What are 7 QC Tools

?
QC tools are the means for

Colleting data

Identifying root causes

Analyzing data &

measuring the results.

04/13/2025 By:Milion R(BSc, MScN) 1
Applying Problem Solving technique & Tools

1. Simple Tools for Problem Analysis

1.1 Why -Why Analysis
1.2 What If Analysis
2 Simple 7 QC Tools (Statistical Tools)
•Stratification
•Pareto Diagram
•Cause and Effect Diagram
•Check Sheet
•Control Chart/Graph
•Histogram
•Scatter Diagram
04/13/2025 By:Milion R(BSc, MScN) 2
Problem Solving Tools
What is a “Problem “?
“Problem is an undesirable event” or ..

Any Gap between what is expected and what is

obtained , can be called as a Problem, and any effort to
reduce this gap can be called as “Problem Solving”
Expected
(Gap ?) A Problem!

Obtained

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Applying Problem Solving Tools
Symptoms and the Root Causes

An undesirable end result is only a starting point

or Symptom.

Eg: When an equipment breaks down , It is an end

result or a Symptom of a Problem.

The abnormalities present in the responsible factors , are

referred to as root cause(s) of the problem

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Problem Solving Tools
Four types of Problems

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Apply Problem Solving Tools
Why - Why
Library analysis
of Problem - An Example
Solving Tools

Purpose : It is the simple tool used by the team

/observer to find out the cause of the
problem/Accident/ Breakdown at the Workplace.

Many times, the root cause of the problem can be identified by

asking Why 5 times and the repetition of such problems can
be prevented by taking countermeasure immediately.

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Apply Problem Solving Tools
Why - Why
Library analysis
of Problem - An Example
Solving Tools
Water Dripping in Substation 1
WHY ?
Water accumulated at the roof
WHY ?
Outlet drain chocked
WHY ?
Atmospheric dust & dirt
WHY ?
Periodic cleaning of drain not done
Action

Proper scheduled procedure for roof cleaning is to be prepared

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Apply Problem Solving Tools
What-IfofAnalysis
Library Problem Solving Tools

Purpose : It
is the simple Pro active
tool used by the team / observer, to
identify problems before hand and
take appropriate counter measures to
prevent such problems .

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Problem Solving Tools
What-IfofAnalysis
Library Problem-Solving
An Example
Tools
Area : Equipment :Compressor
Team :
SL. What If Results Countermeasures
1. There is no Water in The Engine heats • Inspect the
the Radiator of an up and Piston may Temperature of
Automobile ? And it get seized. outlet water .
is not noticed. • Provide the temp.
Indictor for the
driver

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 Pareto Diagram
1. What is Pareto diagram ?
A Pareto diagram is a combination of bar and line
graphs of accumulated data, where data associated
with a problem (e.g., a defect found, mechanical
failure, or a complaint from a customer) are divided
into smaller groups by cause or by phenomenon
and sorted, for example, by the number of
occurrences or the amount of money involved.
(The name “Pareto” came from an Italian
mathematician who created the diagram.)

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 Pareto Diagram
2. When is it used and what results will be obtained?

Please refer to the table on next slide for the

usage and benefits of a Pareto diagram. It is
mainly used to prioritize matters, and because
of its easiness of use, the diagram is used in a
wide variety of fields.

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 Pareto Diagram
Method Usage Result
 Used to identify and prioritize a
problem.  Allows clarification of
important tasks.
Pareto Diagram Used to review the effects of an  Allows identification of a
(No. of Occurrences) action taken.
starting point (which task to
start with).
 Allows projection of the
effects of a measure to be
taken
Used to prioritize actions.
(Used during phases to
monitor the situation, analyze
causes, and review
effectiveness of an action.)

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 Pareto Diagram
Example

Assessment using Pareto Confirmation of Effect

diagram (prioritization) (Comparison)
To identify a course of
action to be emphasized Frequently used to check
using a variety of data. the effect of an
improvement.
Details of “ A”

Improved

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 Cause & Effect Diagram
1. What is Cause & effect Diagram ?

