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7 QC Tools
7 Q C Tools                 1
What are 7 QC Tools ?
QC tools are the means for Colleting data ,
analyzing data , identifying root causes and
measuring the results.
THESE TOOLS ARE RELATED TO
Numerical DATA processing

USER HAS TO DEVELOP THE
 SOLUTION & IMPLEMENT
7 Q C Tools                2
7 QC TOOLS
• Pareto Diagram
• Stratification
•Scatter Diagram
•Cause and Effect Diagram
•Histogram
•Check Sheet
•Control Chart/Graph

  7 Q C Tools               3
Application of QC tools in Problem Solving
                       Graphs   Check   Stratifi   Pareto   Cause &       Histogra   Scatter   Control
                                sheet   cation     Diagra   Effect        m          Diagram   Chart
                                                   m        Diagram
Identification of
problem
Defining the
problem
Record of facts

Detecting causes of
problem
Develop
Improvement
method
( Solution )
Implementation

Evaluation of result


Process control
( Standardization )




   7 Q C Tools                                                        4
Pareto Diagram
1. What is Pareto diagram ?
A Pareto diagram is a combination of bar and line graphs of
accumulated data, where data associated with a problem
(e.g., a defect found, mechanical failure, or a complaint
from a customer) are divided into smaller groups by cause
or by phenomenon and sorted, for example, by the number
of occurrences or the amount of money involved. (The
name “Pareto” came from an Italian mathematician who
created the diagram.)




  7 Q C Tools                         5
Pareto Diagram
2. When is it used and what results will be obtained?


  Please refer to the table on next slide for the
  usage and benefits of a Pareto diagram. It is
  mainly used to prioritize matters, and because
  of its easiness of use, the diagram is used in a
  wide variety of fields.




  7 Q C Tools                          6
Pareto Diagram
 Method                    Usage                           Result
                         Used to identify a problem.
                                                          Allows clarification of
        Pareto Diagram
                         Used to identify the cause of   important tasks.
 (No. of Occurrences)    a problem.                       Allows identification of
                         Used to review the effects of   a starting point (which
                         an action to be taken.           task to start with).
                                                          Allows projection of
                         Used to prioritize actions.      the effects of a measure
                         (Used during phases to           to be taken
                         monitor the situation,
                         analyze causes, and review
                         effectiveness of an action.)




      7 Q C Tools                                   7
Pareto Diagram
 Example

 Assessment using Pareto                      Confirmation of Effect
 diagram (prioritization)                     (Comparison)
 To identify a course of
 action to be emphasized                      Frequently used to check
 using a variety of data.                     the effect of an
                                              improvement.
                            Details of “ A”




                                                                Improved




   7 Q C Tools                                    8
Stratification
1. What is Stratification ?


 Stratification means to “divide the whole into smaller portions
 according to certain criteria.” In case of quality control,
 stratification generally means to divide data into several groups
 according to common factors or tendencies (e.g., type of defect
 and cause of defect).
 Dividing into groups “fosters understanding of a situation.” This
 represents the basic principle of quality control.




  7 Q C Tools                             9
Stratification
2. When is it used and what results will be obtained?

 The “common and basic principle” of quality control is
 stratification, i.e., to think a matter out by breaking it
 into smaller portions. Stratification has a number of
 useful purposes. The table below shows only a few
 examples of these purposes.




  7 Q C Tools                          10
Stratification
 Method                     Usage                                Result
Grouping by day,          •Used to observe variations
                                                                •Allows observation
time, place,              among strata.
worker, or                •Used to identify the                 of variations among
process                                                         strata.
                          relationship between cause
                                                                •By performing a
        Number of Units
                          and effect.
                          •Used to identify a purpose           cause analysis using
 X    ★★★★★★★
                                                                the stratified data,
 Y    △△△△                and means to serve the
                                                                the following can be
                          purpose
 Z    ○○○
                          [Used during phases to monitor        accomplished.
                          the situation, analyze causes,       1.Identification and control of a
                          review effectiveness of an action,   problem
                          perform standardization, and         2.“Division of data (obtained by
                          implement a selected control         using each QC tool) into several
                          measure.]                            groups”




