Seven QC Tools 1. Check Sheet: Course Material On 7 QC

Course Material on 7 QC
SEVEN QC TOOLS
1. CHECK SHEET
2. HISTOGRAM
3. PARETO DIAGRAM
4. CAUSE AND EFFECT DIAGRAM
5. SCATTER DIAGRAM
6. STRATIFICATION
7. GRAPHS AND CONTROL CHARTS
PGS Consultants Chennai-1

CHECK SHEET
- THIS IS A DATA COLLECTION DEVICE ORIENTED TOWARDS DEFECT
PREVENTION
- DEFECT PREVENTION IS THE GOAL OF QUALITY CONTROL
- CONSIDER THE FOLLOWING CYCLE
DEFECT PREVENTION
MEANS PREDICTION
MEANS FOLLOWING STATISTICAL LAWS OF BEHAVIOUR
MEANS USE OF DATA
WHICH COMES FROM INSPECTION
HENCE FOR A GOOD DEFECT PREVENTION PROGRAM, THE INSPECTION

SYSTEM SHOULD BE VERY STRONG
THIS MEANS GOOD PLANNING FOR DATA COLLECTION
EXERCISE: WHAT ARE THE CRITERIA FOR PLANNING A GOOD DATA

COLLECTION SYSTEM?
DATA COLLECTION DEVICE CAN BE IN THE FORM OF:
1. TABULAR STRUCTURE
2. PICTORIAL (LOCATION TYPE)
3. GRAPHICAL
4. MATRIX STRUCTURE
5. CHECK LIST STRUCTURE
6. AUTOMATIC ACQUISITION THROUGH ELECTRONIC MEDIA
EXERCISE: DESIGN A CHECK SHEET

HISTOGRAM
HISTOGRAM CAN ALSO BE CONSIDERED AS A CHECK SHEET
- HISTOGRAM IS A FREQUENCY DIAGRAM

- THIS IS MORE APPLICABLE FOR MEASUREMENT DATA
- THE X-AXIS IS THE MEASUREMENT AND THE Y-AXIS IS THE FREQUENCY
- THE SPACING IN THE X-AXIS IS UNIFORM AND THE FREQUENCY IS
REPRESENTED BY A BAR DIAGRAM
- THE X-AXIS IS ORDERED IN THE SENSE THAT IT STARTS FROM THE
SMALLEST AND ENDS WITH THE HIGHEST COVERING THE ENTIRE RANGE
- THE HEIGHT OF THE BAR IN THE Y-AXIS IS PROPORTIONAL TO THE
FREQUENCY
- THE BARS ARE ARRANGED SO THAT THEY TOUCH EACH OTHER
HORIZONTALLY
EXERCISE: DRAW THE HISTOGRAM
THERE ARE FOUR INTERPRETATIONS FOR THE HISTOGRAM:
1. LOOK AT THE SPECIFICATIONS – IT INDICATES THE ACCEPTANCE AND

REJECTION OR NON-CONFORMANCE
2. LOOK AT THE PEAK – IT REPRESENTS THE SETTING
3. LOOK AT THE WIDTH – IT REPRESENTS THE CAPABILITY
4. LOOK AT THE SHAPE – IT REPRESENTS THE PREDICTABILITY
OBVIOUSLY THE IMPORTANCE OF THE ABOVE INTERPRETATIONS IS IN THE

REVERSE ORDER
EXERCISE: COMMENT ON THE HISTOGRAMS GIVEN TO YOU.

PARETO DIAGRAM
IT IS NAMED AFTER THE ITALIAN ECONOMIST PARETO
IT REPRESENTS AN IMPORTANT LAW OF LIFE!
- THIS IS ANOTHER ORDERED BAR DIAGRAM