A cause and effect diagram is “a fish-bone diagram that

presents a systematic representation of the relationship
between the effect (result) and affecting factors (causes).”
Solving a problem in a scientific manner requires
clarification of a cause and effect relationship, where the
effect (e.g., the result of work) varies according to factors
(e.g., facilities and machines used, method of work,
workers, and materials and parts used). To obtain a good
work result, we must identify the effects of various factors
and develop measures to improve the result accordingly.
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 Cause & Effect Diagram
2. When is it used and what results will be obtained?

A cause and effect diagram is mainly used to study the

cause of a certain matter.
As mentioned above, the use of a cause and effect diagram
allows clarification of causal relation for efficient problem
solving.
It is also effective in assessing measures developed and
can be applied to other fields according to your needs.

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 Cause & Effect Diagram
Method Usage Result
 Used when  Can obtain a clear overall
picture of causal relation.
Cause and Effect clarifying a cause (A change in the cause
Diagram
Machine Man
and effect triggers a variation in the
relationship.[Used result.)○ Can clarify
Effect

during a phase to the cause and effect

analyze causes.] relationship.
Material Method

Cause (4M’s) Result  Used to develop  Can list up all causes to

(Controlled State)

countermeasures. identify important causes.

 Can determine the
[Used during a phase to plan direction of action
countermeasures.] (countermeasure).

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 Cause & Effect Diagram
Mechanism of Quality of
Copying Machine Copying Paper
Malfunction of
Running out
Smudges on the the roller
of stock

Many Copying Errors!

copied surface
Printing too Too thin
Internal devices not lightly
working smoothly Dampened
Folded

Deterioration of
Error in
performance due
Keyboard handling placement of Dirt on the
to high
error paper (setting glass
temperatures
its face up) surface
Error in selecting a
Dust
scale of reduction Error in Nicotine-
selecting stained
shading
User Surrounding
Environment

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 Stratification
1. What is Stratification ?

Stratification means to “divide the whole into

smaller portions according to certain criteria.” In
case of quality control, stratification generally means
to divide data into several groups according to
common factors or tendencies (e.g., type of defect
and cause of defect).
Dividing into groups “fosters understanding of a
situation.” This represents the basic principle of
quality control.

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 Stratification
2. When is it used and what results will be obtained?
The “common and basic principle” of quality
control is stratification, i.e., to think a matter
out by breaking it into smaller portions.
Stratification has a number of useful
purposes. The table below shows only a few
examples of these purposes.

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 Stratification
Method Usage Result
Grouping by day, •Used to observe variations
•Allows observation
time, place, worker, among strata.
or process •Used to identify the of variations among
strata.
relationship between cause
•By performing a
Number of Units
and effect.
•Used to identify a purpose cause analysis using
X ★★★★★★★
the stratified data, the
Y △△△△ and means to serve the
following can be
purpose
Z ○○○
[Used during phases to monitor accomplished.
the situation, analyze causes, 1.Identification and control of a
review effectiveness of an action, problem
perform standardization, and 2.“Division of data (obtained by
implement a selected control using each QC tool) into several
measure.] groups”

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 Stratification
Item Method of Stratification
Hour, a.m., p.m., immediately after start of work,
Elapse of time
shift, daytime, nighttime, day, week, month
Worker, age, male, female, years of experience,
Variations among workers
shift, team, newly employed, experienced worker
Processing method, work method, working
Variations among work
conditions (temperature, pressure, and speed),
methods
temperature
Variations among Measurement tool, person performing
measurement/inspection measurement, method of measurement, inspector,
methods sampling, place of inspection

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 Check Sheet
1. What is Check sheet ?
A check sheet is “a sheet designed in advance to allow easy
collection and aggregation of data.” By just entering check
marks on a check sheet, data can be collected to extract
necessary information, or a thorough inspection can be
performed in an efficient manner, eliminating a possibility
of skipping any of the required inspection items.
A check sheet is also effective in performing stratification
(categorization).

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 Check Sheet
2. When is it used and what results will be obtained?

Please refer to the table on next slide for the usage

and benefits of a check sheet. It is frequently used in
daily business operations, often not specifically for
QC purposes.

