The Seven Basic Tools of Quality

The 7 Basic Tools of Quality
(Ishikawa Tools of Quality)
FREE Professional Development Seminar Series
PMI, PMP, PMBOK and the PMI Registered Education Provider logo are registered marks of the Project Management Institute, Inc.
2016 3FOLD Education Centre . All rights reserved . online@3foldtraining.com . www.3foldtraining.com . 800 3FOLD
At the end of the class, please fill the training feedback
form! (Yellow paper in your notebook)
Return the feedback form at the reception!
Agenda
About 3FOLD
What is the seven basic tools of quality?
Tools
Q&A
Certificate Collection
About 3FOLD
Established in 2008
Branches in Abu Dhabi, Dubai and Doha
Approved by KHDA, PMI, AACE, ASQ, IMA and AACE
The most economical institute for the official ASQ trainings
in UAE
Why Do This?
Improve Quality
Decrease Costs
Improve Productivity
Decrease Price
Increase Market
Stay in Business
Provide More Jobs
Return on Investment
PROBLEM SOLVING STEPS
Identify
recognize the symptoms
Define
Agree on the problem and set boundaries
Investigate
Collect data
Analyze
Use quality tools to aid
Solve
Develop the solution and implement
Confirm
Follow up to ensure that the solution is effective
What is it?
The Seven Basic Tools of Quality is a designation given to a

fixed set of graphical techniques identified as being most
helpful in troubleshooting issues related to quality.
They are called basic because they are suitable for people
with little formal training in statistics and because they can
be used to solve the vast majority of quality-related issues.
1. Cause and Effect Diagram
Use a cause-and-effect (fishbone or Ishikawa) diagram to
organize brainstorming information about potential causes of a
problem.
Diagramming helps you to see relationships among potential
causes.
You can draw a blank diagram, or a diagram filled in as much as
you like, including sub-branches.
Although there is no "correct" way to construct a fishbone
diagram, some types lend themselves well to many different
situations.
Example
Using a Pareto chart, you discovered that your parts were
rejected most often due to surface flaws. This afternoon,
you are meeting with members of various departments
to brainstorm potential causes for these flaws.
Beforehand, you decide to print a cause-and-effect
(fishbone) diagram to help organize your notes during the
meeting. The example below illustrates how to generate
a complete cause-and-effect diagram with sub-branches.
Example
2. Check Sheet
Description
A check sheet is a structured, prepared form for collecting and
analyzing data. This is a generic tool that can be adapted for a wide
variety of purposes.
When to Use
When data can be observed and collected repeatedly by the same
person or at the same location, and . . .
When collecting data on the frequency or patterns of events,
problems, defects, defect location, defect causes, and so forth, or . . .
When collecting data from a production process
2. Check Sheet (Procedures)
1. Decide what event or problem will be observed. Develop operational
definitions.
2. Decide when data will be collected and for how long.
3. Design the form. Set it up so that data can be recorded simply by
making check marks or Xs or similar symbols and so that data does
not have to be recopied for analysis.
4. Label all spaces on the form.
5. Test the check sheet for a short trial period to be sure it collects the
appropriate data and is easy to use.
6. Each time the targeted event or problem occurs, record data on the
check sheet.
Example
The below figure shows a check sheet used to collect data on telephone interruptions. The tick
marks ere added as data as collected o er se eral eeks time. What days are worst for
interruptions? Which interruptions are most frequent? This check sheet was designed in the
same format as a contingency table, so that the data can be analyzed with chi-square
hypothesis tests without recopying into a different format.
3. Histogram
Use to examine the shape and spread of sample data.

Histograms divide sample values into many intervals called
bins . Bars represent the number of observations falling
within each bin (its frequency).
Histogram (Cont)
In the histogram below, for example, there are two

observations with values between 2.5 and 7.5, three
observations with values between 7.5 and 12.5, and so on.
Histogram Example (Minitab)
You work for a shampoo manufacturer and need to ensure that
the caps on your bottles are being fastened properly. If fastened
too loosely, they may fall off during shipping. If fastened too
tightly, they may be hard for you customers to open (especially
in the shower).
You collect a random sample of bottles and test the amount of

torque required to remove the caps. Create a histogram with a
fitted normal distribution to evaluate how close your samples
were to the target value of 18 and whether the data are
distributed normally.
Output
Interpreting the results
Mean torque for the sample was
21.26, slightly more than the
target value of 18. Only one cap
was very loose, with a torque of
less than 11. However, the
distribution is positively skewed
and several caps were much
tighter than they should be.
Many caps required a torque of
greater than 24 to remove and
five caps required a torque of
greater than 33, nearly two
times the target value.
Because the sample data are so
skewed, the normal distribution
does not fit very well.
4. Pareto Chart
A Pareto chart is a bar graph. The lengths of the bars

represent frequency or cost (time or money), and are
arranged with longest bars on the left and the shortest to
the right. In this way the chart visually depicts which
situations are more significant.
When to Use a Pareto Chart
When analyzing data about the frequency of problems or

causes in a process.
When there are many problems or causes and you want to
focus on the most significant.
When analyzing broad causes by looking at their specific
components.
When communicating with others about your data.
Minitab Example
Suppose you work for a company that manufactures
motorcycles. You hope to reduce quality costs arising from
defective speedometers.
During inspection, a certain number of speedometers are
rejected, and the types of defects recorded. You enter the name
of each defect into a worksheet column called Defects, and the
corresponding counts into a column called Counts.
You know that you can save the most money by focusing on the
defects responsible for most of the rejections. A Pareto chart
will help you identify which defects are causing most of your
problems.
5. Scatter Diagram
The scatter diagram graphs pairs of numerical data, with