- THE X-AXIS REPRESENTS CATEGORIES
- THE Y-AXIS REPRESENTS CONTRIBUTION IN PERCENTAGE TERMS
- THE X-AXIS IS SPACED UNIFORMLY
- THE Y-AXIS IS REPRESENTED BY BARS WHOSE HEIGHT IS EQUIVALENT
TO THE PERCENTAGE CONTRIBUTION TO THE TOTAL
- THERE IS AN ORDER IN THE ARRANGEMENT OF THE BARS. THE LEFT
SIDE STARTS FROM THE HIGHEST AND GOES DOWN IN THE DESCENDING
ORDER TOWARDS THE RIGHT
- A CUMULATIVE LINE IS ALSO SHOWN IN THE DIAGRAM. THIS
CUMULATIVE LINE IS USED TO IDENTIFY THE VITAL FEW FROM THE
USEFUL MANY.
- THIS PROPERTY OF DISTINGUISHING THE VITAL FEW FROM THE USEFUL
MANY IS THE UNDERLYING PHILOSOPHY OF THE PARETO PRINCIPLE
- THERE IS A BASIC LAW OF NATURE - THERE ARE ONLY A FEW ITEMS
CONTRIBUTING TO A MAJOR SHARE OF THE OUTPUT. HENCE BY
CONTROLLING THE FEW CONTRIBUTORS A GREAT BENEFIT CAN BE
DERIVED.
- OBVIOUSLY THERE IS A MANAGEMENT PRINCIPLE HIDDEN IN THIS LAW
EXERCISE: WHAT IS THE MANAGEMENT PRINCIPLE HIDDEN IN THE PARETO

PRINCIPLE?
EXERCISE: COMMENT ON THE FOLLOWING PARETO DIAGRAM GIVEN TO

YOU
CAUSE AND EFFECT DIAGRAM

THIS IS ALSO KNOWN AS ISHIKAWA DIAGRAM NAMED AFTER THE PERSON
WHO INVENTED IT. OTHER NAMES ARE FISHBONE DIAGRAM, WINDOWS OF
TECHNOLOGY.
- THIS TECHNIQUE IS BASED ON THE BELIEF THAT THERE IS A CAUSE OR

THERE ARE CAUSES WHICH AFFECT ANY OUTPUT.
- THIS IS A STRUCTURED WAY OF CAPTURING ALL THE CAUSES
AFFECTING A GIVEN EFFECT
- BRAINSTORMING IS A GOOD STARTING POINT FOR THIS TECHNIQUE

- THE KEY SUCCESS FACTOR IN THIS TECHNIQUE IS THE ABILITY TO

INVOLVE ALL CONCERNED IN AN ORGANISATION (INCLUDING
WORKMEN)
- THE TECHNIQUE OFFERS A GOOD CLASSIFICATION OF THE CAUSES FOR
FURTHER ACTION
- THE CLASSIFICATION CAN BE MAN MACHINE, METHOD, ETC. OR IT CAN
BE PROCESS STAGE WISE OR IT CAN BE PART WISE FOR AN ASSEMBLY,
ETC.
- THIS TECHNIQUE CAN BE INNOVATIVELY USED FOR THE FOLLOWING:
1. TRAINING
2. DATA COLLECTION
3. PROBLEM SOLVING DISCUSSIONS
4. ON LINE UPDATION OF KNOWLEDGE
5. FURTHER EXPLOSION OF EACH SUB CAUSE
- THIS TECHNIQUE IS THE FOUNDATION FROM WHICH OTHER TECHNIQUES

FOR THE FOLLOWING ARE BUILT:
1. ROOT CAUSE ANALYSIS

2. MASTER CAUSE ANALYSIS TECHNIQUE
3. ASSIGNABLE CAUSE ANALYSIS
4. EXPERIMENTAL FACTORS ANALYSIS FOR DOE
- THE CAUSE SHOULD REFLECT ON THE NATURE OF THE PROBLEM. WE

SHOULD DIFFERENTIATE BETWEEN TECHNOLOGICAL CAUSES AND
PROBLEM RELATED CAUSES. FOR EXAMPLE: TEMPERATURE MAY NOT
BE A CAUSE. TEMPERATURE WILL BE A REQUIREMENT WHEREAS
TEMPERATURE VARIATION WILL BE A CAUSE
EXERCISE:
1. HOW WILL THE CAUSE LOOK LIKE FOR THE PROBLEM OF TYPE “NEVER
BEEN THERE”
2. HOW WILL THE CAUSE LOOK LIKE FOR THE PROBLEM OF TYPE “RECENT
CHANGE”
3. HOW WILL THE CAUSE LOOK LIKE FOR THE PROBLEM OF IDENTIFYING
“ASSIGNABLE CAUSES” IN SPC

SCATTER DIAGRAM
- THIS IS A DIAGRAM WHICH DEPICTS RELATIONSHIP AND ITS NATURE.
RELATIONSHIP IS ALSO REFERRED AS CORRELATION
- IT IS A GRAPH WITH THE INDEPENDENT VARIABLE (CAUSE) ON THE X-
AXIS AND THE DEPENDENT VARIABLE (EFFECT) ON THE Y-AXIS
- THIS TECHNIQUE REQUIRES MEASURABLE DATA FOR ITS APPLICATION
- THE SCALE SHOULD BE CHOSEN CORRECTLY FOR THE VISUAL ANALYSIS
IN THIS TECHNIQUE
- THERE CAN BE DIFFERENT TYPES OF RELATIONSHIP:
1. POSITIVE LINEAR CORRELATION

