7 QC Tools-Trg Module - ACT - Advance Cluster

7
QC tools
Property of ACT ( ACMA Centre for Technology ) 2007
Slide No.
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Seven QC Tools
Scatter Diagram Stratification Histogram Graph and Control Chart Cause and Effect Diagram Pareto Diagram Check Sheet
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Sl.No
1 2 3
Tools
Check Sheet / Data Sheet Pareto Daigram
Function
To Collect the data in a simple manner and to prevent omitting the checks To pick up the important few problems from the trivial many.
Cause and Effect To reorganise the factors (causes) which are Diagram influencing the problem Presentation of data in a pictorial form for Graph and Control better understanding and see if the process Chart is under stable conditions. Histogram Stratification Scatter Diagram To see the distribution pattern compared against the standard values. To segregate data according to contributing sources.(Suppliers,machines,operators etc) To see relation between two sets of data
5 6 7
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Check Sheet
Solder Bath Temperature
Checked by : Raised by : Take reading of temperature nearest to degree. Time Temp (0C) Time Temp (0C) 0800 60 1300 61 0900 62 1400 58 1000 59 1500 63 1100 58 1600 63 1200 59 1700 59 Note : Power failure from 12.00 to 12.15 Hours
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What is Check Sheet ?

A Check sheet is a paper form on which item to be checked have been printed already so that data can be collected easily and concisely. Its main purposes are two-fold : 1) To make data-gathering easy ; 2) To arrange data automatically so that they can be used easily later on
Two Types of Data :

1. Measurement data or Variable data. 2. Attribute data.
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Check sheets are of following types :

a) Check sheet for production process distribution. b) Defective item check sheet. c) Defect location check sheet. d) Defect cause check sheet.
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Check Sheet for Production Process Distribution:

Deviation 5 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 Total
Checks 10 15 20
Frequency
Specification
8.300
1 2 4 6 9 11 8 7 3 2 1 1
Specification
55
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Defective Item Check Sheet:

Product : Manufacturing stage: Final inspection Type of defect: Scar,incomplete crack,misshapen. Total no.inspected : 1525 Remarks : All items inspected.
Type
Surface scars Cracks Incomplete Mishappen Others IIII IIII IIII III IIII Total : Total rejects
Date : Section : Inspectors name : Lot no : Order no :

Checks
IIII IIII IIII IIII I IIII IIII IIII I II
Subtotal
17 11 26 3 5 62 42
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Defect Location Check Sheet

A
1 A B C D 2 1 12 10 15 11 1 3 4
D 1 2
From the location matrix it is clear that most of the blow holes are occupied in the segment B2,B3,C2 & C3.
Defect Location Matrix For Blowholes (50 Defective Components)

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Defect Cause Check Sheet.

Mon Equipment Operator AM PM AM PM AM PM AM PM AM PM AM PM Tue W ed Thu Fri Sat
1 A 2
oo ox x
ooo
xx
ooo xxx
xx oo oo xx xxx
oo xxxx oo
1 B 2
oo
xx
xx
oo x Blowhole Poor finish Crack

10
o Damage
Others
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Points to remembered while making check sheets

v Easy to use and understand.
v Information should be true and accurate. v Decide objective by involving all the members. v Use 5W and 1H principle. v Who will collect the data ? v When will the data be collected ? v Where will the data be collected ? v How will data be collected ? v Check sheets should be displayed on visible area.
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11
Benefits of Check Sheets

Data Collection have the following benefits :
Right decision can be made.

Errors due to subjective feeling or personal bias are avoided. Agreement on decisions necessary rather than different or
subjective opinion.
Measurement understandable to all. Assessments of magnitude of improvements. Discovery of causes affecting quality and productivity.
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12
Pareto Diagram
No of Components
250 200
156 85.28 91.53 96.75 100
100
150
105
60
50.98
100 50
40 20
20 16 9
0 Cold shut oil shot Damage Chip off Bad app
Types of Defects
% Cumulative 13
80
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What is Pareto Diagram ?

