Welcome

To

Training Program
On

Basic 7 QC Tools

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7 QC TOOLS

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WHAT IS 7 QC TOOLS

 Set of Quality Control Tools

 Fundamental instrument to improve the quality of the product

 Used to analyze the production process, identify the major

problems, control fluctuations of product quality, and provide
solutions to avoid future defects

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 LIST OF 7 QC TOOLS

1) Check Sheet
2) Stratification ( Bar Chart, Line Chart, Pie Chart etc)
3) Pareto Diagram
4) Histogram
5) Cause & Effect Diagram
6) Scatter Diagram
7) Control Charts

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 01
CHECK SHEET

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 CHECK SHEET - INTRODUCTION

 It is a simple form that can be used to collect data in an organized manner and
can be converted easily in to readily useful information

 It is a table or a form used to systematically register data as it is collected

 Data collection is very important – it’s a starting point for any analysis

 Check sheet presents information in an efficient, graphical or tabular format

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 WHEN TO USE IT
 When data is to be recorded manually to ensure the accuracy of the data and
further can be used either for direct interpretation ( explanation) or for
transcription (record), like transferring to computer

 When the recording involves counting, classifying, checking or locating

 When it is useful to check each measurement as it is recorded, for example that

it is within normal bounds

 When it is useful to see the distribution of measures as they are built up

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WHEN TO USE IT

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EXAMPLE

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EXAMPLE; PROCESS DISTRIBUTION SHEET

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DEFECTIVE ITEM CHECK SHEET

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LOCATION PLOT

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CHECK LIST

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EXERCISE - 1

 Prepare A Checksheet to collect data for assembly line

problem of a motor vehicle unit

 Make Teams

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 02
STRATIFICATION

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 STRATIFICATION - INTRODUCTION

 Stratification helps in organizing the data by category

 Group the data: Collected data should be grouped in a

way that makes the data valuable and reliable. Similar
problems must be in similar groups.

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 WHEN TO USE IT

 Along with check Sheet in the data collection process

 It’s a method of classifying / Grouping / categorization of data

while colleting
 Example: Collection of Rejection data Shift wise, Machine wise
or Product wise

 Stratification is used to analyze and understand data from different

perspective

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EXERCISE - 2

 Which Machine is responsible for most of the rejection

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 03
PARETO DIAGRAM

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 PARETO DIAGRAM - INTRODUCTION
 Principle:
 Vital Few – Trivial Many

 80 : 20 Rule

Vilfredo Pareto

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 WHEN TO USE IT
 When selecting the most important things on which to focus. i.e. to prioritize

 Use it after improving a process, to show the relative change in a measured

item

 Use it when sorting a set of measurements, to visually emphasize their relative

sizes.

 Use it, rather than a Bar Chart or Pie Chart to show the relative priority of a set
of numeric measurements

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WHEN TO USE IT

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 CONSTRUCTION OF PARETO

 Steps:

1) Collect the data for plotting Pareto

2) Re-arrange the collected data in descending order
3) Calculate the percentage contribution of each parameter.
4) Put cumulative percentage contribution.
5) Each Percentage contribution will be plotted as Bars.
6) The cumulative percentage to be plotted as line.
7) Draw a line from 80% to the Cumulative line and from the intersection to X
axis.
8) The bigger bars which is on the left side of the line will indicate the major
contributors.

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CONSTRUCTION OF PARETO

1. Collect the data for plotting Pareto

Defect Type No. of Defective items

Bad Rubber 91

Poor Adhesion 128

Cracks 9

Voids 36

Impurities 15

Cuts 23

Others 12

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CONSTRUCTION OF PARETO

2. Re-arrange the collected data in

descending order Defect Type No. of Defective items

Poor Adhesion 128

Bad Rubber 91
Voids 36

Cuts 23

Impurities 15

Cracks 9
Others 12
Total 314

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 CONSTRUCTION OF PARETO
3. Calculate the percentage contribution of each parameter
128/314*100=40.76

Defect Type No. of % Contribution

Defective
items
Poor Adhesion 128 40.76
Bad Rubber 91 28.98 91/314*100=28.98
Voids 36 11.46
Cuts 23 7.32
Impurities 15 4.78
Cracks 9 2.87
Others 12 3.82
Total 314 100

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 CONSTRUCTION OF PARETO
4. Put cumulative percentage contribution.

