1

Technical Engineering College

Mechanical Engineering/Production and
Metallurgy Department

Quality Control
Statistical Quality Control(SQC)
Part of 7 Tools

Lecture 5

Fourth Class
 Outline: 1

o Seven Tools in Quality Control

 Control Charts discussed
 Pareto Diagram
 Histogram
 Cause & Effect Diagram
 Scatter Diagram
 Flow Chart
 Check Sheet

The 7 QC Tools are simple statistical tools used for problem solving.
These tools were either developed in Japan or introduced to Japan
by the Quality Gurus such as Deming and Juran. In terms of
importance, these are the most useful.
Kaoru Ishikawa has stated that these 7 tools can be used to solve 95
percent of all problems.
The seven basic quality control is a designation given to a fixed set
of graphical techniques identified as being most helpful in
troubleshooting.
 1
rr--_Plll'('( O C b-art
• ♦

•
Cont1 ol Chart
Scatter Plot

Fish Bone Diagram or

Ishikawa diagram
or

The 7 Quality Cause-Effect Diagrams-

Tools

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 Parelt:J c:har t: A graph that identities and plots prdJ:J1 erns or
1

Pareto Chart 1
defects in desc en d
1 order oti trequJency

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A B C ID
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• Pareto Diagram is a tool that arranges items in the order of the

magnitude of their contribution, thereby identifying a few
items exerting maximum influence.
• The origin of the tool lies in the observation by an Italian
economist Vilfredo Pareto that a large portion of wealth was in
the hands of a few people.
• Pareto principle also known as the 80/20 rule is used in the
field of materials management for ABC analysis & Six Sigma.
 The vital few
causes are only The trivial many causes are only
contributing to contributing to 20% of problem
80% of problem

under 80% line

green

Pareto chart stats that for

many events, roughly 80%
of effects
come from 20% of causes
 1
Example
Pareto diagram

The following data represents paint defects from an automotive assembly

plant. Construct Pareto diagram to control and improve the quality of the
paint, use Pareto principle to determine the vital few and trivial many, and
which defects have the priority to be fixed?

Types of defect No. of defects

Sag 21
Thin paint 5
Sealer under 4
Orange peel 12
Dirt in paint 65
Off color 2
Other 1
Scratch 2
 1
Answer

Step one
arrange

Types of defect No. of defects

Largest value Sort order
,65
V
Dirt in paint ✓ defects from Largest to
Sag 21 Smallest >> des 1ending order
c

Orange peel 12
Thin paint 5
Sealer nnder 4
Off color 2
Scratch 2
.... ,.
Other 1 ~
Smallest value

112
 1
Answer

c~

cumlative
Types of defect 1'o. of defects cu.mlative connt.
percent
Dirt in paint 65 .. 65 65/112 = 0.58 *100 =
, 58%
Sag 21 .. 21 + 65/ = 86 86/112 = 0.767 *100 = 77%
- ,

Orange peel 12 .. 12 + 86 = . 98 88%

Thin paint 5 103 92%
Sealer nnder 4 107 96%
Off color 2 109 97%
Scratch 2 111 99%
Other 1 112 100%

112
 1
vital few Answer trivial many

100 %
20%
80% Line ~

] «>

F I 80 %
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~ ~

n,., i'i"lr!t Off caor Scmch Ott><r

Typ.e of defect

vital few trivial many

Those defects such as: Dirt in paints & Sag have the priority to be fixed
 Histogram 1

• Is a bar graph that represent a frequency distribution.

The X- axis represent the interval and the Y- axis
represent the corresponding frequency. There are no
space between bars.
• Histograms are useful in studying patterns of
distribution and in drawing conclusions about the
process based on the pattern. 1-istogra111· A d tstr ilrtlon mat 1 frequency o1
S'"IOW:i 'le
cu- ,e...JCE-3 of ai \an =h~

When Are Histograms Used?

