7 QC TOOLS

• 7 QC
TOOLS :-a problem solving tool. This are very important
It is basically
tool for collecting data, analyzing data, identify root causes and
measuring results . It is used to find solution in systematic
manner.

Other names of 7QC tools is :-

(1) The Old Seven.
(2) The First Seven.
(3) The Basic Seven.
What is Problem
Problem
:- is gap between the ideal situation and current situation.
It is impossible that No problem is present in our work station,
home or anywhere. There may some little problem everywhere.
Bridge

Problem Solution
Gap Between Bridging the gap
expectation & Current to achieve the
State. objectives.
 TYPES OF 7 QC
TOOLS
It is use monitor how
7.Control a process change over
Chart a time

It is used graph to show

6. frequency distribution.
Histogram
it is a graphical representation of
5.Scatter relationship between two variables.

A flow chart is a type of diagram

4. PFD that
represents a work flow or process.

3.Fishbone it is used in all type of problem

solving
methodology.

It is the tool which is used to priorities the

2.Pareto data.
Chart
The check sheet is a document used to collect data in
1.Check real time at the location where the data is generated.
Sheet
 1.
What is check
Checksheet
sheet ?
The check sheet is a document used to collect data in real time at the location where the data is
generated.
The check sheet is sometimes called a tally sheet.
Purpose :-

Tool is used for counting, organizing and measuring the data. Data collacted can be used as input data for
other
quality tools.
Benefits :-
(1) Collect data in systematic and organised
manner.
(2) To determine source of problem

Checksheet inventor
:-
(1) Check sheet :- It is used to collet the data.
Dr. Kaoru Ishikawa is not inventor of checksheet but he made popular to
checksheet.

Dr. Kaoru Ishikawa

 Points to remember to while make a chechsheet :-
(1) Easy to use and understand.
(2) Describe who will collect the data? When will collect the data? Where will collect the data ? How will data
be
collacted ?
(3) Checksheet should displayed in visibal area.
There are 3 types of checksheet :-
(1) Defective item checksheet or tally sheet.
(2) Defective location check sheet or concentration
diagram.
(3) Defect cause check sheet.
(1). Defective item checksheet or Tally sheet.

(2). Defective location check sheet . (3). Defective cause check sheet .
 2. Pareto
Chart
What is Pareto chart ?

It is the tool which is used to priorities the data. Pareto chart is invented by
Vilfredo Pareto. He is given 80 / 20 principal. It is a combination of bar graph and line
graph.
History of Pareto Chart :-

Vilfredo Pareto was an Italian engineer,

sociologist, economist, political, scientist and
philosopher.

He shows an observation that 80% of the

land in Italy was owned by 20% of the
population.

The Pareto principal was named after

him.

Principal of Pareto
chart :-
(1) Pareto principal is also known as the 80/20 rule...
(2) 80% of the problem comes from 20% of the causes.
(3) 80% of the result comes from 20% of the effort.

Benefits :-

Helps the team to focus on those causes that will have the greatest impact when
solved.
 Drawback of Pareto Chart :-
Pareto chart only Priorities the data but never tells about severity.

Example :- Acar have break fail issue and 50 dents on its body.

Pareto chart Priorities the dents. Basically pareto chart is ok. But we have to use our common
sense,
and find the answer, Is dents is more Sevier or break fail is more Sevier.
of course break fail is more Sevier then dents.
But basic pareto chart are not useful in that condition.
In this condition we have to use Pareto Chart as well as our Common sense.
Pareto Chart :-

We need data which we have to priorities, It will comes from Check sheet.
For example :- This is our data

60 120
53
50
95 96 97 98 99 99 100 100100
94
87 90 92
40 81 85 80
77
72
30 28 63 60
24 2455
45 20 20
20 40
34
12 10
10 23 9 20
6 6 6 4 3 2 2 2 2 1 1 1
0 0
M BLY M TE ER IA) ING KY M ER DY IDE M TE ER ER EET ER ria) DY ME
M M M LA LD OR T AN M OV O S M LA PP OV F OV co BO A
5 8 5 B L 8
2. SSE KT G HO CIC UN T T KT R C ET NA KT R P FLA Y C Y 8 C (ci IN E FR
P
KT A B IN SC ( O EE B LE FE R B EA K NK R M E A S
B T E T I T E M F H L 8 T E E G A N A A M M BA
E R D N D T 8 C O D 6 A
R LER ER
ID PO SI OU LA ES
P R T & IT R
H SS E X SI
T
T T F
S P M G T D EE E BA AL
U N O E E E N F S
A E EB
S E R I O F P R T A 8 B R R
CK LL C H F 7 S A
P I O N U UA
R P U Q
S SQ
E SS
PR
REJECTION QTY. CUMULATIVE
 3. Fishbone
Diagram
Fish bone diagram is used in all type of problem solving
methodology.
Fishbone Diagram
inventor :-
Fish bone diagram invented by Dr. Kaoru Ishikawa In 1943. He used it in Kawasaki Iron
Works in 1943