Pareto diagrams are presentation technique used to show facts and they help us to separate the vital few. Pareto diagram was first thought out by an Italian economist, Pareto (1848 - 1923), when he used it as a method for national income analysis to show that a large proportion of the wealth was centered around a small minority of people. After that, an American Quality Control Authority, Mr.Juran used it in the field of Quality Control.
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14
Steps to make the pareto diagrams :

1) Decide what problems are to be investigated and how to collect the
data. 2) Design a data tally sheet listing the items,with space to record their totals. 3) 4) Fill out the tally sheet and calculate the totals (Example-1) Make the pareto diagram data sheet listing the items, their individual totals,cumulative totals,percentages of overall total, and cumulative percentages (Example-2)
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15
Steps to make the pareto diagrams (contd.) :

1) 2) 3) 4) Draw two vertical axes and a horizontal axis. Construct a bar diagram. Draw the cumulative curve (Pareto curve). Write any necessary items on the diagram. a) Items concerning the diagram. b) Items concerning the data.
5) Arrange the items in the order of quantity,and fill out the data sheet.
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16
Data Tally Sheet - Example -1

Type of Defect
Crack Scratch Stain Strain Gap Pinhole Others Total IIII IIII IIII IIII IIII IIII IIII IIII IIII IIII IIII IIII IIII IIII I IIII IIII IIII . IIII IIII IIII IIII . IIII II
Tally
Total
10 42 6 104 4 20 14 200
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17
Data Sheet for Pareto Diagram - Example - 2

Type of Defect Strain Scratch Pinhole Crack Stain Gap Others Total Number of Defect 104 42 20 10 6 4 14 200 Cumulative Total 104 146 166 176 182 186 200 Percentage of Overall Total 52 21 10 5 3 2 7 100
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Cumulative Percentage 52 73 83 88 91 93 100
18
Parteo Diagram by Defective Items:

200 180
April 1 - June 30
83 73 52 88
100 91 93
100 90 80 70 60 50
No of Defective Units
160 140 120 100 80 60 40 20 0 D
104 42 20 10
A
40 30 20
6
C
4
E
14
Others
10 0
A :Crack, B: Scratch, C: Stain, D: Strain, E: Gap, F: Pinhole. (Number of Units Investigated : 5,000)
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19
Cumulative Percentage
Cause and Effect Diagram

Man Machine
Characteristics
Material
Method
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20
What is Cause and Effect Diagram ?

Any defect in a component, a product or service could be due to one or more causes.To find out the relationship between the causes and effect, a diagram is drawn systematically by mapping out all the probable causes influencing the effect. This is called a Cause and Effect Diagram Cause and effect diagram was introduced by Dr.K.Ishikawa. He used it in Kawasaki Iron Works in 1943. Since final diagram looks like a fish bone it is also called as Fish Bone Diagram.
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Format of a Cause and Effect Diagram

Main Cause Main Cause A Level 3 Cause Level 2 Cause Level 1 Cause Characteristics
Main Cause
Main Cause
Above diagram depicts the basic format of Cause and Effect diagram. There is a hierarchical relationship of the effect to the main causes and their subsequent relationship to the sub-causes.
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22
Procedure for Making Cause-and-effect Diagrams for Identifying Causes:

1) Determine the quality characteristics.
2) Choose one quality characteristics and write it on the righthand side of a sheet of paper, draw in the backbone form left to right, and enclose the characteristic in a square. Next, write the primary causes which affect the quality characteristics as big bones also enclosed by squares.
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Procedure for Making Cause-and-effect Diagrams for Identifying Causes (contd):

3) Write the causes (Secondary causes) which affect the big
bones (primary causes) as medium-sized bones and write the causes (tertiary causes) which affect the medium-sized bones as small bones. 4) Assign an importance to each factor and mark the particularly important factor that seem to have a significant effect on the quality characteristics. 5) Record any necessary information.
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Example of Cause-and-Effect Diagram :

Health
Relaxation Rest Amusement Time Sleep Depth Theory Planning Rules Common sense Information Study of opponent Analysis Observation Power Motion Speed Cooperation Schedule Exercise Quality Quantity Advice Form Repetition
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Spirit
Encouragement Pride Fighting spirit
Nutrition Calories Meal Quantity
Patience Carefulness Concentration
Devotion Calmness Composure Confidence
Defeat in a sports match
Teamwork Judgement of situation Function
Strategy
Experience of matches
Model
Technique
25
Example of Cause-and-Effect Diagram :

