7 QC

Tools
For
Problem Solving
COST of Quality
Cost of Quality

Cost of Conformance Cost of Non- Conformance

Prevention Inspection Internal Failure External Failure

Line
Poka Yoke Rework Scrap Rejection
Warranty
History
Seven basic tools of quality, first emphasized by Kaoru
Ishikawa (1968), a professor of engineering at Tokyo
University and the father of "quality circles."
1. Check Sheet for Data Collection
• Check sheets are simple forms with certain formats that can aid the user to record data in
an firm systematically.
• Data are “collected and tabulated” on the check sheet to record the frequency of specific
events during a data collection period.
• The check sheets are in several, three major types are such as
 Defect-location check sheets;
 tally check sheets, and;
 defect-cause check sheets (Kerzner, 2009).
Tally sheet: Hourly Rejection Check sheet
Defects 1st 2nd 3rd 4th 5th 6th 7th 8th Total
Under fill IIII, II 7 IIII, 5 12
Mismatch IIII, III III 3 11
3
8 I
Burr Lap II 2 IIII 4 6
4
 Defect Location Check sheet
Part Name: Customer Name: Area Name:

Defect
Details

1. U/F-

2. M/M-

3. Burr-
2. Histogram
Histogram is very useful tool to describe a sense of the frequency distribution
of observed values of a variable.
• It is a type of bar chart that visualizes both attribute and variable data of a
product or process,

• It assists users to show the distribution of data and the amount of variation
within a process.

• Also, a histogram can be applied to investigate and identify the underlying

distribution of the variable being explored (Omachonu and Ross, 2004;
Forbes and Ahmed, 2011). Figure 3 illustrates a histogram of the frequency
of defects in a manufacturing process. Figure 3: Histogram for variable
 Histogram for Defects & Hardness
110
110

78
78
68 68
45
45

269 276 283 292

Undersize Burr Lap Mismatch Under fill

Hardness Distribution in BHN

Histogram for Platelets Histogram for Population (Age)
3. Pareto Analysis
• It introduced by an Italian economist, named Vilfredo Pareto, who worked with
income and other unequal distributions in 19th century, he noticed that 80% of the
wealth was owned by only 20% of the population. later, Pareto principle was
developed by Juran in 1950.

• A Pareto chart is a special type of histogram that can easily be apply to find and
prioritize quality problems, conditions, or their causes of in the organization (Juran and
Godfrey, 1998).

• On the other hand, it is a type of bar chart that shows the relative importance of
variables, prioritized in descending order from left to right side of the chart.

• The aim of Pareto chart is to figure out the different kind of “nonconformity” from data
figures, maintenance data, repair data, parts scrap rates, or other sources.
Wastage of Food in a Hotel
4. Cause & Effect Diagram
• Cause and effect)diagram was developed by Dr. Kaoru Ishikawa in 1943 for root cause
analysis and the concept of Quality Control (QC) circles .
• It has also two other names that are Ishikawa diagram and fishbone because the shape of
the diagram looks like the skeleton of a fish to identify quality problems based on their
degree of importance (Neyestani, 2017).
• The cause and effect diagram is a problem-solving tool that investigates and analyzes
systematically all the potential or real causes that result in a single effect.
• It is an efficient tool that equips the organization's management to explore for the possible
causes of a problem (Juran and Godfrey, 1998).
• This diagram can provide the problem-solving efforts by “gathering and organizing the
possible causes, reaching a common understanding of the problem, exposing gaps in
existing knowledge, ranking the most probable causes, and studying each cause”
(Omachonu and Ross, 2004).
• The generic categories of the cause and effect diagram are usually six elements (causes)
such as environment, materials, machine, measurement, man, and method
Brain Storming
Brainstorming is the key to creativity. Though it was developed in 1930 but it is still an
effective technique to solicit ideas to meet a specific list of goals.(Kerwin,1983).

Uses of brainstorming: It can be used in following cases:

• Determine the department’s capability and interests

• Trigger inter area communication

• Suggest approaches to marketing prowess (Skill)

• Improve the professional environment of the department

• Identify policies, procedures and operations that should be reviewed or improved

• Improve productivity, quality etc. (kaizen activities).

5. Scatter Diagram
Scatter diagram is a powerful tool
• to draw the distribution of information in two dimensions,

• which helps to detect and analyze a pattern relationships between two

quality and compliance variables (as an independent variable and a
dependent variable), and

• understanding if there is a relationship between them, so what kind of the

relationship is (Weak or strong and positive or negative).

• The shape of the scatter diagram often shows the degree and direction of
relationship between two variables, and the correlation may reveal the
causes of a problem.
 B
C l
M o o
a r o
r o d
k n
s a P
r
In C e
a s
Ex s su
a e r
m s e

Hrs. of revision No. of Injections Person’s Age

6. Flowchart

Flowchart presents a diagrammatic picture that indicates a series of symbols to

describe the sequence of steps exist in an operation or process.

• On the other hand, a flowchart visualize a picture including the inputs,

activities, decision points, and outputs for using and understanding easily
concerning the overall objective through process.

• This chart as a problem solving tool can apply methodically to detect and
analyze the areas or points of process may have had potential problems by
“documenting” and explaining Neyestani B. (2017)
Process Flow Chart
7. Control Chart
Control chart or Shewhart control chart was introduced and developed by Walter A.
Shewhart in the 1920s at the Bell Telephone Laboratories, and is likely the most “technically
sophisticated” for quality management (Montgomery, 2009).

• Control charts is a special form of “run chart that it illustrates the amount and nature of
variation in the process over time”.

• Also, it can draw and describe what has been happening in the process. Therefore, it is
very important to apply control chart, because it can observe and monitor process to study
process that is in “statistical control” (No problem with quality) accordant to the samplings
or samplings are between UCL and LCL (upper control limit (UCL) and the lower control
limit (LCL)).

• The main aim of control chart is to prevent the defects in process. Its is very essential for
different businesses and industries, the reason is that unsatisfactory products or services
are more costly than spending expenses of prevention by some tools like control charts.
Control Chart

Specification:
0.368±0.02

USL- 0.388

LSL- 0.348

UCL< USL
&
LCL> LSL
ANY QUESTION or QUERY ?

Thank You for Patient

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