• Summarize large data sets graphically.
• Compare measurements to specifications. ii f
• Communicate information to the team. LL

• Assist in decision making.

when you draw Histogram char

should no space between each Repe ir ti me f rnira utes)
 [•___- ~]
1
Histogram

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0 B 10 15 20 25 30 35 40 •5 60 55 60 -- - ~
DAYS OF OPE RATION ~
M EAi-i TIME BETWEEN FAILU RE (IN DA YS ) FOR R- 1051 HF REC ElVER
.Data taken at SIMA. Pearl Harbor, 15 May - 15 JUiy 94

TiUe © Horizontal / X-axis

B ar s © Vertical 1 Y-axi s
L egend
 How to Construct a Histogram
1

Step 1 - Count the total number of data points

Step 2 - Summarize the data on a tally sheet
Step 3 - Compute the range for the data set
Step 4 - Determine the number of intervals required
IF YOU HAVE THIS USE THIS NUfll1BER
MA fvY DATA POl f\J TS OF I NTER VA LS.-

L ess than 5 0 5 to 7 int erva ls

5 0 t o 99 6 to 10 interv-al s

100to 2 5 0 7 to 12 int erva ls

Mo re than 2 5 0 10 t o 20 int erva ls

Step 5 - Compute the interval width

Step 6 - Determine the starting point of each interval
Step 7 - Count the number of points in each interval
Step 8 - Plot the data
Step 9 - Add the title and legend
 Example : Histogram Chart 1

The team decides to look at the waiting time data in a different way. They
decide to create a histogram that represents the varying amounts of time
that users wait before being registered. According to their raw data, the
following waiting periods (in minutes) were measured for users at
registration: 10, 12, 15, 18, 23, 38, 45, 48, 50, 64, 68, 72, 75, 80, 81, 84, 85,
88, 98, 110, 125, 130, 135, and 140. The team counted the number of data
points in the series, and it is 24. Total number of users
*The range of the data : 140-10=130
*24 data points, so they decide to create 5 categories ( intervals = 5 )
• 130/5=26 minutes (rounded to 30 minutes).( intervals Width = 30
• determine the range of each interval by starting at 0 and adding the
interval each time: 30, 60, 90, 120, 150. So the first interval will be 0-30,
the second 31-60, and so on. Frequency Table for Waiting Time Data
l\,Vaiting Time in Nlinutes INu1nbe1· of lJse1·s
110-10 15
13 1-60 14
16 1-90 19
19 1-120 12
112 1-150 it1
!Total 124
 Example : Histogram Chart……..Cont 1

User waiting tfme in minutes

10

1- 30 31-60 61-90 91-120 121 -150

0 -30 31-60 6 1-90 91- 120 121--150

\VaitingTime in Minutes
By looking at the data in a histogram, it is easy to see that the
majority of users wait from 61 to 90 minutes for registration
Also the distribution of data is near to symmetrical shape
 Cause & Effect Diagram
1

Cause-and-effect diagram: A schematic technique used

to discover possible locations of quality problems.
• A Cause-and Effect Diagram is a tool that shows systematic
relationship between a result or an effect and its possible causes.
• It is an effective tool to systematically generate ideas about causes
for problems and to present these in a structured form.
• identifying quality issues and inspection points is the cause-and-
effect diagram, also known as an Ishikawa diagram or a fish-bone
chart (note the shape resembling the bones of a fish). Each “bone”
represents a possible source of error.
Cl!IUSe-a.ru:1-Etfe.cl. Dia.9ra.m: A 1loo I 1l ha.1!
Ide n t Jffes p rooe.ss e I e me n t s {caLJJ.ses)
1i hat may a.ffecti an o u too m.e
cause
,,_...ate rn als Matl'wxlls
Effect

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 1
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Cause and Effect Diagram

EFFECT
 1

Scatter Diagram
• It consists of plotting a series of points representing several
observations on a graph in which one variable is on X-axis
and the other variable in on Y-axis.
• When solving a problem or analyzing a situation one needs to
know the relationship between two variables.
• If a relationship exists, it may be positive or negative, it may
be strong or weak and may be simple or complex.
Sc le.rDi r; m : A gr ph ot the va.h.JJ e
ot one r ialb le v ,s_ another -1anialbl e