2. POSITIVE NON-LINEAR CORELATION
3. NEGATIVE LINEAR CORRELATION
4. NEGATIVE NON-LINEAR CORRELATION
5. NO CORRELATION
- SOME APPLICATIONS OF THIS TECHNIQUE:
1. FOR KNOWING THE EXISTENCE OF RELATIONSHIP

2. FOR PROVIDING SPECIFICATIONS AND TOLERANCE
3. FOR FURTHER COMPLEX ANALYSIS LIKE REGRESSION AND
ESTABLISHING OF NATURE OF RELATIONSHIP AND EXTENT OF
RELATIONSHIP
4. FOR QUALITY ENGINEERING
EXERCISE: INTERPRET THE FOLLOWING SCATER DIAGRAM GIVEN TO YOU
STRATIFICATION
- THIS TECHNIQUE HAS TO BE THE FUNDAMENTAL PRINCIPLE BEHIND
DATA COLLECTION
- STRATIFICATION HAS TO BE PLANNED IN ADVANCE OF DATA
COLLECTION
- STRATIFICATION MEANS SUB-LAYERING OR ANALYSING A SITUATION
COMPONENT OR INDIVIDUAL CONTRIBUTOR WISE. EXAMPLE: MACHINE
WISE, SHIFT WISE, BATCH WISE, PRODUCT WISE, ETC.
- STRATIFICATION CAN BE DONE IN THE SHOP ONLY IF WE IDENTIFY THE
COMPONENTS IN A PLANNED WAY.
- THERE ARE TWO TYPE OF STRATIFICATION THAT CAN BE DONE – PAPER
IDENTIFICATION OR PART/PRODUCT IDENTIFICATION

- STRATIFICATION CAN BE DESIGNED INTO THE BASIC DATA SYSTEM OR

IT HAS TO BE DONE WHEN WE FACE A PROBLEM LIKE CUSTOMER
COMPLAINTS OR PRODUCT NON-CONFORMANCE
- STRATIFICATION CAN BE PLANNED AS A PART OF THE ANALYSIS AFTER
THE CAUSE AND EFFECT DIAGRAM
GRAPHS AND CONTROL CHARTS

GRAPHS:
- THESE ARE VISUAL DEPICTION OF DATATO FACILITATE EASY

UNDERSTANDING AND FOR TAKING IMMEDIATE ACTION
- THE SUCCESS OF THIS TECHNIQUE DEPENDS ON THE CORRECT USAGE.
TYPICAL CORRECT USAGE INCLUDES:
1. USING ONLINE
2. PLOTTING THE DATA IN THE ORDER OF OPERATION
3. TAKING TIMELY CORRECTIVE ACTION
4. ABILITY TO DISTINGUISH BETWEEN RANDOM VARIATION AND
SPECIFIC PATTERN
- LINE GRAPH IS A VERY POPULAR GRAPH

- CRITERIA FOR SELF CONTROL IS TO BE FULFILLED
- SELF CONTROL MEANS:
1. KNOWLEDGE OF WHAT IS TO BE DONE

2. KNOWLEDGE OF WHAT IS BEING DONE
3. MEANS TO TAKE REGULATORY ACTION
- TARGET LINES AND TREND ANALYSIS ARE VERY IMPORTANT FOR

ANALYSIS
EXERCISE: GIVE YOUR INTERPRETATIONS FOR THE GRAPH GIVEN TO YOU
CONTROL CHARTS:
- THEY ARE A TYPE OF GRAPH

- ALL THE POINTS DISCUSSED FOR GRAPHS ARE APPLICABLE
- DATA ARE COMPARED TO COMPUTED CONTROL LIMITES WHICH ARE
ALSO CALLED PROCESS LIMITS. THESE LIMITS ARE COMPUTED BASED
ON ACTUAL PAST DATA
- RUNNING A PROCESS IN A PREDICTABLE FASHION IS THE GOAL OF THE
CONTROL CHARTS

