Scribd Logo
Upload

Welcome to Scribd!

  • 1K views

    Problem Solving Basic 7 QC Tools

    Uploaded by

    shukumar_24
    The document provides an overview of 7 quality control tools that can be used for problem solving. It describes the tools as follows: 1) Check sheets, pareto charts, graphs/flowcharts, cause and effect diagrams, histograms, scatter plots, and control charts make up the basic 7 QC tools. 2) Each tool is designed for a specific purpose like collecting data, identifying causes, relationships between factors, and detecting abnormal trends. 3) Examples are given for each tool to illustrate how they are constructed and interpreted for problem solving. Check sheets collect defect data while pareto charts identify the most important causes to focus on.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd

    Problem Solving Basic 7 QC Tools

    Uploaded by

    shukumar_24
    1K views53 pages
    The document provides an overview of 7 quality control tools that can be used for problem solving. It describes the tools as follows: 1) Check sheets, pareto charts, graphs/flowcharts, cause and effect diagrams, histograms, scatter plots, and control charts make up the basic 7 QC tools. 2) Each tool is designed for a specific purpose like collecting data, identifying causes, relationships between factors, and detecting abnormal trends. 3) Examples are given for each tool to illustrate how they are constructed and interpreted for problem solving. Check sheets collect defect data while pareto charts identify the most important causes to focus on.

    Original Description:

    Basic 7 QC Problem solving tools

    Copyright

    © Attribution Non-Commercial (BY-NC)

    Available Formats

    PPT, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document provides an overview of 7 quality control tools that can be used for problem solving. It describes the tools as follows: 1) Check sheets, pareto charts, graphs/flowcharts, cause and effect diagrams, histograms, scatter plots, and control charts make up the basic 7 QC tools. 2) Each tool is designed for a specific purpose like collecting data, identifying causes, relationships between factors, and detecting abnormal trends. 3) Examples are given for each tool to illustrate how they are constructed and interpreted for problem solving. Check sheets collect defect data while pareto charts identify the most important causes to focus on.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    1K views53 pages

    Problem Solving Basic 7 QC Tools

    Uploaded by

    shukumar_24
    The document provides an overview of 7 quality control tools that can be used for problem solving. It describes the tools as follows: 1) Check sheets, pareto charts, graphs/flowcharts, cause and effect diagrams, histograms, scatter plots, and control charts make up the basic 7 QC tools. 2) Each tool is designed for a specific purpose like collecting data, identifying causes, relationships between factors, and detecting abnormal trends. 3) Examples are given for each tool to illustrate how they are constructed and interpreted for problem solving. Check sheets collect defect data while pareto charts identify the most important causes to focus on.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 53

    Problem Solving Basic 7QC Tools

    What are 7 QC Tools ?


    QC tools are the means for Colleting data , analyzing data , identifying root causes and measuring the results.
    Tools are used to identify , analyze and resolve Problems

    Problem Solving Tools

    1. Simple Tools for Problem Analysis


    1 Why -Why Analysis ( For Corrective action) 2 What If Analysis ( For Potential Problems)

    2 Simple 7 QC Tools (Statistical Tools)


    Check Sheets Pareto Analysis Graph / Flowcharts Cause & Effect Diagram Histograms Scatter Plots Control Charts

    Problem Solving Tools

    What is a Problem ?
    Problem is an undesirable event or ..

    Any Gap between what is expected and what is obtained , can be called as a Problem, and any effort to reduce this gap can be called as
    Problem Solving

    Expected

    Ideal situation / Objective

    (Gap ?) A Problem!

    Present Level
    Obtained

    What is PROBLEM ?
    Example : Objective of machining Throttle body Boring operation Bore Dia 40 + 0.025 mm
    - Actual 39.992 mm

    Objective 40+0.025mm
    Gap = 0.008 mm Actual = 39.992 mm

    Problem Solving Tools


    Four types of Problems

    Problem Solving Tools

    Why - of Problem Solving Tools Library Why analysis - An Example


    Purpose : It is the simple tool used by the team /observer to find out the cause of the problem/Accident/ Breakdown at the Workplace.
    Many times, the root cause of the problem can be identified by asking Why 5 times and the repetition of such problems can be prevented by taking countermeasure immediately.

    Problem Solving Tools

    Why - of Problem Solving Tools Library Why analysis - An Example


    Water Dripping in Substation 1 WHY ? Water accumulated at the roof WHY ? Outlet drain chocked WHY ? Atmospheric dust & dirt WHY ? Periodic cleaning of drain not done

    Action

    Proper scheduled procedure for roof cleaning is to be prepared

    Problem Solving Tools

    What-If Problem Library ofAnalysis Solving Tools


    Purpose : It is the simple Pro active tool used by the team / observer, to identify problems before hand and take appropriate counter measures to prevent such problems .

