QC Tools: Parteo Diagram by Defective Items
QC Tools: Parteo Diagram by Defective Items
QC Tools: Parteo Diagram by Defective Items
180
Parteo Diagram by Defective Items
83
88 91
:
93
100
100
90
160 73 80
140 70
120
52 60
100 50
80 104 40
60 30
42
40 20
20 14
20 10 6 4 10
0 0
D B F A C E Others
7 QC tools
Seven QC Tools
Scatter Diagram
Stratification
Histogram
Pareto Diagram
Check Sheet
Sl.No Tools Function
Check Sheet / To Collect the data in a simple manner and
1
Data Sheet to prevent omitting the checks
To pick up the important few problems from
2 Pareto Daigram
the trivial many.
Cause & Effect To reorganise the factors (causes)which are
3
Diagram influencing the problem
Others IIII 5
Total : 62
Total rejects 42
Defect Location Check Sheet
A B C D
1 2 3 4
1
A 1
B 12 15
2
C 10 11
D 1
3
oo ox ooo xx oo xxxx oo
1
x ooo xx xxx oo xx
A
2
oo xxx
1 oo xx
B
2 xx oo
subjective opinion.
No of Components
100
96.75
91.53
85.28
200 80
% Cumulative
156
150 60
105
100 50.98 40
50 20
20 16
9
0 0
Cold oil shot Damage Chip off Bad app
shut
Types of Defects
What is Pareto Diagram ?
Pareto diagrams are presentation technique used to
their totals.
ø Fill out the tally sheet and calculate the totals (Example-1)
sheet.
Stain IIII I 6
Gap IIII 4
Total 200
Data Sheet for Pareto Diagram - Example - 2
Type of Number of Cumulative Percentage of Cumulative
Defect Defect Total Overall Total Percentage
Scratch 42 146 21 73
Pinhole 20 166 10 83
Crack 10 176 5 88
Stain 6 182 3 91
Gap 4 186 2 93
Cumulative Percentage
160 73 80
140 70
120
52 60
100 50
80 104 40
60 30
42
40 20
20 14
20 10 6 4 10
0 0
D B F A C E Others
Characteristics
Material Method
What is Cause & Effect Diagram ?
Any defect in a component,a product or service could be
Characteristics
as small bones.
quality characteristics.
experience.
709
700
662
Qty Produced
550
400 376
330
275 273
250
Jan'03 Feb Mar Apr May June
Month
Production details
Bar Chart / Graph :
10
9
8
7
7 6.3
6
Hrs
5
4 4
4 3.4
3
3
2
1
0
Jan'01 Feb'01 Mar'01 Apr'01 May'01 Jun'01
Unwanted - 61
Tags removed - 59
Easy to CLI - 855 Leakage - 845
Tags removed - 850 Tags removed - 825
unit1
100% 100%
50%
unit5 unit2
0.85 80%
0%
10 9.25
9 8.75 Frequency
8
7 7
7
Hours
6 5
4.75
5
4 4 4.75
4
3 3 3.5
3
2
1
0
Jan'01 Feb'01 Mar'01 Apr'01 May'01 Jun'01
M AR
M AR
M AR
M AR
M AR
M AR
M AY
NO V
M AY
NO V
M AY
NO V
NO V
NO V
NO V
M AY
NO V
M AY
M AY
O CT
O CT
O CT
O CT
O CT
O CT
O CT
AUG
AUG
AUG
AUG
AUG
AUG
JUN
DEC
JAN
FEB
APR
JUN
JAN
FEB
APR
DEC
FEB
DEC
JAN
FEB
APR
DEC
JAN
FEB
APR
JUN
FEB
APR
JUN
DEC
JAN
DEC
JUN
JAN
APR
JUN
SEP
SEP
SEP
SEP
SEP
SEP
JUL
JUL
JUL
JUL
JUL
JUL
STA G E I n tro d u c ti on s tag e I mp l e me n ta ti on s tag e F u l l s ta g e d e ve l o p me n t S
Sttea
eaddyyaapppplliiccaatitioon
n sstag
tagee
De c la ra tio n of T PM
by M D
T PM ins t ruc to r's
c o urs e tr a ining in
J IPM
