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2008
UDC 658.5 Paper accepted: 00.00.200x
If organizations wish to achieve continuous quality improvement they need to use appropriate
selection of quality tools and techniques. In this paper a review of possibilities of the systematic use of
seven basic quality tools (7QC tools) is presented. It is shown that 7QC tools can be used in all process
phases, from the beginning of a product development up to management of a production process and
delivery. It is further shown how to involve 7QC tools in some phases of continuous improvement process
(PDCA-cycle), Six Sigma (DMAIC) and Design for Six Sigma (DMADV) methodologies, and Lean Six
Sigma.
2009 Journal of Mechanical Engineering. All rights reserved.
Keywords: DMAIC, improvement processes, quality tools, Six Sigma, PDCA, 7QC tools, DMADV
*
Corr. Author's Address: University of Ljubljana, Faculty of Mechanical Engineering, Akereva 6, SI-1000
1
Ljubljana, Slovenia, mirko.sokovic@fs.uni-lj.si
Strojniki vestnik - Journal of Mechanical Engineering 55(2009)5, StartPage-EndPage
Analysis
Identification
Histogram
Pareto diagram
Flow chart
Control chart
Cause and effect diagram
Check sheet Scatter plot
Pareto diagram
Histogram
Data
Data Analysis
Acquisitions Analyses
End
Control chart
Is corr. Condemnation
possible? Records
End
Correction
2 7QC TOOLS THROUGH PDCA-CYCLE dynamic model because one cycle represents one
complete step of improvement.
In successful application of quality tools The PDCA-cycle is used to coordinate
an implemented quality management system is an continuous improvement efforts. It emphasizes
advantage. The quality management principles and demonstrates that improvement programs
are a starting point for the companys must start with careful planning, must result in
management striving for continuous efficiency effective action, and must move on again to
improvement over a long period of time and careful planning in a continuous cycle the
customer satisfaction. A quality management Demings quality cycle is never-ending. It is a
system is based on the integrity of all production strategy used to achieve breakthrough
and support resources of a certain company. It improvements in safety, quality, morale, delivery
enables a faultless process flow in meeting related cost, and other critical business objectives.
contracts, standards and market quality
requirements. Implementation of a quality
management system is always a part of a
companys development process, Fig. 3 [6].
Having a quality management system in
place is a prerequisite for its successful
application on a day-to-day basis. The
management has to show commitment to
development and improvement of a quality
management system. Through a quality
management system the companys leadership
implements their quality policy. Furthermore, a
quality management system has to be well Fig. 4. PDCA-cycle
documented. When in function, the quality
management system provides useful information The completion of one cycle continues
obtained by different process analyses and audits. with the beginning of the next. A PDCA-cycle
If a companys focus is on the customer, the consists of four consecutive steps or phases, as
company has to select the most efficient ways of follows:
data acquisition and market survey to confirm Plan - analysis of what needs to be
that the companys products or services meet improved by taking into consideration
customer demands and expectations. The areas that hold opportunities for change.
gathered information is invaluable in the decision Decision on what should be changed.
making process based on fact. Data collection and Do - implementation of the changes that
analysis is also significant in defining are decided on in the Plan step.
opportunities for further processes and product Check - Control and measurement of
quality improvement. processes and products in accordance to
Continuous improvement as a fifth changes made in previous steps and in
principle of QMS (ISO 9001:2000) could not be accordance with policy, goals and
realized without quality tools which are presented requirements on products. Report on
through four groups of activities of Demings results.
quality cycle or PDCA-cycle, shown in Fig. 4 [6]. Act - Adoption or reaction to the changes
The PDCA-cycle is an integral part of process or running the PDCA-cycle through again.
management and is designed to be used as a Keeping improvement on-going.
Table 1. Seven basic quality tools (7QC tools) in correlation with PDCA-cycle steps
Steps of PDCA-cycle
Seven basic
quality tools Plan Do Plan, Check Plan, Act Check
(7QC tools) Problem Implement Solutions Result
Process analysis
identification solutions development evaluation
Flow chart 9 9
Cause-and- 9 9
effect diagram
Check sheet 9 9 9
Pareto diagram 9 9 9
Histogram 9 9
Scatter plot 9 9 9
Control charts 9 9 9
The main purpose of PDCA-cycle 3 7QC TOOLS IN SIX SIGMA
application lies in process improvement [7].
When process improvement starts with careful Six Sigma is an organization-wide approach
planning, it results in corrective and preventive used to specify exactly how organization managers
actions supported by appropriate quality set up and achieve objectives. It demonstrates how
assurance tools which lead to true process breakthrough improvements tied to significant
improvement. The application of the seven basic bottom-line results can be achieved [10].
quality tools in correlation with four steps of The Six Sigma methodology goes beyond the
PDCA-cycle is shown in Table 1 [8]. improvement process and tools because it requires
As shown in Table 1, most of the 7QC tools an intelligent use of data, emphasis of statistical
can be used for problem identification: Flow chart, analysis and designed experiments.
