Quality ToolsQuality ToolsProblem Solving

Munif Ahmad/Introduction To Management/ Quality Improvement

Quality Control ToolsQuality Control Tools• Pareto chart• Histogram • Process flow diagram• Check sheet• Scatter diagram• Control chart

• Run chart

• Cause and effect diagram

Munif Ahmad/Introduction To Management/ Quality Improvement

Pareto chartPareto chart

7 Quality Tools7 Quality Tools

28

16

12 12

64 3

0

5

10

15

20

25

30

LooseThreads

Stitchingflaws

Buttonproblems

Materialflaws

% C

om

pla

ints

Munif Ahmad/Introduction To Management/ Quality Improvement

Pareto Pareto Chart Chart

Per

cent

fro

m e

ach

caus

e

Causes of poor quality

Mac

hine

cal

ibra

tions

Defec

tive

parts

Wro

ng d

imen

sions

Poor D

esig

n

Ope

rato

r erro

rsDef

ectiv

e m

ater

ials

Surfa

ce a

bras

ions

0

10

20

30

40

50

60

70(64)

(13)(10)

(6)(3) (2) (2)

Munif Ahmad/Introduction To Management/ Quality Improvement

HistogramHistogram

0

5

10

15

20

25

Category

Fre

qu

ency

7 Quality Tools7 Quality Tools

Munif Ahmad/Introduction To Management/ Quality Improvement

HistogramHistogram

0

510152025303540

1 2 6 13 10 16 19 17 12 16 20 17 13 5 6 2 1

Munif Ahmad/Introduction To Management/ Quality Improvement

FlowchartsFlowcharts Flowcharts

• Graphical description of how work is done.• Used to describe processes that are to be

improved.

7 Quality Tools7 Quality Tools

Munif Ahmad/Introduction To Management/ Quality Improvement

Flow DiagramsFlow Diagrams

" 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.

Munif Ahmad/Introduction To Management/ Quality Improvement

FlowchartFlowchart

Activity

DecisionYesYes

NoNo

7 Quality Tools7 Quality Tools

Munif Ahmad/Introduction To Management/ Quality Improvement

FlowchartFlowchart

Munif Ahmad/Introduction To Management/ Quality Improvement

Flow DiagramsFlow Diagrams

Munif Ahmad/Introduction To Management/ Quality Improvement

Flow DiagramsFlow Diagrams

Process Chart SymbolsProcess Chart Symbols

Operations

Inspection

Transportation

Delay

Storage

Munif Ahmad/Introduction To Management/ Quality Improvement

Munif Ahmad/Introduction To Management/ Quality Improvement

Process ChartProcess ChartS

tep

Op

erat

ion

Tra

nsp

ort

Insp

ect

Del

ayS

tora

ge

Dis

tan

ce(f

eet)

Tim

e(m

in)Description

ofprocess

1

2

3

4

5

6

7

8

9

10

11

Unload apples from truck

Move to inspection station

Weigh, inspect, sort

Move to storage

Wait until needed

Move to peeler

Apples peeled and cored

Soak in water until needed

Place in conveyor

Move to mixing area

Weigh, inspect, sort

TotalPage 1 0f 3 480

30

5

20

15

360

30

20

190 ft

20 ft

20 ft

50 ft

100 ft

Date: 9-30-00

Analyst: TLR

Location: Graves Mountain

Process: Apple Sauce

Munif Ahmad/Introduction To Management/ Quality Improvement

Munif Ahmad/Introduction To Management/ Quality Improvement

Check SheetCheck SheetCheck SheetCheck Sheet

ShiftsShifts

De

fect

Typ

eD

efe

ct T

ype

7 Quality Tools7 Quality Tools

Munif Ahmad/Introduction To Management/ Quality Improvement

Check SheetCheck Sheet

COMPONENTS REPLACED BY BSB LABTIME PERIOD: 22 Feb to 27 Feb 2011REPAIR TECHNICIAN: Hj. Ottman Bin Hj Ghani

TV SET MODEL 1013

Integrated Circuits ||||

Capacitors |||| |||| |||| |||| |||| ||

Resistors ||

Transformers ||||

CommandsCRT |

Munif Ahmad/Introduction To Management/ Quality Improvement

Cause-and-Effect DiagramsCause-and-Effect DiagramsCause-and-Effect DiagramsCause-and-Effect Diagrams Show the relationships between a

problem and its possible causes. Developed by Kaoru Ishikawa (1953) Also known as …

• Fishbone diagrams• Ishikawa diagrams

7 Quality Tools7 Quality Tools

Munif Ahmad/Introduction To Management/ Quality Improvement

Cause and Effect Cause and Effect “Skeleton”“Skeleton”Cause and Effect Cause and Effect “Skeleton”“Skeleton”

QualityProblem

Materials

EquipmentPeople

Procedures

7 Quality Tools7 Quality Tools

Munif Ahmad/Introduction To Management/ Quality Improvement

Fishbone Diagram Fishbone Diagram

QualityProblem

MachinesMeasurement Human

ProcessEnvironment Materials

Faulty testing equipment

Incorrect specifications

Improper methods

Poor supervision

Lack of concentration

Inadequate training

Out of adjustment

Tooling problems

Old / worn

Defective from vendor

Not to specifications

Material-handling problems

Deficienciesin product design

Ineffective qualitymanagement

Poor process design

Inaccuratetemperature control

Dust and Dirt

Munif Ahmad/Introduction To Management/ Quality Improvement

Cause and effect diagramsCause and effect diagrams Advantages

• making the diagram is educational in itself• diagram demonstrates knowledge of

problem solving team• diagram results in active searches for

causes• diagram is a guide for data collection

Munif Ahmad/Introduction To Management/ Quality Improvement

Cause and effect diagramsCause and effect diagrams

To construct the skeleton, remember: For Manufacturing - the 4 M’s

man, method, machine, material For Service applications

equipment, policies, procedures, people

Munif Ahmad/Introduction To Management/ Quality Improvement

Scatter DiagramScatter Diagram

.

Munif Ahmad/Introduction To Management/ Quality Improvement

Run ChartsRun Charts Run Charts (time series plot)

• Examine the behavior of a variable over time.

• Basis for Control Charts