    Problem Solving Tools

    What-If Problem An Example Library ofAnalysis -Solving Tools


    Area : Team :
    SL. What If Results

    Equipment :Compressor

    Countermeasures

    1. There is no Water in the Radiator of an Automobile ? And it is not noticed.

    The Engine heats up and Piston may get seized.

    Inspect the Temperature of outlet water . Provide the temp. Indictor for the driver

    Check Sheets

    What are the Basic Seven QC Tools ?

    Pareto Analysis Graph / Flowcharts

    Cause & Effect Diagram


    Histograms Scatter Plots

    Control Charts

    What is Check sheet :


    A Check sheet is a paper form on which items to be checked have been printed. Purpose : To collect the data

    What is Check sheet :


    Shown a check sheet of molded Component
    Defective Item check sheet
    Part Name: Part No. Total No. inspected Manifold B E178012 780 Date: Lot No. Inspector Name 29/01/2011 Y129 Ahbay

    Sr No. 1 2 3 4

    Check Point Flow Mark Crack Flashes Shrinkage

    Standard Not allowed Not allowed Not allowed Not allowed Total Defects Total Rejects

    Defect (Nos.) 10 4 9 17 40 30

    What is Check sheet :


    Shown a check sheet of molded Component
    Defective Item check sheet
    Part Name: Part No. Total No. inspected Manifold B E178012 780 Date: Lot No. Inspector Name 29/01/2011 Y129 Ahbay

    Sr No. 1 2 3 4

    Check Point Flow Mark Crack Flashes Shrinkage

    Standard Not allowed Not allowed Not allowed Not allowed Total Defects Total Rejects

    Defect (Nos.) 10 4 9 17 40 30

    What is Check sheet :


    Another example
    Daily Assy . Check Sheet
    Part Name: Part No. Total No. inspected Throttle Body assy. 13400 M 67LA0 240 Date: Lot No. Checking Freq. 29/01/2011 C1114 1 / 240

    Sr No. 1 2 3 4

    Check Point Air leak Water leak TPS output ID setting

    Standard 6.4 Kpa max 68 Pa max 80015 mV 61.3~72.5 Kpa Checked by

    Observation 0.2 18 802 66.4 Yoginder

    Purpose of Check Sheet


    Variation in the Quality Characteristics of a Process Applicable for Histogram , Control Chart. Difference between Groups / Machines Applicable for Pareto Diagram. Relation between two characteristics Applicable for Scatter Diagram

    PARETO DIAGRAM
    Pareto is combination of Column & Line graph.

    Purpose : To prioritize major contributing problem

    from others which is less contributing.

    PARETO DIAGRAM
    Invented by Vilfredo Pareto (1848-1923) Italian economist. - 20 % of the population has 80 % of wealth

    Juran 20 % of quality problem caused 80 % of the dollar loss.

    PRINCIPLE OF PARETO
    80-20 Principle
    80 % improvement can be achieved by working on

    20 % of the causes.

    PARETO DIAGRAM
    Monthly Rejection Data
    S. No. Type of Defect No. of defects
    150 90 30 20 7 3

    Cumulative % of overall of Overall Cumulative % total total


    150 240 270 290 297 300 50 30 10 7 2 1 50 80 90 97 99 100

    1 2 3 4 5 6

    Axial Torque Air Leak Left side Clearance Th. Body tight Blow hole Dent

    Total

    300

    100

    PARETO DIAGRAM
    300
    90

    100 97
    99

    100

    90 80 70

    250

    80

    200 50

    60 50

    150 150 100

    40
    30

    90
    20

    50
    10

    30 0 Axial Torque Air Leak Left side Clearance

    20 Th. Body tight

    7 Blow hole

    0 Dent

    PARETO DIAGRAM
    80 % of rejection can be reduced on taking action on

    Axial torque & Air Leak.

    What is defective : A unit that contains at least one defect.


    What is defect : Output of a process that does not meet a defined specification.

    FLOW CHARTS / GRAPHS


    Flow Charts: A Tool that graphically represents the steps of a process
    Purpose :- In which process that Problem occurred

    GRAPHS
    It is pictorial view of data presentation Purpose : Instance Information
    Type of Graph. Line Graph Bar Graph Pie Chart Radar Chart

    LINE GRAPH
    It is used to monitor the trend of process.
    12.015 12.014 12.012

    12.009 12.008 12.007 12.006

    12.009 12.007

    12.005
    12.003 12.001 12 12.01.11 13.01.11 14.01.11 15.01.11 16.01.11 17.01.11 18.01.11

    BAR GRAPH
    It is used to compare with other.
    800 700 600 500 400 300 200 200 300 700

    100 0
    Th. Body Assy. Carburator

    50

    Machining

    PIM

    PIE CHART
    It is used to show share/contribution

    14

    10

    Congress BJP 52 24 JDU

    BSP

    RADAR CHART
    It is used to total sharp image as a composite graph

    CAUSE & EFFECT DIAGRAM


    It shows the relationship between problem & its

    possible cause

    Developed by Kaoru Ishikawa (1953) Also known as o Fishbone Diagram o Ishikawa Diagram

