Seven Basic Quality Tools: List / Use / Interaction

Seven Basic
Quality Tools
List / Use / Interaction
3/31/0209/07/16
2002 Eastman Kodak Company
7 Basic Quality Tools - C & E
What Did The 7 Tools Ever Do

for Us ?
What is the process, how

does it work ?
Flow Chart
Why does stuff happen ?
What sort of stuff happens &

how often ?
When stuff happens how much

of it happens ?
Tally Sheet
Pareto Diagram
Data Collection
When stuff a happens what

happens to stuff b ?
How much stuff would we expect

normally and how variable is it ?
Histogram
Cause & Effect

Diagram
How does the amount of stuff

change over time ?
Scatter Plot
Run Chart
Statistical Process
Control Charts
3/31/02
09/07/16
Seven Basic
Quality Tools
Flowcharts
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What Is It?
A Diagram That Describes A Sequence Of
Operations
Start
Hit Nail
With
Hammer
All the
way in?
No
Yes
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09/07/16
End
Use A Flowchart To
Develop A Common Understanding Of A Current
Process
Create A Team Vision Of What A Process Ought To
Be
Detect Redundancies, Bottlenecks Or Inefficiencies
Start
Hit Nail
With
Hammer
All the
way in?
End
Yes
No
3/31/02
09/07/16
Symbols
Basic
Start or Stop
(use either symbol)
Step
Question , Check , Test, Decision

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09/07/16
Exercise
How To Back Your Car Out Of The Driveway
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Seven Basic
Quality Tools
Cause & Effect
Diagram
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What Is It?
This tool is also known by other names:
Ishikawa Diagram
Kaoru Ishikawa invented the tool
Fishbone diagram
I'm boning up on my quality too
3/31/02
09/07/16
What Do You Get?

A visual organizer of factors that influence a
particular result.
It helps to ensure that nothing important gets
overlooked.
Materials
Machinery
Bread
Toaster
Butter
Jelly or Jam
Toaster oven
Good
Toast
Amount of butter
"Browness" setting
3/31/02Methods
09/07/16
Personal preference
Manpower
10
When And Where To Use It?

Use cause & effect diagrams to:
Identify, explore or display possible causes of a specific
condition or problem.
Troubleshooting
Forecasting and Planning
Exploiting improvement opportunities
Support other problem solving tools:
Brainstorming
Pareto analysis
Histograms
Scatter diagrams
Flow charts
Control charts
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11
Example 1 - Troubleshooting
Why is Joe late for work?
Me
Oversleep
Lousy watch
Slow in AM
Low on gas
Warm up
Car
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09/07/16
Family
kids
Bathroom jam
spouse
Fighting
Breakfast
Traffic
Weather
Late
For
Work
Light @ rt 96
Drive
12
Example 2 - Planning
Planning a Family Vacation
Constraints
Family
Interests
2 weeks
Size
July
close to beach
Affordable
Drivable
Destination
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09/07/16
Kid's ages
Fun
Vacation
For all
Pack car
Reservations
Luggage
Board the dog
Preparation
13
Example 3 - Improvement
Opportunities
Whats causing our waste?
Machine
Manpower
Training
Out of control
Maintenance
Mistakes
Waste
Procedures
Out of spec
Tools
documented
Methods
3/31/02
09/07/16
Wrong materials
Materials
14
How To Construct
Two Approaches
Top Down
Bottom Up
Start with
structure
Finish with
structure
Cause
Cause
Identify
causes
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Cause
Cause
Cause
Cause
Cause
Cause
Cause
Start with
brainstormed
causes
15
How To Construct - Top-Down

Approach
1
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09/07/16
Determine effect
to be studied
Place effect in box at

right & draw
"backbone"
Add primary cause

categories to diagram
Add secondary causes

to diagram
Add further sub-levels

of causes as needed
Review Final
Diagram
16
How To construct - Bottom-Up

Approach
1
Brainstorm list of
potential causes
Arrange into related

groups and give
category a name
Combine groups into

common groups &
name
Continue combining
until no further
combining makes
sense
5
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Turn into Cause &

Effect Diagram
17
How To Construct
Tips
Strength of tool stems from being a group
process
Get the right people present

Get everyone involved
Allow conflicts - work with the group to resolve them
Focus on the issue/problem - not on the people
Allow sufficient time to surface the issues

Use sticky notes for causes
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18
Seven Basic
Quality Tools
Tally Sheets/Pareto
Diagrams
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19
What They Are