Defect Type No. of % Contribution Cumulative %

Defective Contribution
items
Poor Adhesion 128 40.76 40.76
Bad Rubber 91 28.98 69.75
Voids 36 11.46 81.21
Cuts 23 7.32 88.54
Impurities 15 4.78 93.31
Cracks 9 2.87 96.18
Others 12 3.82 100
Total 314 100

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CONSTRUCTION OF PARETO

5. Each Percentage contribution will be plotted as Bars

120.00

100.00

80.00

60.00

40.00

20.00

0.00

io
n er id
s ts es s
er
s
s b b o Cu rit
i
ack h
he t
d Ru V
p u Cr O
A d Im
oor Ba
P

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CONSTRUCTION OF PARETO
6. The cumulative percentage to be plotted as line

120.00

100.00

80.00

60.00

40.00

20.00

0.00

io
n er id
s ts es s
er
s
s b b o Cu rit
i
ack h
he t
d Ru V
p u Cr O
A d Im
oor Ba
P

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 CONSTRUCTION OF PARETO
7. Draw a line from 80% to the Cumulative line and from the intersection to X axis.

120.00

100.00

80.00

60.00

40.00

20.00

0.00

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 CONSTRUCTION OF PARETO
8. The bigger bars which is on the left side of the line will indicate the major contributors

120.00

100.00

80.00

60.00

40.00

20.00

0.00

Major contributors

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 Any Questions…

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 EXERCISE - 3

Make Pareto Diagram for defects in Part A.

Trimming Under
Part Name Un Filling Pitting Overlap Crack Bend Out Weight Under Sizes ID Oversize Short Length Total
A 10 0 0 0 0 0 0 0 0 0 10
B 0 0 0 0 1 0 0 0 5 0 6
A 0 0 0 1 0 0 0 0 0 0 1
B 72 18 0 0 0 0 0 0 0 4 94
A 8 0 1 0 0 0 0 0 0 0 9
B 16 4 2 0 0 0 0 0 0 0 22
A 22 0 0 0 0 0 0 0 0 0 22
B 34 30 10 0 0 0 0 0 0 0 74
A 1 0 0 0 0 0 0 0 0 0 1
B 2 0 0 0 0 0 0 0 0 0 2
A 20 0 0 0 0 1 0 0 0 0 21
B 16 0 0 0 0 0 0 0 0 0 16
A 8 0 0 0 0 0 0 0 0 0 8
B 14 0 0 0 1 0 1 0 0 0 16
A 3 0 0 0 0 0 0 0 0 0 3
B 6 0 0 0 0 0 0 0 0 0 6
A 0 0 0 12 0 0 0 0 0 0 12
B 52 3 0 0 0 0 0 0 0 21 76
A 0 0 0 0 0 0 7 0 0 0 7
B 6 0 0 0 0 0 0 2 0 12 20
A 32 0 0 0 0 0 0 0 0 0 32
B 6 6 0 0 0 0 0 0 0 1 13
A 0 2 0 0 0 0 0 0 0 0 2
B 0 0 3 0 0 0 0 0 0 0 3
A 1 0 0 0 0 0 0 0 0 0 1
B 1 0 0 0 0 0 0 0 0 0 1
Grand Total 337 63 16 13 2 1 8 2 5 38

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 EXERCISE - 1 (A)

Arranged Defect Quantity in Descending Order to make Part wise

Pareto Diagram.

