7QC TOOLS

( Problem Solving Tools)

1
 The Basic 7 Tools of QC

 ‘’The Old Seven”

 “The First Seven”
 “The Basic Seven”

Quality Glossary has many names for these seven basic tools of Quality,
First Emphasized by Kaoru Ishikawa, a professor of Engineering at Tokyo
University and the Father of “Quality Circles”

2
 What is 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

3
 Problem Solving Approach :

1. Conventional Problem Solving Approach

(Experience / Knowledge Based).

2. Statistical Approach (7QC Tools)

3. DOE (Design Of Experiments)

4
Six 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

5
 7 QC TOOLS
- Is a Systematic and scientific method for the problem solving technique
- For process improvement is a set of graphical techniques identified as being most
helpful in trouble shooting issues related to Quality.

1) CHECK SHEET

2) PARETO CHART

3) CAUSE & EFFECT DIAGRAM

4) FLOW CHART

5) SCATTER DIAGRAM

6) HISTOGRAM

7) CONTROL CHART

6
7QC tools :- 1. Check sheet

1.Check Sheet
Counting and Accumulating Data

7
1. CHECK SHEET

 Definition - Check Sheet is a systematic method of collecting, recording

and presenting relevant data in a simple manner.

Benefits of Check sheet

• To make data gathering simple, systematic, easy and effective.
• To arrange and present data in a such a way that it can be understood and used easily.
• Enables “management by facts” as opposed to “management by opinion”.

Types of Check sheet

1) Process Performance Check Sheet.

2) Defective Item Check Sheet.
3) Defect Location Check Sheet.
4) Defect Cause Check Sheet.
5) Task Confirmation Check Sheet.

8
1. CHECK SHEET

 Steps in making a check sheet

1. Establish what information is needed.
2. Establish “Operational Definition” for the data to be collected.
3. Determine 5W and 1H of Check sheet
4. Construct the Check Sheet.
5. Test the Check Sheet
6. Use the Check sheet
7. Use the Information
• (Remember three rules of – What to DO , Why to DO , How to DO while giving
instruction )

9
1. CHECK SHEET

 Step 3 – 5W 1H for Check

Sheet
1. Why is the data needed ?
2. What type of check sheet should be used ?
3. Where should the data be collected from ?
• Place / Machine / Plant
4. Who has to collect the data ?
• Operator / Supervisor / Manager
5. When will the data be collected ?
• Every hour / At the time of receipt
6. How should the data be measured ?
• Instrument / Clock
7. How much data is essential ?

10
1. CHECK SHEET

 Step 4 - Construct the Check Sheet

Check Sheet should broadly have three types of information.
1. Title of the Check Sheet.
2. Source Information
• Name of the project / problem theme
• Location of data collection
• Date and/or Time
• Name of the person recording data
3. Content Information
• Column with defect / event name.
• Column to record frequency
• Column to record total

11
1. CHECK SHEET

 Step 5 - Test the Check Sheet

1. Test the check sheet with at least three different collectors.
2. Check if the operational definition is really “Operational”.
3. Re – confirm that the columns are relevant and required.
4. Check if the check sheet is easy to record and use.
5. Make changes based on the feedback.

 Step 6 : Use the Check Sheet

1. Explain the Check Sheet to the data collector.
2. Ensure that the data collector understands the reason for which the data is being
collected.
3. Collect Data
4. Standardize its use to assure consistency Tally Mark =5

12
1. CHECK SHEET

 Step 7 : Use the Information

1. Pay particular attention to irregular data and irregular conditions.
2. Use data from the check sheet for further analysis
• Pareto Chart, Histogram, Scatter Diagram
3. Ensure that all the data that is recorded is put to use OR is likely to be put to
use in future.
4. Regularly Audit the Use and the Usefulness of Check sheet.

13
7QC tools :- 2. Pareto Chart

2.Pareto Chart
Vital Few and Trival Many

19
2. PARETO CHART

 Pareto Chart is a diagram that shows the order of the largest number of
occurrences by item or by classes, and the cumulative sum total.
Pareto Diagram
Purpose – Prioritize Problems (No. of Occurrences)

Genesis of Pareto
Chart
 Vilfredo Pareto (1848 –  Dr. Joseph M. Juran
1923), an Italian economist applied this principle to
discovered in 1897 that Quality Management
80% of a nation’s wealth and called it the Pareto
was owned by 20% of the Principle.
population.

20
2. PARETO CHART

 Pareto Principle

Juran used the term “Vital few, Trivial many”. He noted that

 80 % of the problems comes from 20% of the causes.

