chart. Determine which steps

add value and which don’t in the process of add value and which don’t in the process of simplifying the work.simplifying the work.

Flow ChartsFlow Charts

• Examples of When to Use a Flow Examples of When to Use a Flow ChartChart– Two separate stages of a process flow Two separate stages of a process flow

chart should be considered:chart should be considered:•The making of the productThe making of the product•The finished productThe finished product

Run ChartsRun Charts

• Run Charts DefinedRun Charts Defined– Run charts are used to analyze Run charts are used to analyze

processes according to time or order.processes according to time or order.

Run ChartsRun Charts• Creating a Run ChartCreating a Run Chart

– Gathering DataGathering Data• Some type of process or operation must be available to take Some type of process or operation must be available to take

measurements for analysis.measurements for analysis.– Organizing DataOrganizing Data

• Data must be divided into two sets of values X and Y. X values Data must be divided into two sets of values X and Y. X values represent time and values of Y represent the measurements taken represent time and values of Y represent the measurements taken from the manufacturing process or operation.from the manufacturing process or operation.

– Charting DataCharting Data• Plot the Y values versus the X values.Plot the Y values versus the X values.

– Interpreting DataInterpreting Data• Interpret the data and draw any conclusions that will be beneficial to Interpret the data and draw any conclusions that will be beneficial to

the process or operation.the process or operation.

Run ChartsRun Charts• An Example of Using a Run ChartAn Example of Using a Run Chart

– An organization’s desire is to have their An organization’s desire is to have their product arrive to their customers on time, but product arrive to their customers on time, but they have noticed that it doesn’t take the same they have noticed that it doesn’t take the same amount of time each day of the week. They amount of time each day of the week. They decided to monitor the amount of time it takes decided to monitor the amount of time it takes to deliver their product over the next few to deliver their product over the next few weeks.weeks.

Control ChartsControl Charts

• Control Charts DefinedControl Charts Defined– Control charts are used to determine Control charts are used to determine

whether a process will produce a whether a process will produce a product or service with consistent product or service with consistent measurable properties.measurable properties.

Control ChartsControl Charts• Steps Used in Developing Process Control Steps Used in Developing Process Control

ChartsCharts– Identify critical operations in the process where Identify critical operations in the process where

inspection might be needed.inspection might be needed.– Identify critical product characteristics.Identify critical product characteristics.– Determine whether the critical product Determine whether the critical product

characteristic is a variable or an attribute.characteristic is a variable or an attribute.– Select the appropriate process control chart.Select the appropriate process control chart.– Establish the control limits and use the chart to Establish the control limits and use the chart to

monitor and improve.monitor and improve.– Update the limits.Update the limits.

Control ChartsControl Charts

• An Example of When to Use a Control An Example of When to Use a Control ChartChart– Counting the number of defective Counting the number of defective

products or servicesproducts or services•Do you count the number of defects in a Do you count the number of defects in a

given product or service?given product or service?• Is the number of units checked or tested Is the number of units checked or tested

constant?constant?

ActivityActivity• Process Flow Chart for Finding the Best Process Flow Chart for Finding the Best

Way HomeWay Home– Construct a process flow chart by making Construct a process flow chart by making

the best decisions in finding the best route the best decisions in finding the best route home.home.

– Refer to the prior notes on flowcharts.Refer to the prior notes on flowcharts.•Remember: Define and analyze the process, Remember: Define and analyze the process,

build a step-by step picture of the process, and build a step-by step picture of the process, and define areas of improvement in the process.define areas of improvement in the process.

SummarySummaryThis presentation provided learning material for each of This presentation provided learning material for each of Ishikawa’s seven basic tools of quality. Ishikawa’s seven basic tools of quality.

Each tool was clearly defined with definitions, a step-by-Each tool was clearly defined with definitions, a step-by-step process and an example of how the tool can be used. step process and an example of how the tool can be used.

These tools can be used for solving process problems These tools can be used for solving process problems

Only practicing this tools make the man perfect.Only practicing this tools make the man perfect.