Cumm. Cumm.
Defect Qty. Total %age
Un Filling 105 105 81.40%
Crack 13 118 91.47%
Under Weight 7 125 96.90%
Pitting 2 127 98.45%
Overlap 1 128 99.22%
Trimming Out 1 129 100.00%
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 EXERCISE -3 Pareto Diagram for Major Defect Contribution

Pareto Diagram - Part A

120 120.00%

105
100 98.45% 99.22% 100.00% 100.00%
96.90%
91.47%

80 81.40% 80.00%

60 60.00%

40 40.00%

20 20.00%
13
7
2 1 1
0 0.00%
Un Filling Crack Under Weight Pitting Overlap Trimming Out
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 04
HISTOGRAM

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HISTOGRAM - INTRODUCTION
 Frequency distribution chart: Graphically shows
count of data points falling in various ranges
Frequency

Score

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WHEN TO USE IT
 Use to investigate the distribution of set of measurements

 When it is suspected that there are multiple factors affecting a

process, to see if this shows up in the distribution

 Use it to help define reasonable specification limits for a process

by investigating the actual distribution

 When you want to see the actual shape of the distribution, as

opposed to calculating single figures like the mean or standard
deviation

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WHEN TO USE IT

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 EXERCISE - 4 HISTOGRAM CONSTRUCTION

Construct Histogram for below mentioned data:

29.9 30.1 30.3 30.2 30.1 29.1 30.0 29.7

30.6 30.4 29.9 29.5 30.4 30.0 29.7 30.5

29.9 30.6 29.1 30.2 30.3 30.2 29.4 29.8

29.6 29.4 29.8 29.9 29.8 30.3 30.0 30.0

30.1 29.9 29.3 29.8 30.4 29.8 29.2 30.0

29.9 30.0 29.6 30.5 29.8 30.4 29.8 29.9

30.4 29.4 30.3 30.0 29.9 30.0 30.3 29.5

30.0 30.4 29.4 30.0 30.0 29.7 29.6 29.9

30.5 29.7 29.9 30.1 30.6 30.4 29.5 29.7

30.2 30.8 29.5 29.9 30.2 30.1 29.8 29.9

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HISTOGRAM CONSTRUCTION

Max = 30.8 General Value of ‘ K ’ Number of

Min = 29.1 Readings
K = 10 50-100
Width = (Max – Min)/k
= (30.8 – 29.1)/10 K = 12 100-250

= 0.17 K = 20 Above 250

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20

15

10

0
29.05 – 29.25 – 29.45 – 29.65 – 29.85 – 30.05 – 30.25 – 30.45 – 30.65 –
29.25 29.45 29.65 29.85 30.05 30.25 30.45 30.65 30.85

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HISTOGRAM PATTERNS

HISTOGRAM PATTERN SYMPTOM POSSIBLE PROBLEM

Bar range too narrow

Low with gaps There is no continuous
flow of data.

Could be extreme version

High with few bars of reduced distribution.

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HISTOGRAM PATTERNS
HISTOGRAM SYMPTOM POSSIBLE PROBLEM
PATTERN
Skewed Natural distribution
(Off Center ) (this is (more variation in one
positive; negative skew direction) or incomplete
has tail to right) data being used.

Distribution is not bell-

Exponential shaped (extreme version
of skewed)

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HISTOGRAM PATTERNS

HISTOGRAM PATTERN SYMPTOM POSSIBLE PROBLEM

Measurement is of two
processes. This is very
Dual-peaked (bimodal) common, e.g. data from
two periods, process
changed mid-stream.

Two processes being

Isolated-peaked measured (well-separated
bimodal distribution).

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HISTOGRAM PATTERNS

HISTOGRAM PATTERN SYMPTOM POSSIBLE PROBLEM

Cog-toothed (or Combed) Faulty measurement,

rounding error or version
of plateau distribution

Combination of multiple
Plateau bell-shaped curves,
extreme version of
bimodal distribution
(multiple processes) or
faulty measurement

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HISTOGRAM PATTERNS

HISTOGRAM SYMPTOM POSSIBLE PROBLEM

PATTERN

Modified data - often

caused by shifting data
Edge-peaked that was out of
specification back inside
specification limits.

