Seven Tools Ppt

8/13/2019 Seven Tools Ppt

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ISHIKAWAS BASIC TOOLS OF QUALITY

Kaoru Ishikawa developed seven basic visualtools of quality so that the average personcould analyze and interpret data.

These tools have been used worldwide bycompanies, managers of all levels andemployees.

SEVEN TOOLS OF QUALITY-


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Are the fundamental methods for gathering& analyzingquality related data.

1) CHECK SHEET/ DEFECT CONCENTRATIONDIAGRAM The check sheet is a simple document that is used for

collecting data in real-time and at the location where thedata is generated.

Is a form used to collect information in such a way that itmakes not only the collection of data easy, but also theanalysis of that data automatic.

The function is to present information in an efficient ,graphical format.

In this the operator merely adds a mark to the tally on the

prepared sheet.


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The document is typically a blank form that is designed forthe quick, easy, and efficient recording of the desired

information, which can be either quantitative or qualitative.When the information is quantitative, the checksheet issometimes called a tally sheet.

The frequency of a particular defect helps the operators tospot problems.

WHEN TO USE When data can be observed and collected repeatedly by the

same person or at the same location.When collecting data on the frequency or patterns of events,

problems, defects, defect location, defect causes, etc.

When collecting data from a production process.


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Check Sheet Procedure-

Decide what event or problem will be observed.Develop operational definitions.

Decide when data will be collected and for how long.

Design the form. Set it up so that data can be recorded

simply by making check marks or Xs or similarsymbols and so that data do not have to be recopied foranalysis.

Label all spaces on the form.

Test the check sheet for a short trial period to be sure itcollects the appropriate data and is easy to use.

Each time the targeted event or problem occurs, recorddata on the check sheet.


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DefectiveItem

2/5(M)

2/6(T)

2/7(W)

2/8(T)

2/9(F)

Total

Mold

Cracked

//// /// // //// // 15

Fibers // //// / 7Pinholes //// // /// / 12Spots

/ //// //7

Seamdefects

// /// // //// 11

Other / /// // 6

Total 11 12 11 14 8 56

CHECK LISTProduct NameXXXXXXX

Line NameABC


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2) PARETO CHARTS-

Named after Italian economist Vilfred Pareto.

Is a graphical tool for ranking causes of problems from themost significant to the least significant.

Its is a bar graph. The lengths of the bars represent frequency

or cost (time or money), and are arranged with longest bars onthe left and the shortest to the right.

The number of occurrences of an events is arranged in thedescending order.

It puts the data in a hierarchical order which allows thesignificant problems to be corrected first.

Helps to identify those defects that cause most problems.


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When analyzing data about the frequency of problems or causesin a process.

When there are many problems or causes and you want to focuson the most significant.

When analyzing broad causes by looking at their specificcomponents.

When communicating with others about your data.

When to Use

To identify the VITAL FEW FROM TRIVIAL MANY and to concentrate on the vital few for improvement.

They are actually histograms aided by the 80/20 rule.

Remember the 80/20 rule states that approximately 80%of the problems are created by approximately 20% of thecauses.

A Pareto diagram indicates which problem we should solvefirst in eliminating defects and improving the operation.


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Pareto Chart Procedure-

Decide what categories you will use to group items.Decide what measurement is appropriate. Commonmeasurements are frequency, quantity, cost and time.

Decide what period of time the Pareto chart will cover: Onework cycle? One full day? A week?

Collect the data, recording the category each time. (Or assembledata that already exist.)

Subtotal the measurements for each category.Determine the appropriate scale for the measurements you have

collected. The maximum value will be the largest subtotal fromstep 5. Mark the scale on the left side of the chart.

Construct and label bars for each category. Place the tallest atthe far left, then the next tallest to its right and so on. If there are

many categories with small measurements, they can be groupedas other.


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Example #1 shows how many customercomplaints were received in each of fivecategories.


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3) Flowchart-

A flowchart is defined as a pictorial representationdescribing a process being studied.