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 Check Sheet
Method Usage Result
 Used to collect data.  Ensures collection of
Check Sheet  Used when required data.
 Allows a thorough
Day
Process performing a
Process 1
thorough inspection of all check
Process 2
inspection. items.
 Can understand
Process 3

Used during phases to monitor tendencies and variations.

the situation, analyze causes,  Can record required data.
review effectiveness of an
action, perform standardization,
and implement a selected control
measure

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 Check Sheet
A check sheet used to identify defects

Date
Total
Defect

Vertical Scratch

Scratch

Dent

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Control Chart (Control Chart / Graph 1)
1. What is Control Chart ?
A control chart is used to examine a process to see if it is
stable or to maintain the stability of a process.
This method is often used to analyze a process.
To do so, a chart is created from data collected for a certain
period of time, and dots plotted on the chart are examined to
see how they are distributed or if they are within the
established control limit.
After some actions are taken to control and standardize various
factors, this method is also used to examine if a process is
stabilized by these actions, and if so, to keep the process in a
stable state.
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 Control Chart
2. When is it used and what results will be obtained?

There are two types of control charts: one used for

managerial purposes and the other for analytical purposes.
A control chart is used to identify dots that are outside the
control limit, which indicate some anomalies in a process.
In addition, seven consecutive dots showing values that are
below or above the mean (central) value, or an increasing or
a decreasing trend represented by seven consecutive dots
also indicate “a problem in a process.”

We need to examine what has caused such a tendency.

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 Control Chart
Method Usage Result
Used to observe a Can identify a change
Control Chart
caused by elapse of
change caused by
time.
elapse of time.
Can judge the
[Used during phases to
process if it is in its
monitor the situation,
normal state or there
x-R Control Chart analyze causes, review
are some anomalies
effectiveness of an
by examining the dots
action, perform
plotted on the chart.
standardization, and
implement a selected In the example “x bar ” -R
control chart, “X bar”
control measure
represents the central value,
while “R” indicates the range.
Control Chart for Managerial Purposes: Extends the line indicating the control limit used for analytical purposes
to plot data obtained daily to keep a process in a good state.
Control Chart for Analytical Purposes: Examines a process if it is in a controlled state by collecting data for a certain
period of time. If the process is not controlled, a survey is performed to identify its cause and develop
countermeasures.

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 Control Chart
Examples of Values
Represented by Dots
Values above the
control limit
represented
seven by
seven
Consecutive dots

Control
x- Chart
A decline
represented
representedbyby
seven

consecutive dots

Group Number

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 Graph
1. What is Graph ?
A graph is “a graphical representation of data, which allows
a person to understand the meaning of these data at a
glance.”
Unprocessed data simply represent a list of numbers, and
finding certain tendencies or magnitude of situation from
these numbers is difficult, sometimes resulting in an
interpretational error.
A graph is a effective means to monitor or judge the situation,
allowing quick and precise understanding of the current or
actual situation.
A graph is a visual and summarized representation of data
that need to be quickly and precisely conveyed to others.
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 Graph
2. When is it used and what results will be obtained?

A graph, although it is listed as one of the QC

tools, is commonly used in our daily life and is the
most familiar means of assessing a situation.

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 Graph
Method Usage Result
120
Changes in a time-sequential Can observe changes in
100

80 order – line graph a time-sequential order,

60 East ratios, and amounts.
40

20 Amounts – bar graph, etc.

0 A graph is the most
1st Qtr 2nd Qtr 3rd Qtr 4th Qtr

Ratios – pie graph, band chart, frequently used tool to

etc. examine the various
4th Qtr
13%
1st Qtr
13% matters such as those
2nd Qtr
17%
(The items listed above are listed on the left.
representative examples.)
3rd Qtr
57%

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 Graph
[ Bar Graph of Sales] [Band Chart of Expenses]
・ Survey Period: Dec. 1999
million) (¥ million)
・ Prepared by: M/T

million)

Before
Sales

Chemicals Oils Electricity

Taking
(430) (200) (170)
Actions
( Total: ¥ 8 million)

After Chemicals Oils

Taking (240) (150)
Actions
( Total: 4.95
(Total: ¥ 4.95 million)
million)

Sales AIwate BTokyo COsaka DShizuoka Electricity

Office (108)

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 Histogram
1. What is Histogram ?