Tally Sheet (Also called Check Sheet)
A way to collect categorical data (defects, occurrences,

etc.)
Purpose: Record data easily as they occur
Pareto Diagram
A way to present information by order of importance

Purpose: Separate the vital few from the trivial many
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20
What Are They

Tally Sheet / Check Sheet
Reasons for Being Late to Work
Check Sheet
Traffic
Long Wait at Light
Bathroom Hang Up
3
12
Breakfast Hang Up
Weather
Car Problems
Clock Disagrees
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21
Tally Sheet
Example : Weak spots on a glove
x
x
xxx
xx
x
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22
Tally Sheet
Tally Sheet Paint Shop
Problem
Order 1
Order 2
Order 3
Total
Scratches
IIII II
II
IIII I
15
Runs
IIII IIII IIII
IIII IIII I
IIII IIII
34
Dirt
IIII
IIII
11
Wrong Color
IIII
Paint Peeling
Total
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32
15
22
69
23
How to Construct a Tally

Sheet
Using percentages
Reasons for Being Late for Work
Check Sheet
Bathroom Hang Up
IIII IIII II
Long Wait at Light
Frequency
Percent*
12
48
IIII
16
Weather
III
12
Breakfast Hang Up
II
Clock Disagrees
II
Car Problems
Traffic
25
100
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Total
24
Pareto Principle
The 80 / 20 Rule
Pareto noted that 80% of the wealth

was controlled by 20% of the people
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25
How to Construct a Pareto

Diagram
Example
14
Reasons for Being Late for Work
12
10
8
6
4
2
0
Bathroom
Weather
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Light
Clock
Breakfast
Car
Traffic
26
Examples
Check Sheet
Check Sheet
Frequency
Percent
Color incorrect
4.3%
Printing smudged
II
8.6%
Dirt on box
IIII
17.4%
IIII IIII IIII I
69.5%
Print not registered correctly
Unusable Film Boxes
Pareto Diagram
80
70
60
50
40
30
20
10
3/31/02
09/07/16
Print not
registered
Dirt
Print
smudged
Color
incorrect
27
Seven Basic
Quality Tools
Histograms
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28
Rochester Winters
It Just Doesnt Snow Around Here Like It Used To
1958-59
1959-60
1960-91
1961-62
1962-63
1963-64
1964-65
1965-66
1966-67
1967-68
1968-69
1969-70
1970-71
1971-72
1972-73
1974-74
3/31/02
357.1
410.7
227.1
166.6
194.0
233.7
180.6
262.1
188.0
194.6
202.7
303.8
362.4
267.0
185.4
253.2

09/07/16
1974-75
1975-76
1976-77
1977-78
1978-79
1979-80
1980-81
1981-82
1982-83
1983-84
1984-85
1985-86
1986-87
1987-88
1988-89
1989-90
231.6
218.9
233.9
408.7
351.8
183.4
239.8
326.1
152.1
299.7
221.2
179.6
170.4
165.6
220.0
268.7
1990-91
1991-92
1992-93
1993-94
1994-95
1995-96
1996-97
1997-98
1998-99
1999-00
2000-01
2001-02
2002-03
2003-04
2004-05
2005-06
178.0
299.7
334.0
320.5
142.2
331.0
265.9
253.5
273.8
283.5
336.6
146.0
29
What Is It?
A Histogram is a way of organizing measurements
It shows you how many of each there are
Yearly Snowfall - Rochester
1959-2002
14
C
o
u
n
t
12
10
8
6
4
2
0
130
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180
230
280
330
380
430
Centimeters of Snow
30
Elements Of A Histogram
Label or
Identification
Size of Eggs
Happy Chick Farm Study - 1994
Count /
Frequency
10
9
8
7
6
5
4
3
2
1
Cells
or
Bins
3/31/02Numeric Measure
09/07/16
Individual
Measurements
x
x
3.20
to
3.79
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
3.80
to
4.39
4.40
to
4.99
5.00
to
5.59
5.60
to
6.19
Size (Centimeters)7 Basic Quality Tools - C & E
31
What Do You Get?