Flowcharts can be used for:(i) defining and analyzing processes;(ii) building a step by step picture of the process for analysis,

discussion, or communication purposes;(iii) defining, standardizing, or finding areas for improvement

in a process;(iv)comparing and contrasting the actual work flow of a

process with an ideal flow; and(v)to help train employees

Flow charting is the first step we take in understanding a process.


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Flow charts can be drawn in many styles.

They can be drawn by using pictures, engineering symbols,or just squares and rectangles.

Also, flow charts can be used to describe a single process, parts of a process, or a set of processes.

There is no right or wrong way to draw a flow chart.By breaking the process down into its constituent steps,

flowcharts can be useful in identifying where errors are.


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Shirts arrivefrom laundry

Pull shirts

From rack

Removehangers

Inspectfor damages Note anyrepair req.

Damage Discard

Sort acc.To size

FoldShirt

PlaceOn

Rack

Check forProper rack

OKOr

Not

UpdateRecords

Yes

No

Yes

Steps:Dry-cleaned shirts arrive at laundryArranged / kept on racksPut shirts from rackRemove hangerInspect Note repair needsDiscard if badly damaged

Sort according to sizeFold shirtPlace on proper rack

Dry-cleaning& Repair process


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4) CAUSE & EFFECT DIAGRAM

Also referred as Ishikawa Diagram after its inventor.

Also known as Fish bone because of its shape, similar to theside view of a fish skeleton.

The fishbone diagram identifies many possible causes for aneffect or problem.

It can be used to structure a brainstorming session. Itimmediately sorts ideas into useful categories

It is simply a diagram that shows the causes of a certain event.

The undesirable outcome is shown as effect & related causesare shown as leading to or potentially leading to said effect.


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Steps:Identify & state the problem.

Identify the causesBrainstorm the major categories of causes of theproblem. If this is difficult use generic headings:

MethodsMachines (equipment)People (manpower)MaterialsMeasurementEnvironment

Now organize the causes & sub causes in diagramformat.

Helps the person to think systematically & logically.

It graphically illustrates the relationship between a


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WHEN TO USE-

When identifying possible causes for a problem.Especially when a teams thinking tends to fall into ruts.


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E.g- Possible causes for tackling pattern alignment errors.

CustomersDirectionunclear

Incorrectlyaligned pattern

EFFECT

Method Materials

Information Machines People

No StandardOperating

procedure

Pattern Not proper

TemplatePlace

wrong

TrainingIgnored

instruction

CAUSES


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Seam Puckering

PoorPermanentPresscutting

Unskilledoperator

Thread tensionToo tight

Structural jamming

Too many stitchesPer inch

CAUSES EFFECT


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Diagram of the Incorrect Deliveries Example:


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5) HISTOGRAM-

Is a bar chart or bar graph

Plots data in a frequency distribution

The most commonly used graph for showing frequencydistributions, or how often each different value in a set ofdata occurs.

Histograms provide the easiest way to evaluate thedistribution of data.

Different from check sheet as in this data is grouped intorows so identity of individual value is list.

Graphical depiction of number of occurrences an event.

Works best with small amounts of data that varyconsiderably.


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WHEN TO USE

The data are numerical values.To see the shape of the datas distribution, especiallywhen determining whether the output of a process isdistributed approximately normally.

Analyzing whether a process can meet the customersrequirements.Analyzing what the output from a suppliers processlooks like.Whether a process change has occurred from onetime period to another.To determine whether the outputs of two or moreprocesses are different.To communicate the distribution of data quickly and

easily to others.


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HISTOGR M SH PES ND ME NING Normal. A common pattern is the

bell-shaped curve known as thenormal distribution. In anormal distribution, points are aslikely to occur on one side of theaverage as on the other .

Skewed. The skewed distribution isasymmetrical because a natural limit

prevents outcomes on one side.The distributions peak is off centertoward the limit and a tail stretchesaway from it.


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Double-peaked or bimodal. Thebimodal distribution looks likethe back of a two-humpedcamel.

