Training module on

Problem Solving Tools

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What are 7 QC Tools ?

QC tools are the means for Colleting data , analyzing data , identifying root causes and measuring the results. THESE TOOLS ARE RELATED TO Numerical DATA processing

USER HAS TO ARRIVE AT THE SOLUTION & IMPLEMENT

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Problem Solving Tools

1. Simple Tools for Problem Analysis

1.1 Why -Why Analysis 1.2 What If Analysis

2 Simple 7 QC Tools (Statistical Tools)

Stratification Pareto Diagram Cause and Effect Diagram Check Sheet Control Chart/Graph Histogram Scatter Diagram
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Problem Solving Tools

What is a Problem ?
Problem is an undesirable event or .. Any Gap between what is expected and what is obtained , can be called as a Problem, and any effort to reduce this gap can be called as Problem Solving Expected (Gap ?) A Problem! Obtained

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Problem Solving Tools

Symptoms and the Root Causes

An undesirable end result is only a starting point or Symptom. Eg: When an equipment breaks down , It is an end result or a Symptom of a Problem. The abnormalities present in the responsible factors , are referred to as root cause(s) of the problem

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Problem Solving Tools

Four types of Problems

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Problem Solving Tools

Why - Why analysis - An Example Library of Problem Solving Tools

Purpose : It is the simple tool used by the team /observer to find out the cause of the problem/Accident/ Breakdown at the Workplace.
Many times, the root cause of the problem can be identified by asking Why 5 times and the repetition of such problems can be prevented by taking countermeasure immediately.

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Problem Solving Tools

Why - Why analysis - An Example Library of Problem Solving Tools

Water Dripping in Substation 1

WHY ? Water accumulated at the roof WHY ? Outlet drain chocked WHY ? Atmospheric dust & dirt WHY ? Periodic cleaning of drain not done Action
Proper scheduled procedure for roof cleaning is to be prepared 7 Q C Tools

Problem Solving Tools

Why - Why analysis - Example-2 Library of Problem Solving Tools

WHY WHY ANALYSIS ( ACCIDENT )
JANUARY2001 LOCATION :- WOOL COMBING ACCIDENT OCCURRED TO SRI K.N.PAUL

PROBLEM : Right hand fingers got seriously injured

WHY ?

While fitting feed roller spiked rings, his RH fingers got pressed with the F/Roller
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Problem Solving Tools

Why - Why analysis - Example-2 Library of Problem Solving Tools (Contd..)

WHY ?
The F/R shaft was lifted from the m/c & placed about 2 ft.high from the floor by means of a chain-pulley block & a supporting device. Suddenly the belt fastener got slipped off causing the feed roller to fall down

WHY ?
Since the job was being done for the first time,proper fastening device suitable for the spiked feed roller could not be designed

ACTION
Development of suitable fastening device being contemplated and to be adopted for a repetitive jobs 7 Q C Tools

Problem Solving Tools

What-Ifof Analysis Library Problem Solving Tools

Purpose : It is the simple Pro active tool used by the team / observer, to identify problems before hand and take appropriate counter measures to prevent such problems .

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Problem Solving Tools

What-Ifof Analysis - Solving An Example Library Problem Tools

Area : Team :
SL. What If Results

Equipment :Compressor
Countermeasures

1. There is no Water in the Radiator of an Automobile ? And it is not noticed.

The Engine heats Inspect the up and Piston may Temperature of get seized. outlet water . Provide the temp. Indictor for the driver

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Pareto Diagram
1. What is Pareto diagram ?

A Pareto diagram is a combination of bar and line graphs of accumulated data, where data associated with a problem (e.g., a defect found, mechanical failure, or a complaint from a customer) are divided into smaller groups by cause or by phenomenon and sorted, for example, by the number of occurrences or the amount of money involved. (The name Pareto came from an Italian mathematician who created the diagram.)

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Pareto Diagram
2. When is it used and what results will be obtained?