Example might be a
plot of productivity • •
and absenteeism ,as •
shown in Figure
• • •
• •
•
Ab.senteeis
 Scatter Diagram 1

Example : Scatter diagrams show the relationship between two

measurements. An example is the Negative relationship between
Reliability of product &Temperature… means strong negative
relationship between two variables such as reliability of product
and temperature

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 Flow Chart 1

Flowcharts: Block diagrams that graphically describe a process or

system. Flowcharts graphically present a process or system using
annotated boxes and interconnected lines
• A diagram that uses graphic symbols to depict the nature and
flow of the steps in a process.
• Identify problem areas and improvement opportunities.
• Promote process understanding. Symbols Used in Flowcharts
Start I End
• Provide tool for training.
Process Step

Decision

Connector

FJ!OtArchart ( Proce-ss D'iag,ram): A chart! 'llhat descri bes the Measurement

steps In a prooess
Yes
END ~~:=.=.:.:r - =======4::: : :=: :;. --l _oecision
No

START
..----it-- -1-- Process Step
 Aruold Pahuer Hospital bas u n denake11 a series of process iln_p r oven1eul iuitiatives. O:ne of th ese is
1
to 111ake the ~IRI service efficient for palienl, doctor, and hospitaL 'T he fir st step, the ad1n i11istrato r
believes,. is lo develop a flov.rcharl for this process.
APPROACH ► A process inrprov,e1nent staffe·r observed a 11un1ber of patients and fo11ow,ed th.en1 (and
mforu1alion tlowJ fro1n sta rt to end_ Here a re the I ] steps:
I. Physician schedules MRI after e.xan1i.ning patient (START) .
.2. Patient ta.k,e n [rom th e exan1.ina tion roon1 io the MRI lab wit h H:sl order and copy of niedical
:records.
3. Patienl signs in, completes required papern·ork.
4. Patien t is p repped by lecbnician f0[ scan. Example· Flow Chart
5. Technician carries out th e MR] scan.
6. TecboiciaD in spects fl ln1 for d arity.
7. If lvJR[ not satisfactory (200/4 of tin1et Steps 5 a mdl 6 a re repeated_
8,. Patient taken back to hospitaJ roo111.
9. l\1RI is .read by .radiologist a11d .report is prepared _
10.
1
1\il RI and repon are transferred electronically to physician.
11. Patient and physician discuss reoon (END).
SOLUTIONI ► Here is th e flowch.an:

2 3 4 5

20%
INSIGHT ► \Vit h the nuv,rchan in h and, tbe hospital can anal)rze ea:ch step aod identify value-added
activities and activities thal can be imnprovcd or eliminated.
 Check Sheet1

Check Sheet is a check sheet is any kind of a form that is

designed for recording data

• As measurement and collection of data forms the basis for any

analysis, this activity needs to be planned in such a way that the
information collected is both relevant and comprehensive.
• Check sheets are tools for collecting data. They are designed
specific to the type of data to be collected. Check sheets aid in
systematic collection of data. Some examples of check sheets are
daily maintenance check sheets, attendance records, production
log books, etc.
• Data collected using check sheets needs to be meaningfully
classified. Such classification helps gaining a preliminary
understanding of relevance and dispersion of the data so that
further analysis can be planned to obtain a meaningful output.
Meaningful classification of data is called stratification.
Stratification may be by group, location, type, origin, etc.
 1

Check Sheets
A check sheet is any kind of a form that is designed for recording data.
In many cases, the recording is done so the patterns are easily seen
while the data are being taken [see Figure. Check sheets help analysts
find the facts or patterns that may aid subsequent analysis. An example
might be a drawing that shows a tally of the areas where defects are
occurring or a check sheet showing the type of customer complaints.

_ C h ech S e.e1.: An organ ized ethod ot

recor n g d at.a
H our
Defect
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Exercise to Histogram Chart