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Assignment 1

The document outlines the seven basic quality tools used for problem analysis and resolution in manufacturing: Cause-and-Effect Diagram, Flow Charts, Check Sheets, Pareto Charts, Histograms, Scatter Diagrams, and Control Charts. It also presents a case study where these tools are applied to address customer complaints about product dimensions, emphasizing the use of Check Sheets, Pareto Charts, and Fishbone Diagrams to identify root causes and suggest corrective actions. The document concludes with a structured approach to improve manufacturing processes through data collection and analysis.

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9 views6 pages

Assignment 1

The document outlines the seven basic quality tools used for problem analysis and resolution in manufacturing: Cause-and-Effect Diagram, Flow Charts, Check Sheets, Pareto Charts, Histograms, Scatter Diagrams, and Control Charts. It also presents a case study where these tools are applied to address customer complaints about product dimensions, emphasizing the use of Check Sheets, Pareto Charts, and Fishbone Diagrams to identify root causes and suggest corrective actions. The document concludes with a structured approach to improve manufacturing processes through data collection and analysis.

Uploaded by

krishkrishna99pkk
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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1. List the 7 basic quality tools and provide a brief explanation of each.

Cause-and-Effect Diagram (Fishbone/Ishikawa Diagram):


A graphical tool used to
identify and analyse potential
causes of a specific problem or
issue. It organizes causes into
categories, such as people,
processes, materials, or
equipment, to find root causes.

Flow Charts:
A flowchart is a diagram that
represents the sequence of steps in a
process or system. It uses standardized
symbols to represent actions,
decisions, inputs, and outputs, making
complex processes easier to
understand.
Check sheets:
A simple, structured form used
to collect data in real time. It can be
used to tally occurrences of specific
events or defects. The check sheet is
useful for identifying patterns or
trends.

Pareto Charts:
A Pareto chart is a bar chart
that displays the relative frequency of
different problems or causes, with the
bars arranged in descending order. It
is based on the Pareto principle
(80/20 rule), which suggests that 80%
of problems come from 20% of the
causes

Histograms:
A histogram is a bar chart that
represents the frequency distribution of
a set of continuous data. It helps to
understand how data is spread out and
whether it follows a normal distribution.
Scatter Diagrams:
A scatter diagram is a
graphical representation of data
points, showing how one variable
affects another. It helps in
identifying correlations between
variables.

Control Charts:
A control chart is a graphical
tool used to track variations in a
process. It shows whether the
process is stable or if there are
variations that require attention. It
includes upper and lower control
limits to define acceptable variation.
2. Case Study
Read the following scenario:
A manufacturing unit is experiencing frequent customer complaints about the
dimensions of its products. Upon reviewing the process, inconsistencies in
machine settings and operator errors are suspected.
a) Identify which quality tools would be most appropriate for analysing and
resolving the issue.
b) Create a mock Fishbone Diagram and suggest actions to address the root
causes identified.

a) 1. Check Sheets
To systematically collect data on dimensional defects and identify
patterns. This helps in understanding the frequency and types of dimensional
issues.
2. Pareto Chart
To prioritize the most common dimensional issues contributing to
complaints. Focuses efforts on the most significant problems, adhering to the
80/20 rule.
3. Cause-and-Effect Diagram (Fishbone/Ishikawa Diagram)
To identify potential causes of dimensional inconsistencies, such as operator
errors or machine settings. Encourages a structured exploration of root causes
under categories like Machine, Method, Manpower, Material, and Environment.
4. Control Charts
To monitor the production process for variations in product dimensions over
time. Helps distinguish between normal (common cause) and special (assignable
cause) variations.
5. Scatter Diagrams
To analyze the relationship between machine settings or operator actions and
dimensional defects. Reveals correlations that may indicate the root causes of
inconsistencies.
6. Flowchart
To visualize the entire manufacturing process and identify potential points of
failure. This helps pinpoint where errors or inconsistencies are likely to occur.
Strategy:
Start with Check Sheets to gather and organize defect data. Use a Pareto
Chart to prioritize the major issues. Employ a Cause-and-Effect Diagram to
brainstorm and identify potential causes. Implement Control Charts to track
process stability and detect variations. Use Scatter Diagrams to investigate
correlations and validate causes. Review the process with a Flowchart to identify
improvement opportunities.

b)
Fishbone Diagram:

Actions to Address Root Causes:


Machine
1. Perform regular maintenance and calibration of machines.
2. Establish a preventive maintenance schedule.
3. Invest in automated monitoring systems for critical machine settings.
Method
1. Develop and enforce detailed standard operating procedures (SOPs).
2. Implement consistent inspection protocols, including random sampling.
3. Review and optimize the manufacturing process flow.
Manpower
1. Provide regular training for operators on machine handling and inspection
techniques.
2. Implement a rotation schedule to reduce fatigue.
3. Establish accountability for adherence to SOPs through checklists or
audits.
Material
1. Conduct incoming quality checks on raw materials.
2. Improve material handling and storage conditions to maintain
consistency.
3. Approve any material substitution only after rigorous testing.
Measurement
1. Calibrate all measurement tools regularly and document the process.
2. Train operators to ensure consistent measurement techniques.
3. Define and communicate clear dimensional tolerances for all products.
Environment
1. Control temperature and humidity in critical production areas.
2. Improve lighting in manufacturing and inspection zones.
3. Minimize environmental disturbances like vibrations with proper facility
design.

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