Dr. Kaoru Ishikawa

President of Musashi Institute of technology Member of union of Japanese

Scientists .
Important Points :-

1. Fish bone diagram is used in all type of problem solving methodology.

2. Fish bone diagram is called because its shape looks like a fish bone.
3. It is very important tool to identified potential / possible root cause.
4. 6M used in fish bone diagram is :- (i) Men (ii) Method (iii) Material
(iv) mother nature (environment) (v) Machine (vi) Measurement
5. We only find potential / possible causes only, root cause is not find in this process.
6. After find possible cause we have to use another tool to find root cause.
Example :- Why-Why analysis etc.
7. For find out potential / possible cause in fish bone diagram, we need to do first
brainstorming.
8. After brainstorming potential causes are filled in to fish bone diagram,
Category wise, that is men
9. related cause in men column etc.
10. There are primary, secondary or tracery cause or 4th level or may be 5th level of
cause identified depend upon team maturity.
11. It is minimum required 20 to 25 possible cause identified for a good identification
of cause, many industry identify only 5 to 6 cause , it is not a good practice.
Methodology of Fishbone Diagram :-

Step 1 :- Make fish bone diagram and write all possible

causes in 6M after brainstorming session.
Step 2 :- Find out suspected cause from the possible cause.
Step 3 :- Validate all the suspect cause and write the result.
All the validated results are valid cause problem
Step 4 :- Do the Why - Why analysis of the valid cause and
find out the root causes of the problem.

Step :- 4
Suspecte
Step :- 2

Step :- 3
d Cause
Step :-

Possibl

Cause
Cause

Valid

Cause
Root
1

Analysi
Why-
Why

s
Annexure :- 1
 4. Histogram
What is a Histogram ?

A histogram is used to summarize data of one continuous variable that is

dimension, weight etc. It is the most commonly used graph to show frequency
distribution.
History of Histogram :-

invented by Karl Pearson follower of Sir Francis Galton. And histogram is one of the
seven basic tools of quality control.

Histogram :- It is used to check shape

of the process. It is invented by Karl
Pearson in 1891 follower of Sir Francis
Galton.

When to use Histogram :-

When the data is numerical. It is used to check past history, or lot which is manufactured in
past.
Importance of Histogram :-

1. Simple to use.
2. Use on all variable data.
3. Histogram provides a visual representation of data
distribution.
Point to be noted :-

1. Only 1 variable histogram is drawn in one time or one graph.

2. For draw histogram minimum 50 to 100 pcs data should
available.
1. Bell shaped distribution or Symmetric distribution :-
it is suitable where the tolerance is given Bilateral ( both ± side ). Also if tolerance is unilateral, we
have to mean the tolerance and after use it.

2. A Right - Skewed distribution :- 3. A Left - Skewed distribution :-

A right-skewed distribution is also called A Left-skewed distribution is also called a
a positively skewed distribution. As per Negatively skewed distribution. As per required
required condition we have to use it, condition we have to use it,
For example :- In case of doctor For example :- In case of school result how
treatment how much patient cured in 1 much students gets higher marks.
day or 2 days etc.

Krishna Tomar
 5. Flow chart

What is a Flow chart ?

A diagram that uses graphic symbols to describe

the nature and flow of the steps in a process.
OPERATION NUMBER OPERATION NAME PROCESS FLOW

RAW MATERIAL RECEIVING

10

INCOMING INSPECTION

BLANKING +
20
IN-PROCESS INSPECTION

SIDE PIERCING
30
+ IN-PROCESS INSPECTION

BENDING & EMBOSSING

40
+ IN-PROCESS INSPECTION

FRONT PIERCING
50
+ IN-PROCESS INSPECTION

ZINC PLATING
60
(OUT SOURCE)

70 PRE DISPATCH INSPECTION

80 PACKING

90 DISPATCH

Krishna Tomar
 6.Scatter
Diagram
What is a Scatter
Diagram ?
Scatter diagram is a graphical representation of relationship between two
variables. One variable is plotted on the horizontal axis and other is plotted on the
vertical axis. The pattern of their intersecting points can graphically show
relationship of patterns.
Inventor of Scatter
Diagram :-

Sir Francis Galton.