Incompletely reported
Truncated data or measured after
(Shortened) inspection has rejected
items outside
specification limits.

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 05
CAUSE & EFFECT
DIAGRAM
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BRAINSTORMING

 Purpose - generate a
list of
 Problems / Causes
 opportunities
 ideas
 Success requires
 no criticism
 no arguing
 no negativism
 no evaluation
CAUSE & EFFECT DIAGRAM - INTRODUCTION

“One of the greatest principles

behind QC is consumer satisfaction.
Within a company, the next process
is the customer. If this way of
thinking is driven home, the walls of
sectionalism will crumble and fresh
air will breeze through the company.”
- Dr. K. Ishikawa.

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 IMPORTANCE
 Also known as;
 Ishikawa Diagram (after its originator, Kaoru Ishikawa, who first used in

1940s)
 Fishbone Diagram ( Because of its structure)

C C C
E
C C C

 It is simply a tree or hierarchy, showing how causes are related to the given
effect
 Main usage: to discover potential causes of unwanted problems.

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 WHEN TO USE IT

 When investigating a problem, to identify and select key problem

causes to further investigate or address

 When the primary symptom (or effect) of a problem is known, but

possible causes are not all clear

 When working in a group, to gain a common understanding of

problem causes and their relationship

 Use it to find other causal relationships, such as potential risks or

causes of desired effects

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WHEN TO USE IT

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STRUCTURE

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STRUCTURE

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EXERCISE - 5

 Prepare Cause & Effect diagram by brainstorming.

 Make Teams
 Take Major complaints, Reasons, each team one Reason
 List out causes by brainstorming
 Separate the causes in groups of Man, Machine, Method,
Material, etc.
 Mark the major causes.

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EXERCISE - 3
MACHINE MANPOWER

Major Parts

MATERIALS METHOD

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 06
SCATTER DIAGRAM

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 SCATTER DIAGRAM - INTRODUCTION

 It’s a tool to analyze the relationship between two variables

 Independent variable is plotted on the horizontal axis and

dependent variable is plotted on vertical axis

 The pattern of their intersecting points can graphically show the

relationship pattern among the two variables

 Most often it is used to give evidence for a cause – and – effect

relationships but they alone can’t prove it

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INTRODUCTION

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 WHEN TO USE IT

 When it is suspected that the variation of two items is connected

in some way, to show any actual correlation between the two

 When it is suspected that one item may be causing another, to

build evidence for the connection between the two

 Use it only when both items being considered can be measured

together, in pairs

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WHEN TO USE IT

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 WHY SCATTER DIAGRAM

Scatter Diagram shows correlation for three reasons:

1) Cause and effect relationship between the two measured items: one is
causing the other (at least in part).
Example: Change in cooling rate of molten metal changes the
brittleness

2) The two measured items are both caused by a third item.

Example: Crack and Transparency of glass utensils are effected due to
changes in furnace temperature.

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HOW TO PLOT SCATTER DIAGRAM

Sl. No Steps Points to Consider

• One is suspected cause and other is suspected

Determine two Variables effect
1 • They may come from other tools like C & E
to be compared ( x & y)
Diagram or Relationship Diagram

• Both (x & y) must be variable

Identify the
2 • Must be possible to measurable both at the same
measurements to be taken
time

Collect 50 to 100 pairs of • Try to keep all other variables as steady as

3
measurements possible

Plot these data as scatter • Design the scales of axes to give maximum visual
4
diagram spread points

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INTERPRETATION OF SCATTER DIAGRAM
SCATTER DIAGRAM DEGREE OF INTERPRETATION
CORRELATION

No relationship can be seen. The

None 'effect' is not related to the 'cause'
in any way.

