Seven Tools for Quality Control

To make rational decisions using data obtained on the product, or process, or from the consumer,
organizations use certain graphical tools. The seven quality control tools are:

1. Pareto charts 2. Check sheets 3. Cause and effect diagram

4. Scatter diagrams 5. Histogram 6. Graphs or flow charts

7. Control charts

1. PARETO CHARTS

Pareto charts help prioritize by arranging them in decreasing order of importance. In an environment of
limited resources these diagrams help companies to decide on the order in which they should address
problems.

The Pareto analysis can be used to identify the problem in a number of forms.

(a) Analysis of losses by material (number or past number).

(b) Analysis of losses by process i.e., classification of defects or lot rejections in terms of the process.

(c) Analysis of losses by product family.

(d) Analysis by supplier across the entire spectrum of purchases.

(e) Analysis by cost of the parts.

(f) Analysis by failure mode.

CHECK SHEETS

Check sheets facilitate systematic record keeping or data collection observations are recorded as they
happen which reveals patterns or trends. Data collection through the use of a checklist is often the first
step in analysis of quality problem.

3. CAUSE AND EFFECT DIAGRAM

It is sometimes called as Fish-bone diagram. It is first developed by Kaorv Ishikawa in 1943 and is
sometimes called as Ishikawa diagram. The diameter helps the management trace customer complaints
directly to the operations involved. The main quality problem is referred to Fish-head; the major
categories of potential cause structural bones and the likely specific causes to ribs. It explores possible
causes of problems, with the intention being to discover the root causes. This diagram helps identify
possible reasons for a process to go out of control as well as possible effects on the process.
4. SCATTER DIAGRAM (SCATTERPLOTS)

It often indicates the relationship between two variables. They are often used as follow-ups to cause
and effect analysis to determine whether a stated cause truly does impact the quality characteristics.

5. HISTOGRAM (OR) BARCHARTS

It displays the large amounts of data that are difficult to interpret in their raw form. A histogram
summarizes data measured on a continuous scale showing the frequency distribution of some quality
characteristics (in statistical terms the central tendency and the dispersion of the data).

6. FLOW CHARTS (OR) GRAPHS

It shows the sequence of events in a process. They are used for manufacturing and service operations.
Flow charts are often used to diagram operational procedures to simplify the system.

7. CONTROL CHARTS

It distinguish special causes of variations from common causes of variation. They are used to monitor
and control process on an ongoing basis. A typical control chart plots a selected quality characteristic
found from sub-group of observations as a function of sample number. Characteristics such as sample
average, sample range and sample proportion of non-conforming units are plotted. The center line on a
control chart represents the average value of characteristics being plotted. Two limits known as the
upper control limit (UCL) and lower control limit (LCL) are also shown on control charts. These limits are
constructed so that if the process is operating under a stable system of chance causes, the problem of
an observation falling outside these limits is quite small
Causes of Variation in Quality

The variation in the quality of product in any manufacturing process is broadly classified as:

(a) Chance causes

(b) Assignable causes.

(A) CHANCE CAUSES

The chance causes are those causes which are inherit in manufacturing process by virtue of operational
and constructional features of the equipment involved in a manufacturing process.

This is because of—

1. Machine vibrations

2. Voltage variations

3. Composition variation of material, etc.

(B) ASSIGNABLE CAUSES

These are the causes which creates ordinary variation in the production quality.

Assignable cause’s variation can always be traced to a specific quality. They occur due to—

1. Lack of skill in operation

2. Wrong maintenance practice

3. New vendors

4. Error in setting jigs and fixtures

5. Raw material defects

Variation due to these causes can be controlled before the defective items are produced.

STATISTICAL PROCESS CONTROL

Statistical process control (SPC) is the application of statistical techniques to determine whether the
output of a process conforms to the product or service design. It aims at achieving good quality during
manufacture or service through prevention rather than detection. It is concerned with controlling the
process that makes the product because if the process is good then the product will automatically be
good.

Control Charts

SPC is implemented through control charts that are used to monitor the output of the process and
indicate the presence of problems requiring further action. Control charts can be used to monitor

processes where output is measured as either variables or attributes. There are two types of

control charts: Variable control chart and attribute control chart.

1. Variable control charts: It is one by which it is possible to measures the quality characteristics of a
product. The variable control charts are X-BAR chart, R-BAR chart, SIGMA chart.

2. Attribute control chart: It is one in which it is not possible to measures the quality characteristics of a
product, i.e., it is based on visual inspection only like good or bad, success or failure, accepted or
rejected. The attribute control charts are p-charts, np-charts, c-charts, u-charts. It requires only a count
of observations on characteristics e.g., the number of nonconforming items in a sample.

CHARACTERISTICS OF CONTROL CHARTS

A control chart is a time-ordered diagram to monitor a quality characteristic, consisting of:

1. A nominal value, or center line, the average of several past samples.

2. Two control limits used to judge whether action is required, an upper control limit (UCL) and a lower
control limit (LCL).

3. Data points, each consisting of the average measurement calculated from a sample taken from the
process, ordered overtime. By the Central Limit Theorem, regardless of the distribution of the
underlying individual measurements, the distribution of the sample means will follow a normal
distribution. The control limits are set based on the sampling distribution of the quality measurement.

BENEFITS OF USING CONTROL CHARTS

Following are the benefits of control charts:

1. A control chart indicates when something may be wrong, so that corrective action can be taken.

2. The patterns of the plot on a control chart diagnosis possible cause and hence indicate possible
remedial actions.

3. It can estimate the process capability of process.

4. It provides useful information regarding actions to take for quality improvement.

OBJECTIVES OF CONTROL CHARTS

Following are the objectives of control charts:

1. To secure information to be used in establishing or changing specifications or in determining whether
the process can meet specifications or not.

2. To secure information to be used on establishing or changing production procedures.

3. To secure information to be used on establishing or changing inspection procedures or acceptance

procedures or both.

4. To provide a basis for current decision during production.