C om p a ny w ide 1 S, 2 S
A c tiv ity
Le ve l 1 t ra in i ng
T PM a w a r e ne s s
Le v el 2 t ra in i ng
pr ogra m to c ov e r a ll
e m p loy e e s
Se le c t M o de l Le v el 3 t ra in i ng
S e l ec t 4 m ac hi n es o ne f rom ea c h u n it
m a c hine s a nd
im pl e m e nt T PM
TP M Kic k -o ff by M D
F o r A ra n k m ac h in e s - 10 m ac hi n es
S t e p 1 , 2, 3 Ste p 4
Ho ri zo nt a l rep l ic at i o n a s i n A ra n k m ac hi n es
J IS H U H O ZEN
AC TIVI TY P LAN F o r B ra n k m ac h in e s - 10 m ac hi n es
S t e p 1 , 2, 3 S te p 4
Ho
H ori
ri zo
zontnat all rep
repllicic ataitioonnaass iinnBB ra
rannkk m
m ac
ac hihinnes
es
F o r A ra n k m ac h in e s - 10 m ac hi n es
E l i mi n at e sc rap S u st a i n ze ro sc rap
Ho ri zo nt a l rep l ic at i o n a s i n A ra n k m ac hi n es
HIN SH ITS U H O ZEN
AC TIVI TY P LAN F o r B ra n k m ac h in e s - 10 m ac hi n es
E l i mi n at e sc rap S u st a in ze ro sc rap
Ho
H ori
ri zo
zontnat all rep
repllicic ataitioonnaass i innBB ra
rannkk m
m ac
ac hihinnes
es
F o r A ra n k m ac h in e s - 10 m ac hi n es
I mp ro ve OE E t o 8 5 %
Ho ri zo nt a l rep l ic at i o n a s i n A ra n k m ac hi n es
KO B ETS U KA IZEN
AC TIVI TY P LAN F o r B ra n k m ac h in e s - 10 m ac hi n es
I mp ro ve OE E t o 8 5 %
Ho
H ori
ri zo
zontnat all rep
repllicic ataitioonnaass iinnBB ra
rannkk m
m ac
ac hihinnes
es
F or A ra nk m ac hi n es - 10 m ac hi n es
E l im i na t e b re ak do wn S us t ai n ze ro b r e ak do wn
b y i nt r o du c in g TB M
H riori
Ho z ozontnatlalrerep
p li cl icatai on
ti o naassi ni nAAr arannkkmmacachihinneses
P LA NN ED
M A INT EN AN C E F or B ra nk m ac hi n es - 10 m ac hi n es
AC TIVIT Y P LAN
E l im i na t e b re ak do wn S us t ai n ze r o b re ak do w n
b y i nt ro du c in g TB M
H ri
Ho ori
zo zontnat lalrerep
p li lcicatai tion
o naassi n
i nBB ra
rannkkmmacachihinneses
IN ITIA L FL OW
C ON TR O L
O FFIC E T PM
ED UC A TIO N &
TR AIN IN G A C TIVIT Y
P LAN
PR EL IM INA R Y
AU D IT
FI NA L AU D IT
Y E AR M AR
M AR
M AR
M AR
M AR
M AR
M AY
NO V
M AY
NO V
M AY
NO V
M AY
NO V
M AY
NO V
M AY
NO V
NO V
O CT
O CT
O CT
O CT
O CT
O CT
O CT
AUG
AUG
AUG
AUG
AUG
AUG
JAN
FEB
APR
JUN
JAN
APR
DEC
FEB
JUN
DEC
FEB
APR
DEC
FEB
JUN
JAN
FEB
APR
DEC
FEB
JUN
JAN
APR
JAN
JUN
JAN
APR
DEC
JUN
DEC
SEP
SEP
SEP
SEP
SEP
SEP
JUL
JUL
JUL
JUL
JUL
JUL
1 9 98 1 9 99 2 0 00 2 0 01 2 0 02 2 0 03 2 0 04
and two limit lines on either side of the central line called “Upper
2. Assignable Causes :
ø Calculate x
x = x1 + x2 +……+ xn
n - Size of a sub group
n
ø Calculate x
x = x1 + x2 +……+ xk
k - Number of subgroups
k
Procedure to make control charts :
x - R Chart
ø Calculate R
ø Calculate R
R = Rx1 + Rx2 +……+ Rn
k
Procedure to make control charts :
x - R Chart
ø Calculate the control lines
x Chart
Central line :
CL = x
Upper control limit :
UCL = x + A2R.