The outcomes of two processeswith different distributions arecombined in one set of data.

A two-shift operation might bebimodal.

These distributions are called right- or left-skewed according tothe direction of the tail.


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For example, if your data ranges from 1.1 to 1.8, youcould have equal bins of 0.1 consisting of 1 to 1.1, 1.2 to1.3, 1.3 to 1.4, and so on.

The vertical axis of the histogram is labeled Frequency(the number of counts for each bin), and the horizontal axisof the histogram is labeled with the range of your response

variable.


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Examples of How Histograms Can Be Used Histograms can be used to determine distribution of

sales. Say for instance a company wanted to measure the

revenues of other companies and wanted tocompare numbers.


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6) SCATTER DIAGRAM or X Y graph or Scatter plot

It is a graphical technique that is used to analyze the

relationship between two a performance measure and factorsthat might be driving it.

The scatter diagram graphs pairs of numerical data, with onevariable on each axis, to look for a relationship between them.

If the variables are correlated, the points will fall along a lineor curve. The better the correlation, the tighter the points willhug the line.

It cannot prove that one variable causes the change in the

other.This graphical approach is quick, easy to communicate to

others, and generally easy to interpret.

It depicts that relationship exists & how strong it is.


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In this horizontal (x) axis represents themeasurement values of one variable & the vertical (y)axis represents the measurement of second variable.

E.g.- The strength of the yarn is dependent on twistsper inch, moisture absorbency in the fabric, fabricthickness & so on.

When to Use a Scatter Diagram

When you have paired numerical data.When trying to determine whether the two variables are related,

such asWhen trying to identify potential root causes of problems.

After brainstorming causes and effects using a fishbonediagram, to determine objectively whether a particular cause andeffect are related.

When determining whether two effects that appear to be related

both occur with the same cause.


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Positive Correlation

As the item on the X axis increases,

the item on the Y axis alsoincreases, and vice versa


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No relationship; Changing the values of item X does nothave any effect on the value of item Y,


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7) CONTROL CHART or Statistical process control -

Displays statistically determined upper & lower limits drawn

on either side of the process average.If the chart indicates that the process is currently under control

then it can be used with confidence to predict the future performance of the process.

If the chart indicates that the process being monitored is not incontrol, the pattern it reveals can help determine the source ofvariation to be eliminated to bring the process back into control.

This chart shows if the collected data are within upper or lowerlimits previously determined through statistical calculations ofraw data from earlier traits.

Simple chart with time on x axis & characteristic measured ony axis, with control limits for the quality characteristicsmeasured.


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http://upload.wikimedia.org/wikipedia/en/f/f7/ControlChart.svg


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Variations or Fluctuations can be Normal or Abnormal: Normal- small differences causes the data to fluctuate like

small differences in material, atmospheric conditions,

equipments etc.Abnormal- large differences causes changes in a process

resulting in variation in the characteristics measured like materialtaken from different lot, inexperienced operator, new setting in

machines etc.The process is in control, all points will plot within the control

limits.

Any observations outside the limits, or systematic patternswithin, suggest the introduction of a new (and likelyunanticipated) source of variation, known as a special causevariation.

Since increased variation means increased quality cost.


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The two broadest groupings are for variable dataand attribute data.

Variable data are measured on a continuous scale.For example: time, weight, distance or temperaturecan be measured in fractions or decimals. Thepossibility of measuring to greater precisiondefines variable data.

Attribute data are counted and cannot havefractions or decimals. Attribute data arise whenyou are determining only the presence or absence

of something: success or failure, accept or reject,correct or not correct. For example, a report canhave four errors or five errors, but it cannot havefour and a half errors.


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QC in Garment Manufacturing unit

Export houses earn foreign exchange for the country, so it becomes mandatory to have good quality control of their products.

In the garment industry quality control is practiced rightfrom the initial stage of sourcing raw materials to the stage offinal finished garment.