When creating a histogram, “a range of data is

divided into smaller sections having a uniform
span,and the number of data contained in each
section (the number of occurrences) is counted to
develop a frequency distribution table.”
Then, “a graph is formed from this table by using
vertical bars, each having the height proportional to
the number of occurrences in each section.”

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 Histogram
2. When is it used and what results will be obtained?
A histogram is mainly used to analyze a process by
examining the location of the mean value in the
graph or degree of variations, to find a problem point
that needs to be improved. Its other applications are
listed in the table below.

04/13/2025 By:Milion R(BSc, MScN) 35

 Histogram
Method Usage Result
•Used to assess the actual conditions.
•Used to analyze a process to identify •Can identify the
Histogram a problem point that needs to be location of the mean
Standard
Range improved by finding the location of (central) value or degree
the mean value or degree of of variations.
variations in the graph. •Can find out the scope
•Used to examine that the target
quality is maintained throughout the
of a defect by inserting
X Axis (Values
process. standard values.
•Can identify the
Actually
Range of
Variations
Measured)
•Others
condition of distribution
[Used during phases to (e.g., whether there is an
monitor the situation, analyze isolated, extreme value).
causes, and review
effectiveness of an action.]

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 Scatter Diagram
1. What is Scatter Diagram ?
A scatter diagram is used to “examine the
relationship between the two, paired, interrelated
data types, ” such as “height and weight of a
person.”
A scatter diagram provides a means to find
whether or not these two data types are
interrelated.
It is also utilized to determine how closely they are
related to identify a problem point that should be
controlled or improved.
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 Scatter Diagram
2. When is it used and what results will be obtained?

The table on next slide shows some examples of

scatter diagram’s usage.
If, for example, there is a relationship where “an
increase in the number of rotations (x) causes an
increase in abrasion (y),” there exists “positive
correlation.”
If, on the other hand, the existence of a relationship
where “an increase in the number of rotations (x)
causes a decline in abrasion (y)” indicates that there
is “negative correlation.”

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 Scatter Diagram
Method Usage Result
Scatter Diagram
•Used to identify a relationship •Can identify cause
between two matters.
ｙ Axis
•Used to identify a relationship and effect relation.
•Can understand the
Abrasion

between two matters and establish

countermeasures based on their
cause and effect relation. relationship
x Axis Example Usage between two
Number of
Rotations
1.Relationship between thermal results.
treatment temperature of a steel
material and its tensile strengths
2.Relationship between visit made
by a salesman and volume of sales
3.Relationship between the number
of persons visiting a department
store and volume of sales
4 Others
[Used during phases to monitor the
situation, analyze causes, and review
effectiveness of an action.]

04/13/2025 By:Milion R(BSc, MScN) 39

 Scatter Diagram

ｙ Axis
Abrasion (micron)

x Axis
Number of
Rotations

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 Application of QC tools in Problem Solving
Graphs Check Stratific Pareto Cause & Histogram Scatter Control Chart
sheet ation Diagram Effect Diagram
Diagram
Identification of
problem
Defining the problem

Record of facts

Detecting causes of
problem
Develop Improvement
method
( Solution )

Implementation

Evaluation of result

Process control
( Standardization )

Relation :-
Strong Normal

04/13/2025 By:Milion R(BSc, MScN) 41

To sum up 7 QC tools (Numerical data ) are used as follow:

• Stratification Basic processing performed when collecting data

• Pareto Diagram To identify the current status and issues
• Cause and Effect Diagram
To identify the cause and effect
relationship
• Histogram To see the distribution of data
• Scatter Diagram To identify the relationship between two
things
• Check Sheet To record data collection
• Control Chart/Graph To find anomalies and identify the current
status

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 Good problem statement should
answer
• What ? –determine the limiting condition
• Who? –identify the population affected by the condition
• Where ? – the location of the population
• Importance of problem statement
1. It helps to clearly identify the goals of the project and outline the
scope of a project.
2. It also help to guide the activities and decisions of the people
who are working on the project.
Examples
-Employee turnover rate is up by 60% with most of them leaving
due to lack of support for growth opportunities.

04/13/2025 By:Milion R(BSc, MScN) 43

 Thank you !!!!!

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THANK YOU !!!!

04/13/2025 By:Milion R(BSc, MScN) 45