Please refer to the table on next slide for the usage and benefits of a Pareto diagram. It is mainly used to prioritize matters, and because of its easiness of use, the diagram is used in a wide variety of fields.

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Pareto Diagram
Method
Pareto Diagram
(No. of Occurrences)

Usage
Used to identify and prioritize a problem.

Result
Allows clarification of important tasks. Allows identification of a starting point (which task to start with). Allows projection of the effects of a measure to be taken

Used to review the effects of an action taken.

Used to prioritize actions.(Used during phases to monitor the situation, analyze causes, and review effectiveness of an action.)

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Pareto Diagram
Example
Assessment using Pareto diagram (prioritization)

Confirmation of Effect (Comparison)

To identify a course of action to be emphasized using a variety of data.

Details of A

Frequently used to check the effect of an improvement.

Improved

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Cause & Effect Diagram

1. What is Cause & effect Diagram ?

A cause and effect diagram is a fish-bone diagram that presents a systematic representation of the relationship between the effect (result) and affecting factors (causes). Solving a problem in a scientific manner requires clarification of a cause and effect relationship, where the effect (e.g., the result of work) varies according to factors (e.g., facilities and machines used, method of work, workers, and materials and parts used). To obtain a good work result, we must identify the effects of various factors and develop measures to improve the result accordingly.
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Cause & Effect Diagram

2. When is it used and what results will be obtained?

A cause and effect diagram is mainly used to study the cause of a certain matter. As mentioned above, the use of a cause and effect diagram allows clarification of causal relation for efficient problem solving. It is also effective in assessing measures developed and can be applied to other fields according to your needs.

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Cause & Effect Diagram

Method
Cause and Effect Diagram
Machine Man

Usage
Used when clarifying a cause and effect relationship.[Used during a phase to analyze causes.]

Result
Can obtain a clear overall picture of causal relation. (A change in the cause triggers a variation in the result.) Can clarify the cause and effect relationship. Can list up all causes to identify important causes. Can determine the direction of action (countermeasure).

Material Cause (4Ms)

Method Result (Controlled State)

Effect

Used to develop countermeasures.

[Used during a phase to plan countermeasures.]

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Cause & Effect Diagram

Mechanism of Copying Machine
Smudges on the copied surface Internal devices not working smoothly Malfunction of the roller Printing too lightly Too thin Dampened Folded Deterioration of Error in performance due placement of to high paper (setting temperatures its face up) Error in selecting shading Nicotinestained

Quality of Copying Paper

Running out of stock

Keyboard handling error Error in selecting a scale of reduction

Dirt on the glass surface Dust

User

Surrounding Environment

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Many Copying Errors!

Stratification
1. What is Stratification ?

Stratification means to divide the whole into smaller portions according to certain criteria. In case of quality control, stratification generally means to divide data into several groups according to common factors or tendencies (e.g., type of defect and cause of defect). Dividing into groups fosters understanding of a situation. This represents the basic principle of quality control.

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Stratification
2. When is it used and what results will be obtained?

The common and basic principle of quality control is stratification, i.e., to think a matter out by breaking it into smaller portions. Stratification has a number of useful purposes. The table below shows only a few examples of these purposes.

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Stratification
Method
Grouping by day, time, place, worker, or process
Number of Units

Usage
Used to observe variations among strata. Used to identify the relationship between cause and effect. Used to identify a purpose and means to serve the purpose
[Used during phases to monitor the situation, analyze causes, review effectiveness of an action, perform standardization, and implement a selected control measure.]

Result
Allows observation of variations among strata. By performing a cause analysis using the stratified data, the following can be accomplished.
1.Identification and control of a problem 2.Division of data (obtained by using each QC tool) into several groups

X Y Z

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Stratification
Method of Stratification Hour, a.m., p.m., immediately after start of work, Elapse of time shift, daytime, nighttime, day, week, month Worker, age, male, female, years of experience, Variations among workers shift, team, newly employed, experienced worker Processing method, work method, working Variations among work conditions (temperature, pressure, and speed), methods temperature Variations among Measurement tool, person performing measurement/inspection measurement, method of measurement, inspector, methods sampling, place of inspection Item

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Check Sheet
1. What is Check sheet ?