Lower control limit :
UCL = x - A2R
Procedure to make control charts :
x - R Chart
ø Calculate the control lines
R Chart
Central line :
CL = R
Upper control limit :
UCL = D4R.
Lower control limit :
LCL = D3R
Procedure to make control charts :
List of Coefficients for x - R Chart.
UCL
C/L
LCL
Control Chart for Controlled State
UCL
C/L
LCL
Control Chart for Uncontrolled State
Examples of Control Chart :
LSL
52.039 6
Xdbar 7
52.035 8
UCL XBAR
9
LCL XBAR 10
52.031
1 3 5 7 9 11 13 15 17 19 21 23 25
11
12
Samples
13
14
15
Range chart (R) READINGS
0.015
Re a dings
0.01 UCL R
0.005
LCL R
0
1 3 5 7 9 11 13 15 17 19 21 23 25
Rbar
Samples
How to Read Control Charts :
ø Out of control limits.
Run
How to Read Control Charts :
Trend
3-sigma line
2-sigma line
2-sigma line
3-sigma line
How to Read Control Charts :
3-sigma line
1.5-sigma line
How to Read Control Charts :
Periodicity
Histogram
40 38
35 34
30
25
20
15
9.9
10 9
4 4 4.5
5
2.5 2.5
0
0
in a product or process.
Steps to construct the Histogram :
ø Collect 100 reading.
No of Observations No of Classes ( k )
< 50 6
51 - 100 7
101 - 200 8
201 - 500 9
501 - 1000 10
Graph to Determine K
20
18
16
14
k 12
10
8
6
4
2
0
formula ( R + W ) / K
Note
104.2 - ////
104.6 - ///
104.7 - //
Examples of Histogram :
20
16
15
12
10
10
5
5 3
2 2
0
104.1 104.2 104.3 104.4 104.5 104.6 104.7
in mm
Interpretation of Histogram
2 5
6
3
Types of Histogram :
g) Isolated–peak type
Uses of Histogram :
ø To know the pattern of variation.
ø To assess states of control
ø To assess conformance to specifications
ø To assess spread or variation with reference to specification.
ø To assess process capability.
ø To get clues for bringing process under control - whether to
shift mean or to reduce variation or both.
ø To get clues for possible assignable causes for observed
variation - mixture of lots,suppliers,instruments /
measurements errors,bias of written results etc.
Stratification
30
20 16% 18%
12%
10 6%
0
A B C D E
Types of Defect
What is Stratification :
Stratification is the process of separation of data into
40
Defective %
30
20 16 % 15%
10
0
A B C
Supplier
Defective Quality - Supplier Wise.
Types of Stratification :
Quality Based :
50 48%
Quality Defective(Nos)
40
30
20 16% 18%
12%
10 6%
0
A B C D C
Type of Defect
Defects Data For Each Hour in a Shift
Types of Stratification :
Worker Based :
30
No of Defective
25 22%
20
15
10
5%
5 3%
0
A B C
Worker
Defective Assemblies
Types of Stratification :
Machine Based :
100
90
80
70
Production %
60 57%
50 43%
40
30
20
10
0
A B
Machine
Production Machine Wise
Types of Stratification :
Processing Based :
Power Consumption %
50
40
32%
30
25% 26%
20
12%
10 5%
0
A B C D E
Process Area
Power Consumption Process Area Wise
Scatter Diagram
4.5
4.4
ø Find the maximum and minimum values for both the x and y.
4.5
4.4
4.1
4.0
3.9
* Looking for relationships
3.8 not cause & effect
3.7
Independent variable (“cause”)
3.6
3.5
150 200 250 300 350 400 450 500 550 600 650
Examples of Scatter Diagram :
4.0 y axis
430 x axis
b. No correlation.
c. Negative correlation.
6 6 6
4 4 4
2 2 2
0 0 0
0 2 4 6 x 0 2 4 6 x 0 2 4 6 x
n = 30 r = 0.9 n = 30 r = 0.6
y y
6 6
4 4
2 2
0 0
0 2 4 6 x 0 2 4 6 x