one variable on each axis, to look for a relationship
between them. If the variables are correlated, the points
will fall along a line or curve. The better the correlation, the
tighter the points will hug the line.
When to Use a Scatter Diagram
When you have paired numerical data.
When your dependent variable may have multiple values for each
value of your independent variable.
When trying to determine whether the two variables are related, such
as
When trying to identify potential root causes of problems.
After brainstorming causes and effects using a fishbone diagram, to
determine objectively whether a particular cause and effect are related.
When determining whether two effects that appear to be related both
occur with the same cause.
When testing for autocorrelation before constructing a control chart.
Minitab Example
You are interested in how well your company's camera batteries
are meeting customers' needs. Market research shows that
customers become annoyed if they have to wait longer than 5.25
seconds between flashes.
You collect a sample of batteries that have been in use for varying
amounts of time and measure the voltage remaining in each
battery immediately after a flash (VoltsAfter), as well as the
length of time required for the battery to be able to flash again
(flash recovery time, FlashRecov). Create a scatterplot to examine
the results. Include a reference line at the critical flash recovery
time of 5.25 seconds.
As expected, the lower the voltage

in a battery after a flash, the
longer the flash recovery time
tends to be.
The reference line helps to

illustrate that there were many
flash recovery times greater than
5.25 seconds
6. Flowchart
Flowcharts are used in designing and documenting simple

processes or programs. Like other types of diagrams, they
help visualize what is going on and thereby help
understand a process, and perhaps also find flaws,
bottlenecks, and other less-obvious features within it.
Flowchart
Helps understand the steps and sequence of steps to any process
Load files
Audit files Credit
Send memo
Distribute
7. Control Charts
The control chart is a graph used to study how a process
changes over time. Data are plotted in time order.
A control chart always has a central line for the average, an
upper line for the upper control limit and a lower line for the
lower control limit. These lines are determined from historical
data.
By comparing current data to these lines, you can draw
conclusions about whether the process variation is consistent
(in control) or is unpredictable (out of control, affected by
special causes of variation).
Choosing a Control Chart
Control Charts Variable Data
Variables control charts for subgroups plot statistics from

continuous measurement data , such as length or pressure,
for subgroup data.
Variables control charts for individuals, time-weighted
charts , and multivariate charts also plot measurement
data.
Attributes control charts plot count data, such as the
number of defects or defective units .
X-bar and S Chart - Example
You work at an automobile engine assembly plant. One of the parts, a
camshaft, must be 600 mm +2 mm long to meet engineering
specifications.
There has been a chronic problem with camshaft length being out of
specification, which causes poor-fitting assemblies, resulting in high
scrap and rework rates.
Your supervisor wants to run X and R charts to monitor this
characteristic, so for a month, you collect a total of 100 observations
(20 samples of 5 camshafts each) from all the camshafts used at the
plant, and 100 observations from each of your suppliers. First you will
look at camshafts produced by Supplier 2.
Xbar-R Chart of Supp2 Interpreting the results
1
1
UCL=602.376
602 The center line on the X
Sample Mean
chart is at 600.23, implying

__
600
X=600.23 that your process is falling
within the specification
limits, but two of the points
598 LCL=598.084
1 3 5 7 9 11 13 15 17 19
fall outside the control
Sample limits, implying an unstable
process. The center line on
8 UCL=7.866
the R chart, 3.72, is also
6 quite large considering the
Sample Range
4
_ maximum allowable
R=3.72
variation is +2 mm. There
2
may be excess variability in
0 LCL=0 your process.
1 3 5 7 9 11 13 15 17 19
Sample
Control Charts Attribute Data
Attributes control charts are similar in structure to

variables control charts, except that they plot statistics
from count data rather than measurement data.
For instance, products may be compared against a standard
and classified as either being defective or not. Products
may also be classified by their number of defects .
Minitab Example
You work in a toy manufacturing company and your job is

to inspect the number of defective bicycle tires. You
inspect 200 samples in each lot and then decide to create
an NP chart to monitor the number of defectives.
NP Chart of Rejects
30
1
Inspection lots 9 and 20 fall above
1 the upper control limit, indicating
25
that special causes may have
affected the number of defectives
20 UCL=20.10
for these lots. You should
Sample Count
investigate what special causes

15
may have influenced the out-of-
__ control number of bicycle tire
10 NP=10.6
defectives for inspection lots 9
and 20.
5
LCL=1.10
0
1 4 7 10 13 16 19 22 25 28
Sample
Q&A
ANY QUESTIONS ?
END OF SEMINAR
Please Fill the FEEDBACK FORM and RETURN IT to the

RECEPTION.

The Seven Basic Tools of Quality

Cargado por

Información del documento

Derechos de autor

Formatos disponibles

Compartir este documento

Compartir o incrustar documentos

Opciones para compartir

¿Le pareció útil este documento?

¿Este contenido es inapropiado?

Copyright:

Formatos disponibles

The Seven Basic Tools of Quality

Cargado por

Copyright:

Formatos disponibles

The 7 Basic Tools of Quality

(Ishikawa Tools of Quality)

FREE Professional Development Seminar Series

Return the feedback form at the reception!

The Seven Basic Tools of Quality is a designation given to a

Use to examine the shape and spread of sample data.

In the histogram below, for example, there are two

You collect a random sample of bottles and test the amount of

A Pareto chart is a bar graph. The lengths of the bars

When analyzing data about the frequency of problems or

The scatter diagram graphs pairs of numerical data, with

As expected, the lower the voltage

The reference line helps to

Flowcharts are used in designing and documenting simple

Audit files Credit

Variables control charts for subgroups plot statistics from

chart is at 600.23, implying

Attributes control charts are similar in structure to

You work in a toy manufacturing company and your job is

investigate what special causes

Please Fill the FEEDBACK FORM and RETURN IT to the

También podría gustarte