     7 Q C Tools                                          11
Stratification
           Item                           Method of Stratification
                          Hour, a.m., p.m., immediately after start of work,
Elapse of time
                          shift, daytime, nighttime, day, week, month
                          Worker, age, male, female, years of experience,
Variations among workers
                          shift, team, newly employed, experienced worker
                          Processing      method,     work    method,    working
Variations   among   work
                          conditions (temperature, pressure, and speed),
methods
                          temperature
Variations among          Measurement          tool,      person      performing
measurement/inspection    measurement, method of measurement, inspector,
methods                   sampling, place of inspection




  7 Q C Tools                                       12
Scatter Diagram
1. What is Scatter Diagram ?


 A scatter diagram is used to “examine the relationship between
 the two, paired, interrelated data types, ” such as “height and
 weight of a person.” A scatter diagram provides a means to
 find whether or not these two data types are interrelated. It is
 also utilized to determine how closely they are related to
 identify a problem point that should be controlled or improved.




  7 Q C Tools                             13
Scatter Diagram
2. When is it used and what results will be obtained?

 The table on next slide shows some examples of
 scatter diagram’s usage. If, for example, there is a
 relationship where “an increase in the number of
 rotations (x) causes an increase in abrasion (y),” there
 exists “positive correlation.” If, on the other hand, the
 existence of a relationship where “an increase in the
 number of rotations (x) causes a decline in abrasion
 (y)” indicates that there is “negative correlation.”




  7 Q C Tools                          14
Scatter Diagram
 Method                                Usage                                Result
                                     •Used to identify a relationship     •Can identify cause
             Scatter Diagram         between two matters.
    yAxis
                                     •Used to identify a relationship     and effect relation.
 Abrasion




                                     between two matters and establish    •Can understand the
                                     countermeasures based on their
                                     cause and effect relation.           relationship
                           x Axis    Example Usage                        between two
               Number of
               Rotations
                                     1.Relationship between thermal       results.
                                     treatment temperature of a steel
                                     material and its tensile strengths
                                     2.Relationship between visit made
                                     by a salesman and volume of sales
                                     3.Relationship between the number
                                     of persons visiting a department
                                     store and volume of sales
                                     4 Others
                                    [Used during phases to monitor the
                                    situation, analyze causes, and
                                    review effectiveness of an action.]

            7 Q C Tools                                              15
Scatter Diagram

                    yAxis
Abrasion (micron)




                                   x Axis
                             Number of
                             Rotations




             7 Q C Tools    16
Cause & Effect Diagram
1. What is Cause & effect Diagram ?
A cause and effect diagram is “a fish-bone diagram that
presents a systematic representation of the relationship
between the effect (result) and affecting factors (causes).”
Solving a problem in a scientific manner requires
clarification of a cause and effect relationship, where the
effect (e.g., the result of work) varies according to factors
(e.g., facilities and machines used, method of work,
workers, and materials and parts used). To obtain a good
work result, we must identify the effects of various factors
and develop measures to improve the result accordingly.


  7 Q C Tools                           17
Cause & Effect Diagram
2. When is it used and what results will be obtained?


  A cause and effect diagram is mainly used to study
  the cause of a certain matter. As mentioned above,
  the use of a cause and effect diagram allows
  clarification of causal relation for efficient problem
  solving. It is also effective in assessing measures
  developed and can be applied to other fields
  according to your needs.




  7 Q C Tools                           18
Cause & Effect Diagram
 Method                                              Usage                               Result
                                                        Used when                     Can obtain a clear
                                                                                       overall picture of causal
 Cause and Effect                                       clarifying a cause             relation. (A change in
 Diagram
  Machine            Man
                                                        and effect                     the cause triggers a
                                                        relationship.[Used             variation in the
                                      Effect


                                                        during a phase to              result.)○ Can clarify
                                                        analyze causes.]               the cause and effect
 Material            Method
                                                                                       relationship.
      Cause (4M’s)                 Result
                              (Controlled State)
                                                         Used to develop
                                                                                       Can list up all causes
                                                        countermeasures.
                                                                                       to identify important
                                                                                       causes.
                                                   [Used during a phase to plan
                                                   countermeasures.]                   Can determine the
                                                                                       direction of action
                                                                                       (countermeasure).