Inputs
Causes
Effort 20%

Outputs
80% Effects
Results

21
2. PARETO CHART
Code Causes Freq. Cum. Cumulative
Freq. % age 136 100%

A Virus Attack 52 52 52/136 =

42% 120

Cu m u la ti v e P e rc e n ta g e
80%
B Server Crash 23 52+23=75 75/136 =
55% 100

C Print 11 75+11=86 63%

F re q u e n c y
Problems 80 60%

D Operating 9 86+9=95 70%

System 60
Corrupted 40%

E Boot 8 103 76% 40

Problems
20%
F Bad 6 109 80% 20
Configuratio
n
0 0%
G Loose 5 114 84%
A B C D E F G H I J K
Connection Ca u s e s
H Email not 4 118 87%
functioning
I System Re- 3 121 89%
configuratio
n
J Rodent 3 124 91%
Problem
K Others 12 136 100%
Total 136

22
7QC tools :- 3. Cause & Effect Diagram

3.Cause and Effect Diagram

23
3. CAUSE & EFFECT DIAGRAM

Definition - A diagram which represents meaningful relationship between an effect

and its causes.
 This Tool can identify all possible causes for the problem.
 In this tool we can find possible causes with the help of 6M concepts such as Man,
Machine, Material Method, Measurement & Mother nature.

 A Cause & Effect Diagram, also known as

Fishbone Diagram due to shape.

 Father of Cause & Effect

Diagram
• Dr. Kaoru Ishikawa developed the first cause and
effect diagram in 1943 while consulting for
Kawasaki Steel Works.

• Dr. Juran named it as Ishikawa diagram.

24
3. CAUSE & EFFECT DIAGRAM

Measurement Man Machines

Faulty testing equipment Poor supervision Out of adjustment

Incorrect specifications Lack of concentration Tooling problems

Improper methods Inadequate training Old / worn

Effect
Inaccurate
temperature Poor process design
control Defective from vendor
Ineffective quality
Not to specifications management
Dust and
Dirt Material- Deficiencies
handling problems in product design

Environment Materials Method

25
3. CAUSE & EFFECT DIAGRAM

Steps in Constructing Type C & E Diagram

1. State the undesirable effect.

2. List all possible causes using brainstorming.

3. Arrange causes and sub–causes showing the

relationship between cause and effect.

4. Identify Valid Causes.

26
3. CAUSE & EFFECT DIAGRAM

Step 1

State the undesirable effect.

Time for
Installation
of Machine
is High

27
3. CAUSE & EFFECT DIAGRAM

Step 2
List all possible causes using brainstorming.
Time for
Installation
of Machine
Performance problems
during installation is High Poor follow-up
by branch
Relevant Forms Lorry not
No communication not received available
to branch on civil work
Payment not
collected as per terms
Customer wants
Customer’s Civil work not
see our installation
Project commenced Parts not
Postponed available on
time
Lack of Funds Donot have license
for stamping

28
3. CAUSE & EFFECT DIAGRAM

Step 3
Arrange causes and sub–causes suitably.
Branch
HO Delay Causes Effect
Delay
Relevant Forms Poor follow-up
Parts not avai- not received by branch
lable on time
Donot have license Poor information
for stamping on site readiness
Performance problems Payment not
during installation Time for
collected as per terms
Installation
of Machine
is High
No communication Lack of Funds
Lorry not
to branch on civil work Customer wants available
see our installation
Project Civil work not
Postponed commenced

Customer
Others
Delay

29
3. CAUSE & EFFECT DIAGRAM

Step 4 Identify Valid Causes(s).

HO Branch
Delay Causes Delay Effect
Relevant Forms Poor follow-up
Parts not avai- not received by branch
lable on time
Donot have license Poor information
for stamping on site readiness
Performance problems
during installation
Payment not Time for
collected as per terms
Installation
of Machine
is High
No communication Lack of Funds
Lorry not
to branch on civil work Customer wants available
see our installation
Project Civil work not
Postponed commenced

Customer
Others
Delay

30
7QC tools :- 4. FLOW CHART

4. FLOW CHART

31
4. FLOW CHART

Purpose:
A flow diagram is a graphic representation of the sequence of the steps that
we perform to produce some output. The output may be a physical product,
a service, information, or a combination of the three.

Benefits:
 Identify process improvements
 Understand the process.
 Shows duplicated effort and other non-value-added steps
 Target specific steps in the process for improvement.

Draw a flowchart for whatever you do.

Until you do, you do not know what you are doing, you
just have a job.”