    METHODOLOGY
    Step 1: Identify All Possible causes

    Step 2: Identify Potentional / Suspect causes

    Step 3: Validate the all Potential cause

    Step 4: Root Cause

    CAUSE & EFFECT


    Cause are divided into four major sources:
    MAN MATERIAL METHOD MACHINE

    EFFECT- OUTCOME OF CAUSES

    STEP 1: IDENTIFY PROBABLE CAUSES

    MAN

    MATERIAL

    EFFECT

    METHOD

    MACHINE

    STEP 2: IDETIFY THE POTENETIONAL CAUSE

    MAN

    MATERIAL

    EFFECT

    METHOD

    MACHINE

    STEP 3 : VADILATE THE CAUSE

    Sr. No

    Potentional Cause

    Validation Conclusion

    STEP 4 : ROOT CAUSE


    Why-Why Analysis
    Why 1 Why bracket welding broken Because it was not welded properly

    Why 2

    Why not welded properly

    Because welding jig was loose

    Why 3

    Why welding jig was loose

    Because Welding jig worn

    Why 4

    Why Welding jig worn

    Welding Jig life not defined.

    Why 5

    STEP 4 : ROOT CAUSE


    Why-Why analysis of two type:
    For Occurrence : Why defect generated in process

    For Outflow: Why defect pass to customer.

    Histograms
    PLOTTING THE SHAPE OF A

    DISTRIBUTION COMPARING THE DISTRIBUTION WITH SPECIFICATIONS USEFUL FOR QUALITY, COST AND DELIVERY IMPROVEMENT USEFUL FOR PROCESS CONTROL

    Histograms
    Histogram
    USL

    LSL Frequ ency

    Diameter

    Constructing a Histogram
    Use range to estimate beginning and end
    Calculate the width of each column by dividing the

    range by the number of columns

    Range
    = Width

    # of Columns

    SCATTER DIAGRAM
    A graphical technique to shows the dependency of two variables / factor
    For example : what extent surface finish of machined part varied by changing the speed of lathe.

    SCATTER DIAGRAM
    Data collect for speed & Surface finish
    Speed of lathe (RPM)
    700 Surface finish (Ra) 3.3 3.0

    Cause

    800

    900
    1000 1100 1200

    2.7
    2.4 2.1 1.8

    Effect

    1300
    1400 1500

    1.5
    1.2 0.9

    SCATTER DIAGRAM
    Surface finish (Ra)
    3.5

    3.0

    2.5

    2.0

    Output / Effect

    1.5

    1.0

    0.5

    0.0 600 800 1000 1200 1400 1600 1800

    Causes

    RULE FOR SCATTER DIAGRAM


    There should be minimum 30 readings N=30 to check dependency.
    Positive Scatter Diagram:
    21

    18

    15 30 40 50 60 70

    Negative Scatter Diagram:

    21 20 19 18 17 16 15 30 40 50 60

    SCATTER DIAGRAM
    Speed of car Km/Hr
    30 35

    Mileage Km/Ltr
    15 16

    40
    45 50 55 60 65 70 75 80 85 90 95

    17
    18 19 20 21 20 19 18 17 16 15 14

    SCATTER DIAGRAM
    22
    21 20 19 18 17 16 15 16 18 20 20 19 18 17 16 15

    14

    14

    12 20 40 60 80 100

    CONTROL CHARTS
    Control charts is used to detect the abnormal trends with the help of line graphs.
    Invented by Dr. W.A. Shewhart

    CONTROL CHARTS
    Variable Chart :a)Average & Range Chart b)Median & Range Chart
    Attribute Chart : a)P & np Chart b)c & u Chart

    CONTROL CHARTS
    X bar Chart : It shows the centering of the process.
    R bar Chart : It shows the variation between the subgroup size.

    CONTROL CHARTS
    Diameter of Shaft :- 230.2 No. of Subgroup (N)= 10 Subgroup size = 5

    CONTROL CHARTS
    X =(X1+X2+X3+X4+.+X10)/N R=(R1+R2+R3+R4+..+R10)/N Control Limit Xbar UCLx= X + A2 R = LCLx= X - A2 R Control Limit R bar UCLr= D4 R LCLr= D3 R Where D4,D3 & A2 are constant

    Application of QC tools in Problem Solving


    Graphs / Flow Charts Identification of problem Defining the problem Record of facts Detecting causes of problem Develop Improvement method ( Solution ) Implementation Evaluation of result Process control ( Standardization ) Check sheet Pareto Diagra m Cause & Effect Diagram Histogr am Scatter Diagram Control Chart

    Relation :Strong Normal

    52

    Thank You !!!

    You might also like