      7 Q C Tools                                                                 19
Cause & Effect Diagram
                        Mechanism of                    Quality of
                        Copying Machine                 Copying Paper
                                  Malfunction of
                                                                         Running out
           Smudges on the         the roller
                                                                         of stock




                                                                                         Many Copying Errors!
           copied surface
                                   Printing too         Too thin
   Internal devices not            lightly
   working smoothly                                                           Dampened
                                                            Folded

                                                 Deterioration of
                                  Error in
                                                 performance due
   Keyboard handling              placement of                            Dirt on the
                                                 to high
   error                          paper (setting                          glass
                                                 temperatures
                                  its face up)                            surface
 Error in selecting a
                                                                         Dust
 scale of reduction                Error in         Nicotine-
                                   selecting        stained
                                   shading
                        User                                    Surrounding
                                                                Environment


   7 Q C Tools                                                  20
Histogram
1. What is Histogram ?


 When creating a histogram, “a range of data is divided into
 smaller sections having a uniform span,and the number of data
 contained in each section (the number of occurrences) is
 counted to develop a frequency distribution table.” Then, “a
 graph is formed from this table by using vertical bars, each
 having the height proportional to the number of occurrences in
 each section.”




  7 Q C Tools                           21
Histogram
2. When is it used and what results will be obtained?

 A histogram is mainly used to analyze a process by
 examining the location of the mean value in the
 graph or degree of variations, to find a problem point
 that needs to be improved. Its other applications are
 listed in the table below.




  7 Q C Tools                          22
Histogram
 Method                              Usage                                Result
                                   •Used to assess the actual
                                   conditions.                           •Can identify the
 Histogram                         •Used to analyze a process to         location of the mean
    Standard
     Range                         identify a problem point that needs   (central) value or
                                   to be improved by finding the         degree of variations.
                                   location of the mean value or         •Can find out the scope
                                   degree of variations in the graph.
                                   •Used to examine that the target      of a defect by inserting
                 X Axis (Values
                    Actually       quality is maintained throughout      standard values.
    Range of
    Variations
                   Measured)
                                   the process.                          •Can identify the
                                   •Others                               condition of
                                  [Used during phases to                 distribution (e.g.,
                                  monitor the situation, analyze         whether there is an
                                  causes, and review                     isolated, extreme
                                  effectiveness of an action.]           value).




  7 Q C Tools                                                      23
Histogram

Frequency Distribution Table                               Standard                       Standard

Cutting Length of Steel Wire]                              Lower Limit                        Upper Limit

                         (Standard: 255± 5 mm)
                                                                                 Product
               Section      Mean   Frequency Marking   Occurrences            Standard Value




                                                                     [Histogram of Cutting Length of Steel
                                                                     Wire]




   7 Q C Tools                                                              24
Check Sheet
1. What is Check sheet ?
A check sheet is “a sheet designed in advance to allow easy
collection and aggregation of data.” By just entering check
marks on a check sheet, data can be collected to extract
necessary information, or a thorough inspection can be
performed in an efficient manner, eliminating a possibility
of skipping any of the required inspection items.
A check sheet is also effective in performing stratification
(categorization).




  7 Q C Tools                           25
Check Sheet
2. When is it used and what results will be obtained?


  Please refer to the table on next slide for the usage
  and benefits of a check sheet. It is frequently used in
  daily business operations, often not specifically for
  QC purposes.