A vague relationship is seen. The

'cause' may affect the 'effect', but
only distantly. There are either
more immediate causes to be
Low
found or there is significant
variation in the 'effect'.

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INTERPRETATION OF SCATTER DIAGRAM
SCATTER DIAGRAM DEGREE OF INTERPRETATION
CORRELATION

The points are grouped into a clear

linear shape. It is probable that the
High 'cause' is directly related to the
'effect'. Hence, any change in
'cause' will result in a reasonably
predictable change in 'effect'.

All points lie on a line (which is

usually straight). Given any 'cause'
value, the corresponding 'effect'
value can be predicted with
Perfect
complete certainty.

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INTERPRETATION OF SCATTER DIAGRAM

SCATTER DIAGRAM TYPE OF INTERPRETATION

CORRELATION

Straight line, sloping up from left

to right. Increasing the value of the
Positive 'cause' results in a proportionate
increase in the value of the 'effect'.

Straight line, sloping down from

left to right. Increasing the value of
Negative the 'cause' results in a
proportionate decrease in the value
of the 'effect'.

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 INTERPRETATION OF SCATTER DIAGRAM

SCATTER DIAGRAM TYPE OF INTERPRETATION

CORRELATION
Various curves, typically U- or S-
shaped. Changing the value of the
Curved 'cause' results in the 'effect' changing
differently, depending on the
position on the curve.

Part of the diagram is a straight line

(sloping up or down). May be due to
Part linear breakdown or overload of 'effect', or
is a curve with a part that
approximates to a straight line
(which may be treated as such).

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 07
CONTROL CHARTS

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 CONTROL CHARTS - INTRODUCTION

 Control Chart is the best tool to capture the process to determine whether it is
operating with in the statistical control or not

 Helps to differentiate between natural cause and special cause for process
variation

 Control Chart consists of:

 Points representing measurements of a quality characteristics taken from

the process at different time

 A center line, drawn at the process mean
 Upper and lower control limits that indicate the threshold at which the

process output is considered statistically 'unlikely'

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UNDERSTANDING THE CONTROL CHART

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 WHEN TO USE IT

 During Process Investigation: To determine whether the process is

with in statistical control or not
 To differentiate between special and common causes of variation
 To detect statistically significant trends in measurements. Ex: To
identify when and by how much a change to the process has
improved it
 Use as ongoing Health measure of a process: Helps to spot the
problem before it becomes significant
 Practically can be made use only when the process can be measured
at regular intervals

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WHEN TO USE IT

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INDICATIONS OF SPECIAL CAUSE

One or more points out side the Seven or more consecutive points
control limits on one side of the central line

Six points in a row steadily

increasing or decreasing

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INDICATIONS OF SPECIAL CAUSE

Fourteen points alternating up Two out of three consecutive points

and down in the outer third of the control
region

Fifteen points in a row with in the Eight points on both sides of the
central third of the control region central line with none in the
central third of the control region

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INDICATIONS OF SPECIAL CAUSE

Control Chart Indication – Meaning – Actions Required

Control Actions
Control Chart behavior Meaning
Required
One or More Points out side the control Exhibition of any of these Immediate action to be
1
limits condition implies the taken to identify the
presence of special cause special cause hidden in the
Seven or more consecutive points on one
2 (s) in the process: process.
side of the central line
Six points in a row steadily increasing or Some of the example of Some of the actions can be
3
decreasing special causes: taken are:
4 Fourteen points alternating up and down
a) Poor adjustment of the a) Process re-setting
Fifteen points in a row with in the central equipment b) Die/punch correction
5
third of the control region b) Worn out tool c) Tool Verification
Two out of three consecutive points in c) Operator falls asleep d) Raw material
6 d) Faulty controller verification
the outer third of the control
e) M/c malfunctioning
f) Poor batch of raw
Eight points on both sides of the central material
7 line with non in the central third of the g) Power surges
control region

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 Any Questions…..

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Question & Answer

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