ME-381: Total Quality Management

Chapter-4:
Tools and systems for Quality
Management

By-
Dr. Niharika Gupta
Assistant Professor,
Department of Mechanical Engineering,
NIT Hamirpur
Contact no. 9958114561
 THE 7 BASIC QUALITY TOOLS FOR PROCESS
IMPROVEMENT
❑ Quality pros have many names for these seven basic tools of quality,
first emphasized by Kaoru Ishikawa, a professor of engineering at
Tokyo University and the father of "quality circles."

"The Old Seven." "The First Seven." "The Basic Seven.“

1. Cause-and-effect diagram (also called Ishikawa or fishbone

diagrams): Identifies many possible causes for an effect or problem
and sorts ideas into useful categories.

2. Check sheet: A structured, prepared form for collecting and

analyzing data; a generic tool that can be adapted for a wide variety
of purposes. 2
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3. Control chart: Graph used to study how a process changes over
time. Comparing current data to historical control limits leads to
conclusions about whether the process variation is consistent (in
control) or is unpredictable (out of control, affected by special causes
of variation).

4. Histogram: The most commonly used graph for showing frequency

distributions, or how often each different value in a set of data
occurs.

5. Pareto chart: A bar graph that shows which factors are more
significant.
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6. Scatter diagram: Graphs pairs of numerical data, one variable on

each axis, to look for a relationship.

7. Stratification: A technique that separates data gathered from a

variety of sources so that patterns can be seen (some lists replace
stratification with flowchart or run chart).

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 CAUSE-AND-EFFECT DIAGRAM (ALSO CALLED
ISHIKAWA OR FISHBONE DIAGRAMS)
1. Introduced by Kaoru Ishikawa, the fishbone diagram helps users
identify the various factors (or causes) leading to an effect, usually
depicted as a problem to be solved.
2. Named for its resemblance to a fishbone, this quality management
tool works by defining a quality-related problem on the right-hand
side of the diagram, with individual root causes and sub-causes
branching off to its left.
3. A fishbone diagram’s causes and sub-causes are usually grouped into
six main groups, including measurements, materials, personnel,
environment, methods, and machines. These categories can help
you identify the probable source of your problem while keeping your
diagram structured and orderly 5
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 CHECK SHEETS
1. A Check Sheet is a data recording form that has been designed to
readily interpret results from the form itself.
2. It needs to be designed for the specific data it is to gather.
3. Used for the collection of quantitative or qualitative repetitive data.
Adaptable to different data gathering situations.
4. Minimal interpretation of results required.
5. Easy and quick to use.
6. No control for various forms of bias - exclusion, interaction,
perception, operational, non-response, estimation.

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 CONTROL CHARTS
1. Control charts are a method of Statistical Process Control, SPC.
(Control system for production processes).
2. They enable the control of distribution of variation rather than
attempting to control each individual variation.
3. Upper and lower control and tolerance limits are calculated for a
process and sampled measures are regularly plotted about a central
line between the two sets of limits.
4. The plotted line corresponds to the stability/trend of the process.
5. Action can be taken based on trend rather than on individual
variation.
6. This prevents over-correction/compensation for random variation,
which would lead to many rejects.
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 HISTOGRAM OR BAR GRAPH
1. A Histogram is a graphic summary of variation in a set
of data.
2. It enables us to see patterns that are difficult to see in
a simple table of numbers.
3. Can be analyzed to draw conclusions about the data
set.
4. A histogram is a graph in which the continuous
variable is clustered into categories and the value of
each cluster is plotted to give a series of bars.
5. The example reveals the skewed distribution of a set
of product measurements that remain nevertheless
within specified limits.
6. Without using some form of graphic this kind of
problem can be difficult to analyze, recognize or
identify.
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 PARETO PRINCIPLE
1. The Pareto principle suggests that most
effects come from relatively few causes.
2. In quantitative terms: 80% of the
problems come from 20% of the causes
(machines, raw materials, operators
etc.); 80% of the wealth is owned by 20%
of the people etc.
3. Therefore, effort aimed at the right 20%
can solve 80% of the problems. Double
(back-to-back) Pareto charts can be used
to compare 'before and after' situations.
4. General use, to decide where to apply
initial effort for maximum effect.

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 SCATTER PLOTS
1. A scatter plot is effectively a line graph
with no line - i.e., the point intersections
between the two data sets are plotted
but no attempt is made to physically
draw a line.
2. The Y axis is conventionally used for the
characteristic whose behavior we would
like to predict.
3. Use, to define the area of relationship
between two variables.
4. There may appear to be a relationship on
the plot when there is none, or both
variables relate independently to a third
variable.

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 STRATIFICATION
1. Stratification analysis is a quality assurance tool
used to sort data, objects, and people into
separate and distinct groups.
2. Separating your data using stratification can
help you determine its meaning, revealing
patterns that might not otherwise be visible
when it’s been lumped together.
3. Whether you’re looking at equipment, products,
shifts, materials, or even days of the week,
stratification analysis lets you make sense of
your data before, during, and after its
collection.
4. To get the most out of the stratification process,
consider which information about your data’s
sources may affect the end results of your data
analysis. Make sure to set up your data
collection so that that information is included. 15
 ADVANCED QUALITY TOOLS
1. The seven basic quality tools are effective for data analysis, process control,
and quality improvement (numerical data).
2. However, these basic tools cannot be used for non-numerical or verbal data.
3. To organize verbal data into useful information, the advanced quality tools are
required.
4. The Seven Advanced Tools of Quality/Seven New Tools / Seven Management &
Planning Tools were developed with a design approach to organize verbal data
diagrammatically.
5. These tools work in conjunction with the basic quality tools and can be used by
management and staff to develop ideas, solve problems and formulate plans
for improved project management.
6. They also allow teams to assess situations from a variety of angles, prioritize
tasks, work systematically, anticipate future events and get things right the first
time.

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1. Affinity diagrams: The affinity diagram allows teams to gather large amounts of
data – including ideas and opinions – and organize it into groups based on natural
relationships. This makes further analysis much more feasible.

2. Tree diagrams: The tree diagram helps to move data from the general to the
specific, creating more finely grained analysis that breaks down information into
sub-categories. This leads to better strategies for addressing problems.

3. PDPC: The Process Decision Program Chart contains a list of steps linked together in
sequence that show the events likely to occur by putting a new process into place.
They are helpful to analyze solutions in a situation that is fluid or uncertain.
4. Matrix diagrams: A matrix diagram depicts the relationship between multiple
groups of information and is designed to show the relative strengths and
weaknesses of these relationships. A matrix diagram can also make the overall
structure of a problem immediately clear.
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5. Interrelationship digraphs: An interrelationship diagram or digraphs breaks
down a complex situation by showing the cause-and-effect relationship
between critical functions in a complicated process. They are most useful at the
planning stage and offer a clearer view of the potential issues in a complex
process.

6. Prioritization matrices: A prioritization matrix is designed to help teams select

the best choice from a range of options. It is an L-shaped matrix that makes
comparisons between established criteria and options using an evaluation
based on numerical data

7. Activity network diagram: Also known as an arrow diagram, an Activity

network diagram shows the relationship between tasks needed to implement a
process. It helps teams determine the best scheduling for a process and
identify any potential problems.
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