- TIMELY ACTION ON OUT OF CONTROL POINTS IS THE KEY TO THE

SUCCESS OF THIS TECHNIQUE
- ANY CONTROL CHART CONSISTS OF THREE LINES AS FOLLOWS:
- THERE ARE DIFFERENT TYPES OF CONTROL CHARTS DEPENDING ON THE

NATURE OF DATA USED LIKE VARIABLE AND ATTRIBUTE DATA
- SOME CONTROL CHARTS ARE X-BAR CHART, p CHART, c CHART.
- A CONTROL CHART CORRECTLY USED CAN ACHIEVE THE FOLLOWING
SIMULTANEOUSLY:
1. REDUCING VARIATION
2. INCREASING PRODUCTIVITY
3. REDUCING COST BY ELIMINATING INSPECTION
EXERCISE: IDENTIFY APPLICATIONS OF CONTROL CHART ALONG WITH THE

DESIRED OBJECTIVE IN NON-PRODUCTION AREA?

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Course Material on 7 QC

4. CAUSE AND EFFECT DIAGRAM

7. GRAPHS AND CONTROL CHARTS

PGS Consultants Chennai-1

MEANS FOLLOWING STATISTICAL LAWS OF BEHAVIOUR

MEANS USE OF DATA

WHICH COMES FROM INSPECTION

HENCE FOR A GOOD DEFECT PREVENTION PROGRAM, THE INSPECTION

THIS MEANS GOOD PLANNING FOR DATA COLLECTION

EXERCISE: WHAT ARE THE CRITERIA FOR PLANNING A GOOD DATA

DATA COLLECTION DEVICE CAN BE IN THE FORM OF:

EXERCISE: DESIGN A CHECK SHEET

PGS Consultants Chennai-1

- HISTOGRAM IS A FREQUENCY DIAGRAM

EXERCISE: DRAW THE HISTOGRAM

THERE ARE FOUR INTERPRETATIONS FOR THE HISTOGRAM:

1. LOOK AT THE SPECIFICATIONS – IT INDICATES THE ACCEPTANCE AND

OBVIOUSLY THE IMPORTANCE OF THE ABOVE INTERPRETATIONS IS IN THE

EXERCISE: COMMENT ON THE HISTOGRAMS GIVEN TO YOU.

PGS Consultants Chennai-1

IT REPRESENTS AN IMPORTANT LAW OF LIFE!

- THIS IS ANOTHER ORDERED BAR DIAGRAM

EXERCISE: WHAT IS THE MANAGEMENT PRINCIPLE HIDDEN IN THE PARETO

EXERCISE: COMMENT ON THE FOLLOWING PARETO DIAGRAM GIVEN TO

CAUSE AND EFFECT DIAGRAM

- THIS TECHNIQUE IS BASED ON THE BELIEF THAT THERE IS A CAUSE OR

PGS Consultants Chennai-1

- THE KEY SUCCESS FACTOR IN THIS TECHNIQUE IS THE ABILITY TO

- THIS TECHNIQUE IS THE FOUNDATION FROM WHICH OTHER TECHNIQUES

1. ROOT CAUSE ANALYSIS

- THE CAUSE SHOULD REFLECT ON THE NATURE OF THE PROBLEM. WE

PGS Consultants Chennai-1

1. POSITIVE LINEAR CORRELATION

- SOME APPLICATIONS OF THIS TECHNIQUE:

1. FOR KNOWING THE EXISTENCE OF RELATIONSHIP

EXERCISE: INTERPRET THE FOLLOWING SCATER DIAGRAM GIVEN TO YOU

PGS Consultants Chennai-1

- STRATIFICATION CAN BE DESIGNED INTO THE BASIC DATA SYSTEM OR

GRAPHS AND CONTROL CHARTS

- THESE ARE VISUAL DEPICTION OF DATATO FACILITATE EASY

- LINE GRAPH IS A VERY POPULAR GRAPH

1. KNOWLEDGE OF WHAT IS TO BE DONE

- TARGET LINES AND TREND ANALYSIS ARE VERY IMPORTANT FOR

EXERCISE: GIVE YOUR INTERPRETATIONS FOR THE GRAPH GIVEN TO YOU

- THEY ARE A TYPE OF GRAPH

PGS Consultants Chennai-1

- TIMELY ACTION ON OUT OF CONTROL POINTS IS THE KEY TO THE

- THERE ARE DIFFERENT TYPES OF CONTROL CHARTS DEPENDING ON THE

EXERCISE: IDENTIFY APPLICATIONS OF CONTROL CHART ALONG WITH THE

PGS Consultants Chennai-1

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