Cause-and-Effect diagram, Check sheet, Pareto Six Sigma prescribes an improvement process
diagram, Histogram and Control charts. For known as DMAIC methodology [3]:
problem analysis the following tools can be used: Define - improvement of project goals, goals
Cause-and-Effect diagram, Check sheet, Pareto based on customer needs and wants
diagram, Scatter plot and Control charts. When a Measure - current process and establish
team is developing a solution for the analyzed
metrics to monitor the path to achievement
problem, Flow chart and Scatter plot can be useful
as well. In the phase of achieved results evaluation, of goals
most of 7QC tools can also be successfully Analyze - current process to understand
implemented: Check sheet, Pareto diagram, problems and their causes
Histogram, Scatter plot and Control charts. Improve - process by identifying and piloting
For effective and successful team work in solutions to problems
solving daily quality problems, we propose a simple Control - improved process with
model for systematic usage of "basic quality tools" standardization and ongoing monitoring.
for process monitoring, data acquisition and quality
Each of these processes (phases) can be
improvement, Fig. 5 [6] and [9].
realized with different quality tools and
Loop 1 focuses on the analysis of the biggest
techniques (also 7QC) while some tools can be
causes for defects which are found by Pareto
diagram, and Loop 2 focuses on continuous process used in more than one processes (phases). One
improvement, which is one of the eight QMS possible classification (use) of different quality
principles. The implementation of this principle is a tools and techniques in the Six Sigma
big stride forward which a company can take in methodology, proposed by the authors is
order to change their static quality management to a presented in Fig. 6 [9].
dynamic one.
Fig. 5. Seven basic quality tools (7QC tools) for quality improvement
In Fig. 6 the tools which are used in all proponents of DFSS are promoting it as a holistic
phases of DMAIC methodology are presented. approach of Re-engineering. It is also known as the
Below each phase of DMAIC the main tools for application of Six Sigma techniques to the
each process are presented. Lower still the tools development process. DFSS is centred on designing
which are not essential for that process but can a new product and services while Six Sigma is
also be used (Additional tools) are shown. It can primary a process improvement methodology. The
be seen that, except the Improve phase, the processes often used in practice in DFSS are called
Analysis and Control phases have one or more DMADV (define, measure, analyze, design, verify)
QC tools. or IDOV (identify, design, optimise and validate).
For the development of a new product or a The first phase in DMAIC and DMADV (or IDOV)
process which focuses on "problem prevention" is the same (define the goals of the activities) but
there is a modified version of Six Sigma called after that processes go in different ways. If a process
Design for Six Sigma (DFSS). The fundamental exists then you go by the DMAIC way and if not,
characteristic of DFSS is the verification which you follow the DMADV [11].
makes it different from Six Sigma but the
IPO diagram Check sheets Process mapping Affinity diagram Gant chart
SIPOC diagram Histograms Regression Nominal group Activity network
Flow diagram Run charts analysis technique diagram
CTQ tree Scatter diagrams RU/CS analysis SMED Radar chart
Project charter Cause and effect SWOT analysis Five S PDCA cycle
diagrams PESTLE analysis Mistake proofing Milestone tracker
Pareto diagrams Five whys Value stream diagram
Control charts Interrelationship mapping Earned value
Flow charts diagram Brainstorming management
Process capability OEE Mind mapping
measurement
In Table 2 a possible inclusion of 7QC tools These approaches are different and definitely
in three methodologies is presented: continuous need a deeper analysis but it is evident that 7QC
improvement PDCA-cycle, Six Sigma and Design tools have a big role in all the key phases of these
for Six Sigma [12]. In different phases of the methodologies.
processes various tools can be taken while some
phases like (Plan for the future in PDCA-cycle) need 4 7QC TOOLS IN LEAN SIX SIGMA
some other management, planning or other tools and
techniques. Lean Six Sigma are a set of methods that
In this approach (Table 2) it is also shown companies can apply to any manufacturing,
that in the Improve phase of DMAIC two basic transactional or service process to reduce waste,
quality tools (Control chart and Pareto diagram) eliminate non-value-added actions and cut time.
could be used while in Fig. 6 this phase does not Combining "Lean" with "Six Sigma" can produce
contain any basic tools. On the other hand, in the a program that brings both short-term results
Define phase of DMAIC methodology, Fig 6, there through the power of Lean, and long-term change
is one basic quality tool (Flow diagram) whereas in through the power of Six Sigma. It is for this
Table 2 the Define column is empty. reason that many companies are turning to a
When comparing the inclusion of 7QC tools combined Lean and Six Sigma effort.
in PDCA methodology in Tables 1 and 2 it can be Lean means speed and quick action
seen that the authors in both references [8,12] (reducing unneeded waiting time).
consider that not a single basic quality tool could be Six Sigma means identifying defects and
involved in the process which means realization (Do eliminating them.
or Implement Solutions). Lean Six Sigma Engineering means best-
in-class [13] and [14]. It creates value in
the organization to benefit its customers
and saves money without capital work and the elimination of waste. Once Lean
investment. techniques eliminate much of the noise from a
Both, the Lean and the Six Sigma process, Six Sigma offers a sequential problem-
methodologies have proven over the last twenty solving procedure, the DMAIC cycle, and
years that dramatic improvements in cost, quality, statistical tools so that potential causes are not
and time can be achieved by focusing on process overlooked and viable solutions to chronic
performance. Most practitioners consider these problems can be discovered [14].
two methods as complementing each other to One may obtain Lean Six Sigma training
achieve world class performance (WCP). certification by completing the improvement
Bringing the two concepts together model for Lean Six Sigma Black Belt. This
delivers faster results by establishing baseline training is available at academic institutions, as
performance levels and focusing on the use of well as quality societies or other certified
statistical tools where they will have the most organizations. The preceding steps with quality
impact. Most companies using both tools (also 7QC tools) and techniques for Lean
methodologies began by applying basic Lean - Six Sigma Black Belt are shown in Fig. 7 below
manufacturing techniques - the 5Ss, standardized [13].
Implement solutions
Analyze the process
Tools and
Evaluate results
techniques
Measure
Measure
Improve
Analyze
Analyze
Control
Design
Define
Define
Verify
7 QC tools
Cause-and-Effect x x X
diagram
Control chart x X x x x x x
Check sheet x x
Histogram x x x
Pareto diagram X x x x X x
Scatter diagram x X x x X
Flowchart
Deployment x x x x x
flowchart
Linear or x x x x x
activity
flowchart
Opportunity x x x x
flowchart
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