Scatter diagram also known as x y chart. It is invented by Sir Francis Galton,

and first used in 1888 by Francis. In 1950s Dr.K.Ishikawa popularized the use of
scatter diagram.
Remember points before draw of Scatter
Diagram :-
Please keep in mind that the scatter diagram is different than the Ishikawa diagram. The Ishikawa
(fishbone) diagram shows you only the variables; it does not show you the relationship between
these variables. However, the fishbone diagram can help you draw the scatter diagram;
for example, you can find the two variables (cause and effect), and then draw the scatter
diagram to analyze the relationship between them.
Note :- (1) One diagram can only handle two variable.
(2) For construct diagram minimum data should 30 or maximum 100.

Drawback of Scatter
Diagram :-
1. This chart does not show you the relationship for more than two
variables.

Krishna Tomar
 Types of Scatter
Diagram :-
1. Scatter Diagram with No Correlation
2. Scatter Diagram with Moderate Correlation (may be positive or may be negative correlation
)
3. Scatter Diagram with Strong Correlation
1.Scatter Diagram with No 2.Scatter Diagram with Moderate
correlation:- correlation:-
This type of diagram is also known as This type of diagram is also known as
“Scatter Diagram with Zero Degree of “Scatter Diagram with Low Degree of
Correlation”. Correlation”.

In this type of scatter diagram, data points are Here, the data points are little closer together
spread so randomly that you cannot draw any and you can feel that some kind of relation
line through them. exists between these two variables.
In this case you can say that there is no relation There may be positive correlation present or may
between these two variables. be negative correlation present.
3(a).Scatter Diagram with strong positive 3(b).Scatter Diagram with strong Negative
correlation:- correlation:-
This type of diagram is also known as This type of diagram is also known as
Scatter Diagram with Positive Slant. Scatter Diagram with Negative Slant.

In positive slant, the correlation will be In negative slant, the correlation will be negative,
positive, i.e. as the value of x increases, the i.e. as the value of x increases, the value of y will
value of y will also increase. You can say that decrease. The slope of a straight line drawn
the slope of straight line drawn along the along the data points will go down.
data points will go up. The pattern will For example, if the temperature goes up, sales
resemble the straight line. of winter coats goes down.
For example, if the temperature goes up,
cold drink sales will also go up
Krishna Tomar
 7. Control
Chart
What is a Control
Chart ?
Control charts monitor how a process change over a time
Control charts, also known as Shewhart charts (after Walter A. Shewhart) or process-behavior
charts, are a statistical process control tool used to determine if a manufacturing process is
in a state of control or not.

Inventor & History of Control

Chart :-
The control chart was invented by Walter A. Shewhart working for Bell Labs in the 1920s.
Control chart is used to know weather the process in control or not. Invented by Dr. Walter
Andrew
Shewhart in 1924. He also invented PDCA cycle.

Dr. Walter Andrew Shewhart

Benefits :-
Predict process out of control and out of specifications limit.
Can be used for SPC
STEPS to draw a Xbar and R bar chart :-
1. Collect set of sample
2. Calculate Xbar, Xdbar and R and Rbar
3. Calculate Control Limit (UCL & LCL)
4. Plot the data of X bar and R bar chart

Krishna Tomar
Average Chart :-
X bar charts show the centering (mean) of the process, with the help of X bar chart we control
the mean of the process.
Range Chart :-
R charts shows the spread of the process with the help of R bar chart we control process
spread.
What is the requirement to make X Bar R
Chart :-
1. Data is variable
2. Mass production :- Production rate should moderate, not too much and not less. Generally
automobile sector have moderate production rate
3. Data should of single characteristics. That is only one dimension.
4. Generally dimension should CTQ (critical to customer) is used.
5. Data should taken in rotational sub-group.
6. e.g. If we check 5 psc in hour then continuous take data every hour of 5 psc.
7. Data should taken regular for sub-group, e.g. if our sub-group size is 5 psc, then we have to
check regular 5 psc of production.
8. Rotational subgroup should 20 to 25 or 100 observation.
9. Control chart is not preferred for 1 shift production, Production should running minimum 2 to 3
days
and data should be of 2 to 3 days.
How to made control Chart
:-
(1) Collect the data.
(a) Minimum 100 observation should taken.
(b) Number of samples should take 4 , 5 , 6 and should be taken
continuously.