A picture of where the measurements (data) are.
Center
C
o
u
n
t
10
9
8
7
6
5
4
3
2
1
0
3.20
3.80
4.40
5.00
5.60
6.20
Size in centimeters
3/31/02
09/07/16
Spread
32
How To Use A Histogram

Understand your process
Joes arrival time
MinutesRelativeToStartTime(7:30)
35
34
30
C
O
U
N
T
25
20
15
10
5
0
6
2
-19
to
-15
3/31/02
-14
to
-10

09/07/16
-9
to
-5
-4
to
0
1
to
5
6
to
10
Latest : 15 min late

Earliest: 15 min early
Late: 16%
Most of the time :
10 min. early to start
time (80%)
11
to
15
33
How To Use A Histogram

Understand your process
Filling 1 liter bottles of soda (Spec = 1.0 - 1.02 l.)
C
o
u
n
t
Most Bottles
20
18
16
14
12
10
8
6
4
2
0
0.97
0.98
0.99
1.0
1.01
1.02
1.03
1.04
1.05
Out of Spec
Out of Spec
3/31/02
Stated Volume 7 Basic Quality Tools - C & E
2002
Eastman
Kodak
Company
09/07/16
34
Exercise
What do you see?
What kind of process could produce histograms like
these?
Packaging Machine A
C
o
u
n
t
Packaging Machine B
7
6
5
4
3
2
1
0
5.2
5.3
5.4
5.5
5.6
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09/07/16
5.7
5.8
Weight
5.9
6.0
6.1
6.2
35
Exercise
What do you see?
these?
3/31/02
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36
Exercise
What do you see?
these?
3/31/02
09/07/16
37
Exercise
What do you see?
What kind of process could produce histograms like these?
3/31/02
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38
Exercise
What do you see?
What kind of process could produce histograms like these?
3/31/02
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39
Seven Basic
Quality Tools
Scatter Plots
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40
What Is It?
A picture of two variables
Are the height and weight of high school
students related?
Weight in Kgs
Weight vs Height
100
90
80
70
60
50
40
165
170
3/31/02
Data collected from 18 high school senior boys
09/07/16
175
180
Height in Centimeters
185
Person
Ht.
Wt.
170.2
68.0
172.7
69.8
175.3
77.1
180.3
72.1
177.8
70.8
170.2
65.3
177.8
74.8
170.2
54.4
175.3
66.2
10
180.3
61.7
11
175.3
70.8
12
172.7
59.9
13
185.4
88.0
14
170.2
59.9
15
180.3
87.1
16
185.4
90.7
17
176.6
50.8
18
176.6
58.5
41
Exercise: Gaining Process

Understanding
What do you see?
What is happening?
What kind of process could produce scatter plots like
these?
Yield
Yield
Temperature
3/31/02
09/07/16
Temperature
42

Understanding
What do you see?
What is happening?
these?
Yield
Yield
Temperature
3/31/02
09/07/16
Temperature
43

Understanding
What do you see?
What is happening?
these?
Yield
Yield
Temperature
3/31/02
09/07/16
Temperature
44

Understanding
What do you see?
What is happening?
these?
Yield
Yield
Temperature
3/31/02
09/07/16
Temperature
45
Seven Basic
Quality Tools
Run Charts
3/31/0209/07/16
46
Lets Look at Some Data

Winter
1958-59
1959-60
1960-61
1961-62
1962-63
1963-64
1964-65
1965-66
1966-67
1967-68
1968-69
1969-70
1970-71
1971-72
1972-73
Snow in
Inches
140.6
161.7
89.4
65.6
76.4
92
71.1
103.2
74
76.7
79.8
119.6
142.7
105.1
73
Winter
1973-74
1974-75
1975-76
1976-77
1977-78
1978-79
1979-80
1980-81
1981-82
1982-83
1983-84
1984-85
1985-86
1986-87
1987-88
Snow in
Inches
99.1
91.2
86.2
92.1
160.9
138.5
72.2
94.4
128.4
59.9
118
87.1
70.7
67.1
69.8
Winter
1988-89
1989-90
1990-91
1991-92
1992-93
1993-94
1994-95
1995-96
1996-97
1997-98
1998-99
1999-00
2000-01
2000-02
Snow in
Inches
86.6
105.8
68.3
110.6
131.5
126.2
56.2
130.3
104.7
99.7
111.6
110.7
132.5
57.5
47
Plot The Data!