MAN
Wrong assembly New operator Importance not known to operator Hole location not taken during assembly No Poka yoke In adequate Fixture design In adequate design Milling Depth under size M/c condition not ok High variation in the process
MACHINE
Gap less at suction side
Valve Plate Projecting out of cyl.head in 94 dia cylinder head assembly WHY? Hole position shifted Valve plate outer dimension oversize Improper blanking
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METHOD
MATERIAL
26
Points to remembered.
1)
Once Cause and Effect diagram is made, check for its completeness. If required get reviewed from the experts. 2) A good Cause and Effect diagram gives an excellent understanding of a complex problem in a simple way. 3) 4) Cause and Effect diagram is not an answer of the problem. Main cause to be found out by collecting data or on collective experience. 5) Less educated persons and with poor knowledge about process can be benefited by this.
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Graph and Control Chart

UCL C/L LCL
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What is Graph :
Graph is a pictorial representation of data which is easily understandable at a glance. It is a visual representation of data made up of points, lines, letters, words, numbers, shades etc.
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Types of Graphs :
1) 2) 3) 4) 5) 6) Line graph Bar chart / graph Pie chart or Circle graph Radar chart Compound graphs - bar and line Gantt chart
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Line Graph :
709 700 Qty Produced 662
550 376 275 250 Jan'03 Feb Mar Month Apr May June 273
400
330
Production details
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31
Bar Chart / Graph :

10 9 8 7 6
6.3 4
Hrs
5 4 3 2 1 0 Jan'01 Feb'01
3.4
4 3
Mar'01
Apr'01
May'01
Jun'01
HMC Machine Breakdown

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32
Pie chart or Circle graph :

Unwanted - 61 Tags removed - 59
Easy to CLI - 855 Tags removed - 850
Leakage - 845 Tags removed - 825
Electrical - 332 Tags removed - 325 Damage & Broken - 340 Tags removed - 334
Missing - 385 Tags removed - 380 Loose - 393 Tags removed - 390
Classification of abnormality tags.

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33
Radar chart
Plant performance : 2001-2002
unit1
100% 100%
50%
unit5
0.85 0%
unit2
80%
unit4
60%
unit3
90%
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34
Compound graph - Bar and Line
10 9 8 7 6 5 4 3 2 1 0 Jan'01 Feb'01 Mar'01
9.25 8.75 7 4.75 3 3 5 4 3.5 4 4.75 7
Frequency Hours
Apr'01
May'01
Jun'01
HMC Machine Breakdown

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35
Gantt chart
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36
What is Control Chart :

1) Control chart is a graphical device to aid in process control.
2) It consist of a graph with a central line denoting the target value control limit and Limit control limit and two limit lines on either side of the central line called Upper 3) Quality measured periodically is plotted on the chart and status of control assessed. 4) The control chart was first proposed by Dr.Walter A Shewhart, an engineer in the Bell Telephone Laboratories,USA with a view to eliminate abnormal variation.
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Two Types of Variations :

1. Chance Causes. 2. Assignable Causes. 1. Chance Causes : Which are uncontrollable and comprising very small differences in raw materials in the same batch or machines, actual conditions etc. 2. Assignable Causes : Such as different settings of a machine, different raw material batches, changes in operators, operator errors etc.
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Types of Control Chart

Characteristic Value Continuous value x chart (measured value) pn chart (number of defective units) p chart (fraction defective) Discrete value c chart (number of defects) u chart (number of defects per unit)
Name x - R Chart (average value and range)
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Types of Control Chart :

x - R Chart
1) It is used for controlling and analyzing a process using
continuous values of product quality such as length, weight or concentration and this provides the larger amount of information on the process. 2) x represents an average value of a subgroup and R represents the range of the subgroup. 3) An R chart is used usually in combination with an x chart to control the variation within a subgroup.
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40
Procedure to make control charts :

x - R Chart
1) Collect the data. 2) Calculate x x = x1 + x2 ++ xn n 3) Calculate x x = x1 + x2 ++ xk k
n - Size of a sub group
k - Number of subgroups
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Procedure to make control charts (contd.) :

x - R Chart
4) Calculate R
R = (Maximum value in a subgroup) -(Minimum Value in a subgroup)
5) Calculate R R = Rx1 + Rx2 ++ Rn k
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42

x - R Chart
6) Calculate the control lines x Chart Central line : CL = x Upper control limit : UCL = x + A2R. Lower control limit : UCL = x - A2R
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x - R Chart
7) Calculate the control lines R Chart Central line : CL = R Upper control limit : UCL = D4R. Lower control limit : LCL = D3R
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44
Procedure to make control charts(contd.) :

8) List of Coefficients for x - R Chart.
Size of Subgroup x Chart n A2 2 3 4 5 6 1.88 1.023 0.729 0.577 0.483 R Chart D3 ----------D4 3.267 2.575 2.282 2.115 2.004
Slide No.
d2 1.128 1.693 2.059 2.326 2.534