A check sheet is a sheet designed in advance to allow easy collection and aggregation of data. By just entering check marks on a check sheet, data can be collected to extract necessary information, or a thorough inspection can be performed in an efficient manner, eliminating a possibility of skipping any of the required inspection items. A check sheet is also effective in performing stratification (categorization).

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Check Sheet
2. When is it used and what results will be obtained?

Please refer to the table on next slide for the usage and benefits of a check sheet. It is frequently used in daily business operations, often not specifically for QC purposes.

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Check Sheet
Method
Check Sheet
Day Process Process 1 Process 2 Process 3

Usage
Used to collect data. Used when performing a thorough inspection.
Used during phases to monitor the situation, analyze causes, review effectiveness of an action, perform standardization, and implement a selected control measure

Result
Ensures collection of required data. Allows a thorough inspection of all check items. Can understand tendencies and variations. Can record required data.

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Check Sheet
A check sheet used to identify defects
Date Defect
Vertical Scratch

Total

Scratch

Dent

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Control Chart (Control Chart / Graph 1)

1. What is Control Chart ?

A control chart is used to examine a process to see if it is stable or to maintain the stability of a process. This method is often used to analyze a process. To do so, a chart is created from data collected for a certain period of time, and dots plotted on the chart are examined to see how they are distributed or if they are within the established control limit. After some actions are taken to control and standardize various factors, this method is also used to examine if a process is stabilized by these actions, and if so, to keep the process in a stable state.
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Control Chart
2. When is it used and what results will be obtained?

There are two types of control charts: one used for managerial purposes and the other for analytical purposes. A control chart is used to identify dots that are outside the control limit, which indicate some anomalies in a process. In addition, seven consecutive dots showing values that are below or above the mean (central) value, or an increasing or a decreasing trend represented by seven consecutive dots also indicate a problem in a process. We need to examine what has caused such a tendency.
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Control Chart
Method
Control Chart

Usage
Used to observe a change caused by elapse of time.
[Used during phases to monitor the situation, analyze causes, review effectiveness of an action, perform standardization, and implement a selected control measure

Result
Can identify a change caused by elapse of time. Can judge the process if it is in its normal state or there are some anomalies by examining the dots plotted on the chart.
In the example x bar -R control chart, X bar represents the central value, while R indicates the range.

x-R Control Chart

Control Chart for Managerial Purposes: Extends the line indicating the control limit used for analytical purposes to plot data obtained daily to keep a process in a good state. Control Chart for Analytical Purposes: Examines a process if it is in a controlled state by collecting data for a certain period of time. If the process is not controlled, a survey is performed to identify its cause and develop countermeasures.

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Control Chart
Examples of Values Represented by Dots Values above the control limit control limit represented by seven seven Consecutive dots

x - Control Chart
A decline represented representedby by seven

consecutive dots

Group Number

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Graph
1. What is Graph ?

A graph is a graphical representation of data, which allows a person to understand the meaning of these data at a glance. Unprocessed data simply represent a list of numbers, and finding certain tendencies or magnitude of situation from these numbers is difficult, sometimes resulting in an interpretational error. A graph is a effective means to monitor or judge the situation, allowing quick and precise understanding of the current or actual situation. A graph is a visual and summarized representation of data that need to be quickly and precisely conveyed to others.

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Graph
2. When is it used and what results will be obtained?

A graph, although it is listed as one of the QC tools, is commonly used in our daily life and is the most familiar means of assessing a situation.

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Graph
Method
120 100 80 60 40 20 0 1st Qtr 2nd Qtr 3rd Qtr 4th Qtr East

Usage
Changes in a time-sequential order line graph Amounts bar graph, etc. Ratios pie graph, band chart, etc.
(The items listed above are representative examples.)