Rochester Snow Data 1958-2002
Chart of Individuals
200
Inches of Snow
180
160
140
120
100
80
60
40
20
Year
58
-5
9
60
-6
1
62
-6
3
64
-6
5
66
-6
7
68
-6
9
70
-7
1
72
-7
3
74
-7
5
76
-7
7
78
-7
9
80
-8
1
82
-8
3
84
-8
5
86
-8
7
88
-8
9
90
-9
1
92
-9
3
94
-9
5
96
-9
7
98
-9
9
00
-0
1
Year
48
Elements Of A Run Chart

Label or
Identification
Measure
(Y-Axis)
Rochester Snow Data 1958-2002

Chart of Individuals
Data
Point
200
Inches of Snow
180
Connect
Points
160
140
120
100
80
60
40
20
Year
58
-5
9
60
-6
1
62
-6
3
64
-6
5
66
-6
7
68
-6
9
70
-7
1
72
-7
3
74
-7
5
76
-7
7
78
-7
9
80
-8
1
82
-8
3
84
-8
5
86
-8
7
88
-8
9
90
-9
1
92
-9
3
94
-9
5
96
-9
7
98
-9
9
00
-0
1
Time or point
number
3/31/02 (X-Axis)
09/07/16
Year
49
What Do You Get?

Process understanding
Joes arrival time at work
Start time is 7:30
Arrival Times For Jan - Feb, 1994
50
Arrival Time
(Minutes
after 7 am)
40
30
20
10
3/31/02
09/07/16
10
20
30
40
50
Day
50
What Do You Get?

A picture of what is happening to your process
Filling 1liter bottles of a drink
1040
Regular
Operation
Faulty
Pump
Fixed
Pump
Date: 9/14/94
Machine: 5b
Crew: 2
1020
M
L 1000
S
980
960
7 AM
Time
Sprung
A Leak
3/31/02
09/07/16
Fixed
Leak
3 PM
Adjusted
Changed
Filler Nozzle Filler Nozzle
51

Understanding
What do you see?
What kind of process could produce Run Charts like these?
3/31/02
09/07/16
52

Understanding
What do you see?
3/31/02
09/07/16
53

Understanding
What do you see?
3/31/02
09/07/16
54

Understanding
What do you see?
3/31/02
09/07/16
55
What Did The 7 Tools Ever Do

for Us ?
What is the process, how

does it work ?
Flow Chart
Why does stuff happen ?
What sort of stuff happens &

how often ?
When stuff happens how much

of it happens ?
Tally Sheet
Pareto Diagram
Data Collection
When stuff a happens what

happens to stuff b ?
How much stuff would we expect

normally and how variable is it ?
Histogram
Cause & Effect

Diagram
How does the amount of stuff

change over time ?
Scatter Plot
Run Chart
Statistical Process
Control Charts
3/31/02
09/07/16
56

Seven Basic Quality Tools: List / Use / Interaction

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Seven Basic

2002 Eastman Kodak Company

7 Basic Quality Tools - C & E

What Did The 7 Tools Ever Do

What is the process, how

What sort of stuff happens &

When stuff happens how much

When stuff a happens what

How much stuff would we expect

Cause & Effect

How does the amount of stuff

7 Basic Quality Tools - C & E

2002 Eastman Kodak Company

7 Basic Quality Tools - C & E

7 Basic Quality Tools - C & E

Question , Check , Test, Decision

7 Basic Quality Tools - C & E

7 Basic Quality Tools - C & E

2002 Eastman Kodak Company

7 Basic Quality Tools - C & E

I'm boning up on my quality too

7 Basic Quality Tools - C & E

What Do You Get?

When And Where To Use It?

Support other problem solving tools:

7 Basic Quality Tools - C & E

Board the dog

How To Construct - Top-Down

Place effect in box at

Add primary cause

Add secondary causes

Add further sub-levels

How To construct - Bottom-Up

Arrange into related

Combine groups into

Turn into Cause &

Get the right people present

Allow sufficient time to surface the issues

7 Basic Quality Tools - C & E

2002 Eastman Kodak Company

7 Basic Quality Tools - C & E

What They Are

A way to collect categorical data (defects, occurrences,

A way to present information by order of importance

7 Basic Quality Tools - C & E

What Are They

7 Basic Quality Tools - C & E

7 Basic Quality Tools - C & E

IIII IIII IIII

7 Basic Quality Tools - C & E

How to Construct a Tally

Long Wait at Light

7 Basic Quality Tools - C & E

Pareto noted that 80% of the wealth

7 Basic Quality Tools - C & E

How to Construct a Pareto

Reasons for Being Late for Work

7 Basic Quality Tools - C & E