45
Procedure to make control charts(contd.) :

x - R Chart
9) Plot the points.
10) Draw the control lines. 11) Write the necessary items.
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46
Examples of Control Chart :

UCL C/L LCL Control Chart for Controlled State UCL C/L LCL Control Chart for Uncontrolled State
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47
Examples of Control Chart :

Average chart (X)
READINGS 52.043 Readings 52.039 USL LSL Xdbar 52.035 52.031 1 3 5 7 9 11 13 15 17 19 21 23 25 Samples UCL XBAR LCL XBAR
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48
How to Read Control Charts :

1) Out of control limits. 2) Run. Seven-point length of run is abnormal. Ten out of 11 consecutive points occurring on one side is abnormal.
Run
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How to Read Control Charts (contd.) :

3) Trend
Seven upward points Drastic downward trend
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50

4) Approach to the control limits (2 out of 3 points)
3-sigma line 2-sigma line
2-sigma line 3-sigma line
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How to Read Control Charts :

5) Approach to the central line.
3-sigma line 1.5-sigma line
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52

6) Periodicity
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53
Histogram
40 34 38 35 30
25
20
15 9 9.9
10 4 0 0 4
4.5 2.5 2.5
3.3 3.35 3.4 3.45 3.5 3.55 3.6 3.65 3.7
Slide No.
54
What is Histogram :
Histogram is a graphical representation of a frequency distribution which is a summary of variation in a product or process.
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55
Steps to construct the Histogram :

1) Collect 100 reading. 2) Find out lowest and highest value of reading row wise. 3) Find out lowest and highest from all the rows. 4) Compute the range . R = Max - Min. 5) Follow standard table for no of classes.
No of Observations No of Classes ( k ) < 50 6 51 - 100 7 101 - 200 8 201 - 500 9 501 - 1000 10
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56
Graph to Determine K
20 18 16 14
12 10 8 6 4 2 0 1 2 3 4 5 678 10 20 50 200 500 1,000
n
n - Numbers of Measurements.
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57
Steps to construct the Histogram :

1) Calculate the approximate width of class with the help of formula ( R + W ) / K Where R is the range. W is accuracy in the observation and K is no.of classes.Make the frequency table and then draw the histogram. - Note 1) Classes should be continuous.i.e 1-5,5-10,10-15 etc. 2) All classes should have same width.
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Histogram data sheet

1 2 3 4 5 6 7 8 9 10 104.1 104.4 104.3 104.5 104.4 104.3 104.2 104.5 104.3 104.5 11 12 13 14 15 16 17 18 19 20 104.5 104.3 104.4 104.5 104.4 104.5 104.2 104.4 104.3 104.4 21 22 23 24 25 26 27 28 29 30 104.4 104.5 104.4 104.3 104.2 104.4 104.6 104.4 104.3 104.1 31 32 33 34 35 36 37 38 39 40 104.4 104.3 104.4 104.7 104.2 104.4 104.3 104.5 104.4 104.3 41 42 43 44 45 46 47 48 49 50 104.6 104.4 104.6 104.7 104.3 104.5 104.2 104.5 104.4 104.3
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Tally Data Sheet

104.1 - // 104.2 - //// 104.3 - //// //// // 104.4 - //// //// //// / 104.5 - //// //// 104.6 - /// 104.7 - //
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Examples of Histogram :
20 16 15 10 5 5 0 104.1 104.2 104.3 104.4 104.5 104.6 104.7 in mm 2 3 2 12 10
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61
Interpretation of Histogram
Minimum Limit
1
Maximum Limit
Minimum Limit
4
Maximum Limit
6 3
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62
Types of Histogram :
a) General type
b) Comb type
c) Positively skew type

d) Lefthand precipice type

Slide No.
63
Types of Histogram :
e) Plateau type
f) Twinpeak type
g) Isolatedpeak type
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Uses of Histogram :
1) To know the pattern of variation.
2) 3) 4) 5) 6) To assess states of control To assess conformance to specifications To assess spread or variation with reference to specification. To assess process capability. To get clues for bringing process under control - whether to shift mean or to reduce variation or both. 7) To get clues for possible assignable causes for observed variation mixture of lots, suppliers, instruments /measurements errors, bias of written results etc.
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65
Stratification
Quality Defective (Nos)
50 40 30 20 10 0
A B C D E
48%
16%
18% 12% 6%
Types of Defect
Slide No.
66
What is Stratification :
Stratification is the process of separation of data into categories. It is normally done for identifying the categories contributing to the problem tackled.
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67
Types of Stratification :
A. Material Based :
48%
50 40
Defective %
30 20 10 0
A B C
16 %
15%
Supplier
Defective Quality - Supplier Wise.