For textile and apparel industry product quality iscalculated in terms of quality and standard of fibres, yarns,fabric construction, colour fastness, surface designs and thefinal finished garment products.

quality expectations for export are related to the type ofcustomer segments and the retail outlets.


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There are a number of factors on which quality fitness ofgarment industry is based such as - performance, reliability,

durability, visual and perceived quality of the garment.Quality needs to be defined in terms of a particular

framework of cost.

The national regulatory quality certification andinternational quality programmes like ISO 9000 series laydown the broad quality parameters based on whichcompanies maintain the export quality in the garment andapparel industry.

Some of main fabric properties that are taken intoconsideration for garment manufacturing for export basis:


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Overall look of the garment. Right formation of the garment.

Feel and fall of the garment.Physical properties.Colour fastness of the garment.Finishing propertiesPresentation of the final produced garment.

Basic Thumb Rules for Garment Exporters

For a garment exporter there are many strategies andrules that are required to be followed to achieve good

business.

The fabric quality, product quality, delivery, price, packaging and presentation are some of the many aspectsthat need to be taken care of in garment export business.


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Some rules that are advisable for garment exporters are listed below:

Quality has to be taken care by the exporter, excuses arenot entertained in international market for negligence for lowquality garments, new or existing exporters for both it ismandatory to use design, technology and quality as major upgradation tools.

Apart from superior quality of the garment, its pricing, packaging, delivery, etc has to be also taken care of.

The garment shown in the catalogue should match with the

final garment delivered.It is important to perform according to the promises given

to the buyer, or else it creates very bad impression and resultsin loss of business and reputation.


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In international market, quality reassurance is required atevery point.

Proper documentation and high standard labels on thegarment are also important aspects as these things also creategood impression.

Timely delivery of garments is as important as its quality.

If your competitor has the better quality of garment in same pricing, it is better to also enhance your garment quality.

Before entering into international market, garment exportershave to carefully frame out the quality standards, or else ifanything goes wrong it could harm the organization. And afterthat strictly follow it.

The garment quality should match the samples shown during

taking the orders.


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The garment exporters should know to negotiate a premium price after quality assurance is done.

Quality is ultimately a question of customer satisfaction.Good Quality increases the value of a product or service,establishes brand name, and builds up good reputation for

the garment exporter, which in turn results into consumersatisfaction, high sales and foreign exchange for thecountry.

The perceived quality of a garment is the result of a

number of aspects, which together help achieve thedesired level of satisfaction for the customer.

Therefore quality control in terms of garment, pre-salesservice, posts -sales service, delivery, pricing, etc are

essentials for any garment exporter.


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Quality is a multi-dimensional aspect.There are many aspects of quality based on which thegarment exporters are supposed to work.

Quality of the production.

Quality of the design of the garment.

Purchasing functions' quality should also be maintained

Quality of final inspection should be superior.Quality of the sales has to be also maintained.

Quality of marketing of the final product is also importantas the quality of the garment itself.


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Buttons - Neatly and securely fastened.- Appropriate in size and design.- Placement accurate and attractive, uniform distance fromedge and in spacing between.- Appropriate shank provided.- Stitching started and ended under button.Buttonholes - Flat and securely stitched.- Even in width and length.- Placed at points of strain.

- Attractive and accurate in distance from edge and inspacing between.- Cut on grain.- Appropriate in size.- Appropriate interfacing used.


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Darts - Tapered and smooth-free from pucker or bubble at point.

- Securely fastened at ends.- Symmetrical in shape, length, and spacing.- Attractive placement.- Pressed correctly-vertical darts pressed toward center,horizontal darts pressed down.

Facings - Flat, smooth, free from bulk.- Securely tacked in place at seams, darts, and openings.

- Facing edges free from raveling.- Any edge finish flat, smooth, and free from bulk.


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Fit - Adequate ease for comfort.

- Fitting details (neckline, armhole, waistline) properly locatedon body.- Silhouette lines follow silhouette of body.- Lengthwise grain line perpendicular to floor; crosswise grain

line parallel to floor.- Darts point to and stop short of the fullest part of the areathey fit.- Free from strain and/or excess fullness.