  7 Q C Tools                          26
Check Sheet
 Method                 Usage                               Result
                                                           Ensures collection of
    Check Sheet              Used to collect              required data.
     Day
Process
                             data.                         Allows a thorough
 Process 1

                            Used when                     inspection of all check
 Process 2
                                                           items.
 Process 3
                            performing a
                            thorough                       Can understand
                            inspection.
                     Used during phases to monitor         tendencies and
                     the situation, analyze causes,        variations.
                     review effectiveness of an            Can record required
                     action, perform                       data.
                     standardization, and
                     implement a selected control
                     measure




       7 Q C Tools                                    27
Check Sheet
 A check sheet used to identify defects


              Date
                                               Total
    Defect

    Vertical Scratch



    Scratch


    Dent




  7 Q C Tools                             28
Control Chart (Control Chart / Graph 1)
1. What is Control Chart   ?
A control chart is used to examine a process to see if
it is stable or to maintain the stability of a process.
This method is often used to analyze a process. To
do so, a chart is created from data collected for a
certain period of time, and dots plotted on the chart
are examined to see how they are distributed or if they
are within the established control limit. After some
actions are taken to control and standardize various
factors, this method is also used to examine if a
process is stabilized by these actions, and if so, to
keep the process in a stable state.
  7 Q C Tools                      29
Control Chart
2. When is it used and what results will be obtained?

 There are two types of control charts: one used for
 managerial purposes and the other for analytical
 purposes. A control chart is used to identify dots that
 are outside the control limit, which indicate some
 anomalies in a process.            In addition, seven
 consecutive dots showing values that are below or
 above the mean (central) value, or an increment or a
 decline represented by seven consecutive dots also
 indicate “a problem in a process.”
 We need to examine what has caused such a
 tendency or an increment/decline.


  7 Q C Tools                          30
Control Chart
 Method                            Usage                                                            Result
                              Used to observe a                                               Can identify a change
   Control Chart
                                                                                              caused by elapse of
                              change caused by
                                                                                              time.
                              elapse of time.
                                                                                              Can judge the
                                [Used during phases to
                                                                                              process if it is in its
                                monitor the situation,
                                                                                              normal state or there
   x-R Control Chart            analyze causes, review
                                                                                              are some anomalies
                                effectiveness of an
                                                                                              by examining the dots
                                action, perform
                                                                                              plotted on the chart.
                                standardization, and
                                implement a selected                                       In the example “x bar ” -R
                                                                                           control chart, “X bar”
                                control measure                                            represents the central value,
                                                                                           while “R” indicates the range.
                  Control Chart for Managerial Purposes: Extends the line indicating the control limit used for analytical purposes
                  to plot data obtained daily to keep a process in a good state.
                  Control Chart for Analytical Purposes: Examines a process if it is in a controlled state by collecting data for a certain
                  period of time. If the process is not controlled, a survey is performed to identify its cause and develop
                  countermeasures.



  7 Q C Tools                                                                      31
Control Chart
                             Examples of Values
                             Represented by Dots

                                                   Values above the
                                                   control limit
                                                   represented by
                                                   seven
                                                   consecutive dots



     x- Control Chart
                                                    A decline
                                                    represented by
                                                    seven
                                                    consecutive dots




   Group Number


 7 Q C Tools            32
Graph
1. What is Graph ?


 A graph is “a graphical representation of data, which allows a
 person to understand the meaning of these data at a glance.”
 Unprocessed data simply represent a list of numbers, and
 finding certain tendencies or magnitude of situation from these
 numbers is difficult, sometimes resulting in an interpretational
 error. A graph is a effective means to monitor or judge the
 situation, allowing quick and precise understanding of the
 current or actual situation.
 A graph is a visual and summarized representation of data that
 need to be quickly and precisely conveyed to others.



  7 Q C Tools                             33
Graph
2. When is it used and what results will be obtained?

 A graph, although it is listed as one of the QC tools, is
 commonly used in our daily life and is the most
 familiar means of assessing a situation.




