Case Study on Usage of Classic Quality Tools

Check Sheet/ Check List

Check sheets are simple forms with specific formats that can help a user record data in a
methodical manner in a business. On the check sheet, data is "collected and tabulated" to
record the frequency of various events throughout the course of a data collection period. They
create a "consistent, effective, and cost-efficient strategy" that may be used in quality
assurance audits to review and follow the steps in a process. They also assist the user in
organising the data for subsequent use.
Defect-location check sheets, tally check sheets, and defect-cause check sheets are three of
the most common types of check sheets.
The check sheet is also known as a tally sheet when the data is quantitative. It can be used as
a preliminary data gathering tool for constructing bar graphs, histograms, and other quality
tools because of its simple data capture and visualisation. It can also be used to maintain track
of completed steps and monitor quality by quantifying defects by kind, location, and cause
(machine, labour). A checklist template can be used to create garment inspection reports.

Advantages

● The key advantages of check sheets are that they are simple to use and understand,
and that they can provide a clear picture of the organization's state and condition.
● They are efficient and powerful tools to identify frequent problems, though they don't
have an effective ability to analyze the quality problem in the workplace.

It is used to collect quantitative or qualitative data in a form (document) in real-time at the

location where the data is generated.
The data recorded in the check sheet is recorded with marking marks “check” on it. These
checks are ticked in the sheet at different locations in a matrix and each has its different
significance. These checks are read by observing the location and number of marks on the
matrix.

For better understanding the background information of the data it also consists of the five
w’s which are

● Who filled out the check sheet

● What was collected (what each check represents, an identifying batch or lot number)
● Where the collection took place (facility, room, apparatus)
● When the collection took place (hour, shift, day of the week)
● Why the data were collected.

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Example:

Alternative Chart
:Histogram

Histogram

The histogram is an extremely valuable tool for describing the frequency distribution of
observed values of a variable. It's a form of bar chart that shows the distribution of data and
the amount of variation within a process, as well as both attribute and variable data of a
product or process. It is made up of vertical bars of various heights, each representing a
different collection of data. The frequency (count) of the group determines the height of the
bar. It shows the various central tendency measures (mean, mode, and average). It should be
well-designed so that individuals involved in the operating process may readily use and
comprehend it..Also, a histogram can be applied to investigate and identify the underlying
distribution of the variable being explored.

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It is a representation of the frequency (count) distribution of data among different groups of a
sample or population. The key characteristic of the histogram is that it represents
categorization of continuous data with each group being of similar characteristics. It helps in
summarizing the data that has been collected and represents graphical data frequency
distribution in bar form to highlight areas of needed attention.

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Alternatives: Line Graph

Pareto Analysis

A Pareto chart is a form of histogram that can be used to quickly identify and prioritise
quality issues, conditions, or causes inside an organisation. It is, on the other hand, a form of
bar chart that displays the relative importance of variables in decreasing order from the
chart's left to right side. The purpose of a Pareto chart is to determine the various types of
"nonconformity" based on data figures, maintenance data, repair data, parts scrap rates, and
other sources. In addition, a Pareto chart can be used to investigate quality improvement,
efficiency, "material waste, energy conservation, safety concerns, and cost reductions."

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Fishbone Diagram (or Cause-and-Effect Diagram)

Kaoru Ishikawa is considered by many researchers to be the founder and first promoter of the
‘Fishbone’ diagram for root cause analysis and the concept of Quality Control (QC) circles .
It also has two other names that are Ishikawa diagram and fishbone because the shape of the
diagram looks like the skeleton of a fish to identify quality problems based on their degree of
importance.

The cause and effect diagram is a problem-solving tool that investigates and analizes
systematically all the potential or real causes that result in a single effect. On the other hand,
it is an efficient tool that equips the organization's management to explore for the possible
causes of a problem. This diagram can provide the problem-solving efforts by “gathering and
organizing the possible causes, reaching a common understanding of the problem, exposing
gaps in existing knowledge, ranking the most probable causes, and studying each cause”. The
generic categories of the cause and effect diagram are usually six elements (causes) such as
environment, materials, machine, measurement, man, and method. Furthermore, “potential
causes” can be indicated by arrows entering the main cause arrow.

Scatter Diagram

Scatter diagram is a powerful tool to draw the distribution of information in two dimensions,
which helps to detect and analyze a pattern relationships between two quality and compliance
variables (as an independent variable and a dependent variable), and understanding if there is
a relationship between them, so what kind of the relationship is (Weak or strong and positive
or negative). The shape of the scatter diagram often shows the degree and direction of
relationship between two variables, and the correlation may reveal the causes of a problem.
Scatter diagrams are very useful in regression modeling. The scatter diagram can indicate that
there is one of these following correlations between two variables:

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a) Positive correlation;
b) Negative correlation, and
c) No correlation, as demonstrated in.

Flowchart

A flowchart is a diagrammatic representation of a series of symbols used to depict the

sequence of steps in a process or operation. A flowchart, on the other hand, depicts a picture
that includes the inputs, activities, decision points, and outputs for easy use and
comprehension of the overall goal during the process. This chart, as a problem-solving tool,
can be used to carefully locate and analyse parts or points of a process that may have had
potential problems by "documenting" and explaining an operation, making it extremely
effective in locating and improving quality in the process.

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Control Chart

Control charts is a special form of “run chart that illustrates the amount and nature of
variation in the process over time”. Also, it can draw and describe what has been happening
in the process. Therefore, it is very important to apply control chart, because it can observe
and monitor process to study process that is in “statistical control” (No problem with quality)
accordant to the samplings or samplings are between UCL and LCL (upper control limit
(UCL) and the lower control limit (LCL)). “Statistical control” is not between UCL and LCL,
so it means the process is out of control, then control can be applied to finde causes of quality
problems. In addition, this chart can be utilized for estimating “the parameters” and “
reducing the variability” in a process.

The basic goal of a control chart is to prevent process problems. It is critical for various firms
and industries since the cost of unsatisfactory products or services is higher than the cost of
preventing them with tools like control charts.

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