Gathers - Uniform, evenly distributed. Stitched so pleats are notformed.- Adequately full-do not look skimpy or bulky.


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Hems - Flat and inconspicuous, unless meant to be decorative.

- Seams pressed as required and graded to reduce bulk.- Hem fold pressed so hem hangs smoothly at lower edge.- Hem edge smooth, flat, and free from raveling.- Excess fullness evenly eased, free from pleats.

- Seams aligned.- Hem edge finish should not create ridge or add bulk.- Hem even in width.- Width appropriate for garment style and fabric type.- Topstitching attractive in size and placement, straight.- Hand stitches uniform, secure, and inconspicuous.- Fused hems securely fused and flat.- Hem hangs parallel to floor.- Length attractive for wearer and appropriate for garment.


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Interfacing - Enhances body and wear of garment.

- Color and care requirements compatible to outer fabric.- Free from bulk and ravellings.- Not visible on inside or outside of garment.

Lining - Conceals inner construction of garment without adding excess

bulk.- Color and care requirements compatible with outer fabric.- Fits smoothly inside garment with seams aligned.

- If attached at hems, has pleat for ease.- If free hanging-attached at seams - Hemmed shorter thangarment-1/2 inch shorter than sleeves and 1 inch shorter thanskirt or pants.


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Neckline - Free from bulk.- Facings flat , clipped, and under stitched.

- Design symmetrical.

Needlework (hand stitching) - Uniform stitches, secure.

- Correct technique used-stitch with single thread.- No bulky knots at thread ends.- Correct stitch used for purpose.

Placket - Flat, free from excess bulk.- Inconspicuous unless meant to be decorative.- Correct technique used for purpose-faced, bound, hemmed.

Pleats tucks


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Pleats, tucks - Uniform in width (unless design varies).- On straight grain of fabric when design allows.- Neatly pressed as required.- Stitching straight.- Spacing attractive and accurate.

Pockets - Flat, smooth, free from bulk.- Stitching straight.- Pressed neatly.

For Patch pockets

- Upper corners reinforced.- Square corners mitered; round corners symmetrical.- Hem appropriate width and neatly finished.- Attractive placement.- If in pairs, coordinated in size, shape, and fabric design (ifapplicable).


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In-seam pockets - Interfaced, under stitched, lay flat when worn.- Inconspicuous unless meant to be decorative

Pressing - Garment smooth and free from wrinkles.- Free from sheen and scorch.- No ridges from seams or facings.- Seams pressed flat and inconspicuous.- Darts presses to shape garment.

- Pleats, tucks, creases pressed as design requires.


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Seams - Securely stitched, straight, flat, free from bulk.- Stitches appropriate in size and tension.

- Fullness eased as required.- Crossed seams intersect correctly.- Pressed in correct direction.- Fabric design matched as possible.

- If finish used, no added bulk or tension.- Free from ravelling.

Sleeves Set-in sleeves - Fullness evenly distributed.- Seam smooth and even in width around cap.- Underarm section of seam trimmed and double stitched.- Seam pressed toward sleeve cap.


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Stitching - Stitch length and tension appropriate for fabric.- Straight, knots, and skipped stitches.

- Beginning and ending of stitching locked in appropriate way.- Loose threads cut off.

Waistband

- Smooth, even width.- Free from bulk.- On grain.- Interfaced.- Stitching straight.- Corners square.- Skirt or pants eased to fit band.- Sets exactly at top of zipper.


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Zipper - Placket smooth, flat, and free from puckering.- Stitching straight and even.- Placket appropriate length and width.- Seams and neckline edges match.- Zipper completely covered.

- Zipper slides easily.- Inconspicuous unless meant to be a design feature.- Skirt and zippers end at band.- Neckline zippers end 1/2 inch from neckline so fastener

(hook and eye or snap) can be attached above zipper.

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