  7 Q C Tools                          34
Graph
  Method                                                       Usage                                Result
120
                                                            Changes in a time-sequential         Can observe changes in
100

 80                                                         order – line graph                   a time-sequential order,
 60                                                  East                                        ratios, and amounts.
 40

 20                                                         Amounts – bar graph, etc.
  0                                                                                              A graphs is the most
      1st Qtr     2nd Qtr    3rd Qtr       4th Qtr

                                                            Ratios – pie graph, band             frequently used tool to
                                                            chart, etc.                          examine the various
                   4th Qtr
                    13%
                               1s t Qtr
                                13%                                                              matters such as those
                                          2nd Qtr
                                           17%
                                                              (The items listed above are        listed on the left.
                                                              representative examples.)
                3rd Qtr
                 57%




        7 Q C Tools                                                                         35
Graph
                                 [Bar Graph of Sales]              [Band Chart of Expenses]
                                 ・Survey Period: Dec. 1999
  (¥million)                                                                                       (¥million)
                                 ・Prepared by: M/T



                                                        Before
Sales




                                                                        Chemicals           Oils    Electricity
                                                        Taking
                                                                          (430)            (200)       (170)
                                                        Actions
                                                                   (Total: ¥8 million)



                                                        After     Chemicals        Oils
                                                        Taking      (240)         (150)
                                                        Actions
                                                                  (Total: ¥4.95 million)

        Sales    Iwate   Tokyo     Osaka    Shizuoka                                               Electricity
        Office                                                                                       (108)




   7 Q C Tools                                                    36
To sum up 7 QC tools (Numerical data ) are used as follow:

 •    Pareto Diagram         To identify the current status and issues
 •    Stratification        Basic processing performed when
                            collecting data
 •    Scatter Diagram        To identify the relationship between two
                            things
 •    Cause and Effect Diagram
                            To identify the cause and effect relationship
 •    Histogram              To see the distribution of data

 •    Check Sheet         To record data collection
 •    Control Chart/Graph To find out abnormalities and identify the
                           current status



     7 Q C Tools                               37
Thank you

7 Q C Tools   38

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7 qc tools training material[1]