Slide No.
68
B. Quality Based :
Quality Defective(Nos)
50 40 30 20 10 0
A B C D C
48%
16%
18% 12% 6%
Type of Defect
Defects Data For Each Hour in a Shift

Slide No.
69
C. Worker Based :
30
No of Defective
25 20 15 10 5 0
A
22%
5%
3%
B C
Worker
Defective Assemblies
Slide No.
70
D. Machine Based :
100 90 80 70 60 50 40 30 20 10 0
Production %
57% 43%
Machine
Production Machine Wise

Slide No.
71
E. Processing Based :
Power Consumption %
50 40
32%
30 20
25% 12%
26%
10 0
A B C
5%
D E
Process Area
Power Consumption Process Area Wise

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72
Scatter Diagram
4.5 4.4
Overall rating of the Session
4.3 4.2 4.1 4 3.9 3.8 3.7 3.6 3.5 3.4 100 150 200 250 300 350 400 450 500 550 600 650
4.0 y axis 430 x axis
Average Experience of Training Team (in days)
Slide No.
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What is Scatter Diagram :

Scatter diagram is a graphical representation of relationship between two variables. It can be between a Cause and Effect and between causes. In 1837 J.F.W.Herswchal,an Englishman, used scatter diagram. In 1950s Dr.K.Ishikawa popularized the use of scatter diagram.
Slide No.
74
Steps to draw Scatter Diagram :

1) Collect paired data (x,y) 2) Find the maximum and minimum values for both the x and y. 3) Plot the data. 4) Enter all necessary items.
Slide No.
75
The horizontal (x axis) and vertical (y axis) lines of the diagram:
The measurement scales generally increase as you move up the vertical axis and to the right on the horizontal axis.
4.5 4.4 4.3 4.2 4.1 4.0 3.9 3.8 3.7 3.6 3.5 150 200 250 300 350 400 450 500 550 600 650 * Looking for relationships not cause & effect Dependent variable (effect)
Independent variable (cause)
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Examples of Scatter Diagram :

4.5 4.4 4.3 4.2 4.0 y axis 4.1 430 x axis 4 3.9 3.8 3.7 3.6 3.5 3.4 100 150 200 250 300 350 400 450 500 550 600 650
Overall rating of the Session
Average Experience of Training Team (in days)

Slide No.
77
Possibilities after plotting the points

a. Positive relationship b. No correlation. c. Negative correlation. d. Positive and Negative correlation. e. Negative and Positive correlation.
Slide No.
78
n = 30
y 6 4 2 0 0 2 4
r = 0.9
y 6 4 2 0 6 x 0
n = 30
r = 0.6
y 6 4 2 0
n = 30
r = 0.0
Positive Correlation
Positive Correlation May Be Present
No Correlation
n = 30
y 6 4 2 0 0 2 4
r = 0.9
y 6 4 2 0 6 x 0
n = 30
r = 0.6
Negative Correlation
Negative Correlation May Be Present

Slide No.
79
The Journey is Never Ending

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80

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What is Check Sheet ?

Two Types of Data :

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Check sheets are of following types :

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Check Sheet for Production Process Distribution:

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Defective Item Check Sheet:

Date : Section : Inspectors name : Lot no : Order no :

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Defect Location Check Sheet

Defect Location Matrix For Blowholes (50 Defective Components)

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Defect Cause Check Sheet.

oo x Blowhole Poor finish Crack

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Points to remembered while making check sheets

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Benefits of Check Sheets

Right decision can be made.

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0 Cold shut oil shot Damage Chip off Bad app

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What is Pareto Diagram ?

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Steps to make the pareto diagrams :

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Steps to make the pareto diagrams (contd.) :

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Data Tally Sheet - Example -1

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Data Sheet for Pareto Diagram - Example - 2

Cumulative Percentage 52 73 83 88 91 93 100

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Parteo Diagram by Defective Items:

160 140 120 100 80 60 40 20 0 D

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Cause and Effect Diagram

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What is Cause and Effect Diagram ?

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Format of a Cause and Effect Diagram

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