-- Dr. W. Edwards Deming.

32
4. FLOW CHART

Symbols used in flow diagraming

Activity Symbol
Data Base symbol

Decision Symbol

Connector Symbol
Terminal Symbol

Flow Lines Storage Symbol

Document Symbol

33
4. FLOW CHART

Process Chart Symbols

Operations
Inspection

Transportation

Delay

Storage
4. FLOW CHART

Date: 9-30-00 Location: Graves Mountain

Analyst: TLR Process: Apple Sauce
Operation

Distance
Description
Transport

Storage

(min)
Inspect

Time
of

(feet)
Step

Delay
process

1 Unload apples from truck 20

2 Move to inspection station 100 ft
3 Weigh, inspect, sort 30
4 Move to storage 50 ft
5 Wait until needed 360
6 Move to peeler 20 ft
7 Apples peeled and cored 15
8 Soak in water until needed 20
9 Place in conveyor 5
10 Move to mixing area 20 ft
11 Weigh, inspect, sort 30
Page 1 0f 3 Total 480 190 ft

35
7QC tools :- 5. SCATTER DIAGRAM

5. SCATTER DIAGRAM

36
5. SCATTER DIAGRAM

Definition
 To identify the possible relationship between the changes observed in two
variables.
 This Scatter diagram is known by many names , such as Scatter Plot, Scatter
graph & Co-relation Chart. This Diagram is drawn with two Variables, usually
the first variable is independent and the second variable is dependent on the
first variable.
 This Diagram helps you determine how closely the two variables are related.
After determining the correlation b/w two variables, you can predict the
behavior of the dependent variable based on the measure of independent
variable.

X Axis – Independent variable – Cause

Y Axis – Dependent Variable – Effect

37
5. SCATTER DIAGRAM

Types
• According to the Correlation, Scatter diagram can be divided in to following
categories:
1) Scatter Diagram with no Correlation
2) Scatter Diagram with moderate Correlation
3) Scatter Diagram with strong Correlation

1) Scatter Diagram with no Correlation

38
5. SCATTER DIAGRAM

2) Scatter Diagram with moderate Correlation

3) Scatter Diagram with Strong Correlation

39
5. SCATTER DIAGRAM

Types of correlation

Rational And Benefits

• Supplies the data to confirm a hypothesis that two variables are related

• Provide both visual and statistical means to test the strength of a potential
relationship

40
7QC tools :- 6. HISTOGRAM

6. HISTOGRAM

41
7QC tools :- 6. HISTOGRAM

It is the graphical representation of data from a process that has been collected
over a period of time and its frequency distribution in a vertical bar form.
It was first introduced by Karl Pearson.

Purpose and Benefits

• Displays large amount of data that are difficult to interpret in tabular &
graphical form.
• Shows the relative frequency of occurrence of the various data values
• Provides useful information for understanding the present performance and
predict future performance of the process.
• Helps evaluate process capability & answer the question “Is the process
capable of meeting my customer requirements ?”
• Take corrective action to keep the process within specification limits.

42
7QC tools :- 6. HISTOGRAM
Types of Histogram

Symmetric, unimodal Skewed right Skewed Left

Bi Model Multi Model Symmetric

43
7QC tools :- 7. CONTROL CHART

7. CONTROL CHART

44
7. CONTROL CHART

Purpose
• Control chart is a statistical tool used to control Processes, consisting of graphs
with statistically calculated control limit line.
• To examine the stability of a process.
• To ensure that the process is stable.
• Control Chart were originated by Walter
Shewart in 1931
Objectives
• To detect and eliminate special causes
• To assess the stability of the process
• Understand variation in the process
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).
45
7. CONTROL CHART

46
7. CONTROL CHART

Control Chart Decision Tree

47
7. CONTROL CHART

Analyzing Control Charts

• Control Charts are analyzed for special cause variability (including nonrandom
behavior or data points exceeding the control limits). The following tests for
special causes need to be conducted:
• Rule #1: 1 point more than 3σ from center line
• Rule #2: 9 points in a row on same side of center line
• Rule #3: 6 points in a row, all increasing or all decreasing.
• Rule #4: 14 points in a row, alternating up and down.
• Rule #5: 2 out of 3 points more than 2σ from center line (same side)
• Rule #6: 4 out of 5 points more than 1σ from center line (same side)
• Rule #7: 15 points in a row within 1σ of center line (either side)
• Rule #8: 8 points in a row more than 1σ from center line (either side)
• Minitab can automatically performs these tests for you!

48