  • 1. Training module on 7 QC Tools 7 Q C Tools 1
  • 2. What are 7 QC Tools ? QC tools are the means for Colleting data , analyzing data , identifying root causes and measuring the results. THESE TOOLS ARE RELATED TO Numerical DATA processing USER HAS TO DEVELOP THE SOLUTION & IMPLEMENT 7 Q C Tools 2
  • 3. 7 QC TOOLS • Pareto Diagram • Stratification •Scatter Diagram •Cause and Effect Diagram •Histogram •Check Sheet •Control Chart/Graph 7 Q C Tools 3
  • 4. Application of QC tools in Problem Solving Graphs Check Stratifi Pareto Cause & Histogra Scatter Control sheet cation Diagra Effect m Diagram Chart m Diagram Identification of problem Defining the problem Record of facts Detecting causes of problem Develop Improvement method ( Solution ) Implementation Evaluation of result Process control ( Standardization ) 7 Q C Tools 4
  • 5. Pareto Diagram 1. What is Pareto diagram ? A Pareto diagram is a combination of bar and line graphs of accumulated data, where data associated with a problem (e.g., a defect found, mechanical failure, or a complaint from a customer) are divided into smaller groups by cause or by phenomenon and sorted, for example, by the number of occurrences or the amount of money involved. (The name “Pareto” came from an Italian mathematician who created the diagram.) 7 Q C Tools 5
  • 6. Pareto Diagram 2. When is it used and what results will be obtained? Please refer to the table on next slide for the usage and benefits of a Pareto diagram. It is mainly used to prioritize matters, and because of its easiness of use, the diagram is used in a wide variety of fields. 7 Q C Tools 6
  • 7. Pareto Diagram Method Usage Result Used to identify a problem. Allows clarification of Pareto Diagram Used to identify the cause of important tasks. (No. of Occurrences) a problem. Allows identification of Used to review the effects of a starting point (which an action to be taken. task to start with). Allows projection of Used to prioritize actions. the effects of a measure (Used during phases to to be taken monitor the situation, analyze causes, and review effectiveness of an action.) 7 Q C Tools 7
  • 8. Pareto Diagram Example Assessment using Pareto Confirmation of Effect diagram (prioritization) (Comparison) To identify a course of action to be emphasized Frequently used to check using a variety of data. the effect of an improvement. Details of “ A” Improved 7 Q C Tools 8
  • 9. Stratification 1. What is Stratification ? Stratification means to “divide the whole into smaller portions according to certain criteria.” In case of quality control, stratification generally means to divide data into several groups according to common factors or tendencies (e.g., type of defect and cause of defect). Dividing into groups “fosters understanding of a situation.” This represents the basic principle of quality control. 7 Q C Tools 9
  • 10. Stratification 2. When is it used and what results will be obtained? The “common and basic principle” of quality control is stratification, i.e., to think a matter out by breaking it into smaller portions. Stratification has a number of useful purposes. The table below shows only a few examples of these purposes. 7 Q C Tools 10
  • 11. Stratification Method Usage Result Grouping by day, •Used to observe variations •Allows observation time, place, among strata. worker, or •Used to identify the of variations among process strata. relationship between cause •By performing a Number of Units and effect. •Used to identify a purpose cause analysis using X ★★★★★★★ the stratified data, Y △△△△ and means to serve the the following can be purpose Z ○○○ [Used during phases to monitor accomplished. the situation, analyze causes, 1.Identification and control of a review effectiveness of an action, problem perform standardization, and 2.“Division of data (obtained by implement a selected control using each QC tool) into several measure.] groups” 7 Q C Tools 11
  • 12. Stratification Item Method of Stratification Hour, a.m., p.m., immediately after start of work, Elapse of time shift, daytime, nighttime, day, week, month Worker, age, male, female, years of experience, Variations among workers shift, team, newly employed, experienced worker Processing method, work method, working Variations among work conditions (temperature, pressure, and speed), methods temperature Variations among Measurement tool, person performing measurement/inspection measurement, method of measurement, inspector, methods sampling, place of inspection 7 Q C Tools 12
  • 13. Scatter Diagram 1. What is Scatter Diagram ? A scatter diagram is used to “examine the relationship between the two, paired, interrelated data types, ” such as “height and weight of a person.” A scatter diagram provides a means to find whether or not these two data types are interrelated. It is also utilized to determine how closely they are related to identify a problem point that should be controlled or improved. 7 Q C Tools 13
  • 14. Scatter Diagram 2. When is it used and what results will be obtained? The table on next slide shows some examples of scatter diagram’s usage. If, for example, there is a relationship where “an increase in the number of rotations (x) causes an increase in abrasion (y),” there exists “positive correlation.” If, on the other hand, the existence of a relationship where “an increase in the number of rotations (x) causes a decline in abrasion (y)” indicates that there is “negative correlation.” 7 Q C Tools 14