Result
Can observe changes in a time-sequential order, ratios, and amounts. A graph is the most frequently used tool to examine the various matters such as those listed on the left.

4th Qtr 13%

1st Qtr 13%

2nd Qtr 17%

3rd Qtr 57%

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Graph
[Bar Graph of Sales]
Survey Period: Dec. 1999 Prepared by: M/T million) million) ( million)

[Band Chart of Expenses]

Sales

Before Taking Actions

Chemicals (430)
(Total: 8 million)

Oils (200)

Electricity (170)

After Taking Actions

Chemicals (240)

Oils (150)

(Total: 4.95 4.95 million) million)

Sales Office

Iwate A

Tokyo B

Osaka C

Shizuoka D

Electricity (108)

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Histogram
1. What is Histogram ?

When creating a histogram, a range of data is divided into smaller sections having a uniform span,and the number of data contained in each section (the number of occurrences) is counted to develop a frequency distribution table. Then, a graph is formed from this table by using vertical bars, each having the height proportional to the number of occurrences in each section.

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Histogram
2. When is it used and what results will be obtained?

A histogram is mainly used to analyze a process by examining the location of the mean value in the graph or degree of variations, to find a problem point that needs to be improved. Its other applications are listed in the table below.

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Histogram
Method
Histogram
Standard Range

Usage
Used to assess the actual conditions. Used to analyze a process to identify a problem point that needs to be improved by finding the location of the mean value or degree of variations in the graph. Used to examine that the target quality is maintained throughout the process. Others

Result
Can identify the location of the mean (central) value or degree of variations. Can find out the scope of a defect by inserting standard values. Can identify the condition of distribution (e.g., whether there is an isolated, extreme value).

Range of Variations

X Axis (Values Actually Measured)

[Used during phases to monitor the situation, analyze causes, and review effectiveness of an action.]

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Scatter Diagram
1. What is Scatter Diagram ?

A scatter diagram is used to examine the relationship between the two, paired, interrelated data types, such as height and weight of a person. A scatter diagram provides a means to find whether or not these two data types are interrelated. It is also utilized to determine how closely they are related to identify a problem point that should be controlled or improved.

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Scatter Diagram
2. When is it used and what results will be obtained?

The table on next slide shows some examples of scatter diagrams usage. If, for example, there is a relationship where an increase in the number of rotations (x) causes an increase in abrasion (y), there exists positive correlation. If, on the other hand, the existence of a relationship where an increase in the number of rotations (x) causes a decline in abrasion (y) indicates that there is negative correlation.

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Scatter Diagram
Method
Scatter Diagram
Axis

Usage
Used to identify a relationship between two matters. Used to identify a relationship between two matters and establish countermeasures based on their cause and effect relation. Example Usage 1.Relationship between thermal treatment temperature of a steel material and its tensile strengths 2.Relationship between visit made by a salesman and volume of sales 3.Relationship between the number of persons visiting a department store and volume of sales 4 Others [Used during phases to monitor the situation, analyze causes, and review effectiveness of an action.]

Result
Can identify cause and effect relation. Can understand the relationship between two results.

Abrasion

x Axis

Number of Rotations

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Scatter Diagram
Axis

Abrasion (micron)

x Axis Number of Rotations

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Application of QC tools in Problem Solving

Graphs Check sheet Stratifi cation Pareto Diagra m Cause & Effect Diagram Histogra m Scatter Diagram Control Chart

Identification of problem Defining the problem Record of facts Detecting causes of problem Develop Improvement method ( Solution ) Implementation Evaluation of result Process control ( Standardization )

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Relation :Strong Normal

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To sum up 7 QC tools (Numerical data ) are used as follow: Stratification Basic processing performed when collecting data Pareto Diagram To identify the current status and issues Cause and Effect Diagram To identify the cause and effect relationship Histogram To see the distribution of data Scatter Diagram To identify the relationship between two things Check Sheet To record data collection Control Chart/Graph To find anomalies and identify the current status

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Thank you
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