Krishna Tomar
 (a)

Points outside of the limit

Control limits are calculated to measure the
natural variability of a process. Any point or
on outside the limit is considered abnormal
and requires investigation

(b)
8. List of coefficients of Average or Range Chart

Shift (Run):
A shift is indicated when points lie continually
on one side of the center line, A shift of seven
consecutive points is considered abnormal.

(c)

Trends :
Seven consecutive points in a
continuous upward or downward
direction.

Krishna Tomar
 Why we not use line chart and run chart
instead
(d) of control charts:-
1. Firstly we used the line charts for
understanding
a problem. But there is no center line, to
show which is the center of process
This is a simple chart , we can not get any result
to see this chart.

Hugging the center line :

When most points lie within the center line and
1.5 sigma, the process is not in control state.
This usually indicates the mixing of data from
different populations.

(e)
2. S
e
c
o
n
d
l
y

w
e

u
p
g
r
a
d
e
Approaching control limits :
2 of 3 points lying outside the 2 sigma line t
is considered abnormal. o

R
u
n
Krishna Tomar
 Difference in Run Chart & Control charts :-

Run Chart :- Run Chart :-

1. A run chart is a line graph of 1. A control chart is also a line graph of

data plotted over time. data plotted over time with control limits.
2. A run chart does not show statistical 2. Control chart have UCL and LCL, If there
control limits. is any point going outside of the control
limits it clearly shows process is out of limits
3. A control chart also help in identification
3. A run chart can help in identification
of special causes in process and also help in
of special causes in process.
achieve Statistical process control.

Krishna Tomar
 A. Process Flow
Chart
What is Process flow
chart :-
A flow chart is a type of diagram that represents a work flow or
process.
Inventor & History of
PFDThe
:- first "process flow chart", was introduced by Frank and Lillian Gilbreth. In1947,ASME adopted
a symbol set derived from Gilbreth's original work as the "ASME Standard:(American Society of
Mechanical Engineers) In Japan ,Kaoru Ishikawa(1915-1989),a key figure in quality initiatives in
manufacturing ,named flow charts as one of the key tools of 7QC tools.
Purpose of
PFD :-
(a) Schematic drawing of the process to measure or
improve.
(b)Potential weakness in the process are made
visual. (c.) Standardize a Process.
(d) It is to communicate to others that how a process
is done.

Krishna Tomar
Example of
PFD :-

Benefits of PFD :-
(a) Its easy to identify process improvements.
(b) Its easy to understand the process.
(c) Shows duplicate efforts and other non-value added steps.
(d) Clarify working relationship between people and
organizations.
(e) Serves as a training aid to explain the complete process.

Krishna Tomar
 B.
Why graph is used ? Graphs
When data is shown in pictorial form then graph is used. Graph is used to reporting the
management
and for better understanding in short time of period.
Different types of
Graph :-
1. Bar Graph 2. Pie Graph
3. Radar Graph 4. Line Graph

1. Bar Graph :-

A bar chart or bar graph is a chart or graph that presents different category data with rectangular
bars . A bar graph may run horizontally or vertically. The important thing to know is that the longer the
bar, the greater its value. A bar graph will have two axes. One axis will describe the types of
categories being compared, and the other will have numerical values that represent the values of the
data.

2. Pie Graph :-
A pie chart (or a circle chart) is a circular statistical graphic, which is divided into slices to
illustrate numerical proportion. They're widely used in business presentations.

Krishna Tomar
3. Radar Graph :-

It is used to show the gaps in performance (expected vs. actual) when too many variables are
involved.
Uses :-
(a) Radar Chart is used to control of quality improvements, and display the performance metrics
of
ongoing program.
Example :- Radar chart used to show system audit result, 5S audit result etc.
(b) It is also used in sports to show the strength and weakness of player, and generally called
spider chart.

4. Line Graph :-
A Graph to show the changes in quantum w.r.t. to change in condition.
A line graph, also known as a line chart, is a type of chart used to visualize the value of
something over time.

Krishna Tomar