  • 15. Scatter Diagram Method Usage Result •Used to identify a relationship •Can identify cause Scatter Diagram between two matters. yAxis •Used to identify a relationship and effect relation. Abrasion between two matters and establish •Can understand the countermeasures based on their cause and effect relation. relationship x Axis Example Usage between two Number of Rotations 1.Relationship between thermal results. treatment temperature of a steel material and its tensile strengths 2.Relationship between visit made by a salesman and volume of sales 3.Relationship between the number of persons visiting a department store and volume of sales 4 Others [Used during phases to monitor the situation, analyze causes, and review effectiveness of an action.] 7 Q C Tools 15
  • 16. Scatter Diagram yAxis Abrasion (micron) x Axis Number of Rotations 7 Q C Tools 16
  • 17. Cause & Effect Diagram 1. What is Cause & effect Diagram ? A cause and effect diagram is “a fish-bone diagram that presents a systematic representation of the relationship between the effect (result) and affecting factors (causes).” Solving a problem in a scientific manner requires clarification of a cause and effect relationship, where the effect (e.g., the result of work) varies according to factors (e.g., facilities and machines used, method of work, workers, and materials and parts used). To obtain a good work result, we must identify the effects of various factors and develop measures to improve the result accordingly. 7 Q C Tools 17
  • 18. Cause & Effect Diagram 2. When is it used and what results will be obtained? A cause and effect diagram is mainly used to study the cause of a certain matter. As mentioned above, the use of a cause and effect diagram allows clarification of causal relation for efficient problem solving. It is also effective in assessing measures developed and can be applied to other fields according to your needs. 7 Q C Tools 18
  • 19. Cause & Effect Diagram Method Usage Result Used when Can obtain a clear overall picture of causal Cause and Effect clarifying a cause relation. (A change in Diagram Machine Man and effect the cause triggers a relationship.[Used variation in the Effect during a phase to result.)○ Can clarify analyze causes.] the cause and effect Material Method relationship. Cause (4M’s) Result (Controlled State)  Used to develop Can list up all causes countermeasures. to identify important causes. [Used during a phase to plan countermeasures.] Can determine the direction of action (countermeasure). 7 Q C Tools 19
  • 20. Cause & Effect Diagram Mechanism of Quality of Copying Machine Copying Paper Malfunction of Running out Smudges on the the roller of stock Many Copying Errors! copied surface Printing too Too thin Internal devices not lightly working smoothly Dampened Folded Deterioration of Error in performance due Keyboard handling placement of Dirt on the to high error paper (setting glass temperatures its face up) surface Error in selecting a Dust scale of reduction Error in Nicotine- selecting stained shading User Surrounding Environment 7 Q C Tools 20
  • 21. Histogram 1. What is Histogram ? When creating a histogram, “a range of data is divided into smaller sections having a uniform span,and the number of data contained in each section (the number of occurrences) is counted to develop a frequency distribution table.” Then, “a graph is formed from this table by using vertical bars, each having the height proportional to the number of occurrences in each section.” 7 Q C Tools 21
  • 22. Histogram 2. When is it used and what results will be obtained? A histogram is mainly used to analyze a process by examining the location of the mean value in the graph or degree of variations, to find a problem point that needs to be improved. Its other applications are listed in the table below. 7 Q C Tools 22
  • 23. Histogram Method Usage Result •Used to assess the actual conditions. •Can identify the Histogram •Used to analyze a process to location of the mean Standard Range identify a problem point that needs (central) value or to be improved by finding the degree of variations. location of the mean value or •Can find out the scope degree of variations in the graph. •Used to examine that the target of a defect by inserting X Axis (Values Actually quality is maintained throughout standard values. Range of Variations Measured) the process. •Can identify the •Others condition of [Used during phases to distribution (e.g., monitor the situation, analyze whether there is an causes, and review isolated, extreme effectiveness of an action.] value). 7 Q C Tools 23
  • 24. Histogram Frequency Distribution Table Standard Standard Cutting Length of Steel Wire] Lower Limit Upper Limit (Standard: 255± 5 mm) Product Section Mean Frequency Marking Occurrences Standard Value [Histogram of Cutting Length of Steel Wire] 7 Q C Tools 24
  • 25. Check Sheet 1. What is Check sheet ? A check sheet is “a sheet designed in advance to allow easy collection and aggregation of data.” By just entering check marks on a check sheet, data can be collected to extract necessary information, or a thorough inspection can be performed in an efficient manner, eliminating a possibility of skipping any of the required inspection items. A check sheet is also effective in performing stratification (categorization). 7 Q C Tools 25
  • 26. Check Sheet 2. When is it used and what results will be obtained? Please refer to the table on next slide for the usage and benefits of a check sheet. It is frequently used in daily business operations, often not specifically for QC purposes. 7 Q C Tools 26
  • 27. Check Sheet Method Usage Result Ensures collection of Check Sheet Used to collect required data. Day Process data. Allows a thorough Process 1 Used when inspection of all check Process 2 items. Process 3 performing a thorough Can understand inspection. Used during phases to monitor tendencies and the situation, analyze causes, variations. review effectiveness of an Can record required action, perform data. standardization, and implement a selected control measure 7 Q C Tools 27
  • 28. Check Sheet A check sheet used to identify defects Date Total Defect Vertical Scratch Scratch Dent 7 Q C Tools 28
  • 29. Control Chart (Control Chart / Graph 1) 1. What is Control Chart ? A control chart is used to examine a process to see if it is stable or to maintain the stability of a process. This method is often used to analyze a process. To do so, a chart is created from data collected for a certain period of time, and dots plotted on the chart are examined to see how they are distributed or if they are within the established control limit. After some actions are taken to control and standardize various factors, this method is also used to examine if a process is stabilized by these actions, and if so, to keep the process in a stable state. 7 Q C Tools 29
  • 30. Control Chart 2. When is it used and what results will be obtained? There are two types of control charts: one used for managerial purposes and the other for analytical purposes. A control chart is used to identify dots that are outside the control limit, which indicate some anomalies in a process. In addition, seven consecutive dots showing values that are below or above the mean (central) value, or an increment or a decline represented by seven consecutive dots also indicate “a problem in a process.” We need to examine what has caused such a tendency or an increment/decline. 7 Q C Tools 30
  • 31. Control Chart Method Usage Result Used to observe a Can identify a change Control Chart caused by elapse of change caused by time. elapse of time. Can judge the [Used during phases to process if it is in its monitor the situation, normal state or there x-R Control Chart analyze causes, review are some anomalies effectiveness of an by examining the dots action, perform plotted on the chart. standardization, and implement a selected In the example “x bar ” -R control chart, “X bar” control measure represents the central value, while “R” indicates the range. Control Chart for Managerial Purposes: Extends the line indicating the control limit used for analytical purposes to plot data obtained daily to keep a process in a good state. Control Chart for Analytical Purposes: Examines a process if it is in a controlled state by collecting data for a certain period of time. If the process is not controlled, a survey is performed to identify its cause and develop countermeasures. 7 Q C Tools 31
  • 32. Control Chart Examples of Values Represented by Dots Values above the control limit represented by seven consecutive dots x- Control Chart A decline represented by seven consecutive dots Group Number 7 Q C Tools 32
  • 33. Graph 1. What is Graph ? A graph is “a graphical representation of data, which allows a person to understand the meaning of these data at a glance.” Unprocessed data simply represent a list of numbers, and finding certain tendencies or magnitude of situation from these numbers is difficult, sometimes resulting in an interpretational error. A graph is a effective means to monitor or judge the situation, allowing quick and precise understanding of the current or actual situation. A graph is a visual and summarized representation of data that need to be quickly and precisely conveyed to others. 7 Q C Tools 33
  • 34. Graph 2. When is it used and what results will be obtained? A graph, although it is listed as one of the QC tools, is commonly used in our daily life and is the most familiar means of assessing a situation. 7 Q C Tools 34
  • 35. Graph Method Usage Result 120 Changes in a time-sequential Can observe changes in 100 80 order – line graph a time-sequential order, 60 East ratios, and amounts. 40 20 Amounts – bar graph, etc. 0 A graphs is the most 1st Qtr 2nd Qtr 3rd Qtr 4th Qtr Ratios – pie graph, band frequently used tool to chart, etc. examine the various 4th Qtr 13% 1s t Qtr 13% matters such as those 2nd Qtr 17% (The items listed above are listed on the left. representative examples.) 3rd Qtr 57% 7 Q C Tools 35
  • 36. Graph [Bar Graph of Sales] [Band Chart of Expenses] ・Survey Period: Dec. 1999 (¥million) (¥million) ・Prepared by: M/T Before Sales Chemicals Oils Electricity Taking (430) (200) (170) Actions (Total: ¥8 million) After Chemicals Oils Taking (240) (150) Actions (Total: ¥4.95 million) Sales Iwate Tokyo Osaka Shizuoka Electricity Office (108) 7 Q C Tools 36
  • 37. To sum up 7 QC tools (Numerical data ) are used as follow: • Pareto Diagram To identify the current status and issues • Stratification Basic processing performed when collecting data • Scatter Diagram To identify the relationship between two things • Cause and Effect Diagram To identify the cause and effect relationship • Histogram To see the distribution of data • Check Sheet To record data collection • Control Chart/Graph To find out abnormalities and identify the current status 7 Q C Tools 37
  • 38. Thank you 7 Q C Tools 38