7 QC TOOLS

Q7T/PPT- 1

Slide : 1

Lets do an exercise!

You have to cut down your

house expenditure by 20% per month

How will you do it ?
Q7T/PPT- 2

Slide : 2

Objective

OBJECTIVE:
After the completion of this training programme:
You will be able to choose the appropriate QC tool to solve
problems in your work area.

Q7T/PPT- 3

Slide : 3

Types

7QC tools
Check Sheet

Pareto Diagram
Cause & Effect diagram

7 QC Tools

Graph &Control charts

Histogram
Flow chart
Scatter Diagram

Q7T/PPT- 4

Slide : 4

Check sheet

Check sheet

Q7T/PPT- 5

Slide : 5

Check sheet

What is a check sheet?

Why is a check sheet necessary?

Q7T/PPT- 6

Slide : 6

Check sheet

Example:

Q7T/PPT- 7

Slide : 7

Check sheet

Check sheet
Check sheets are forms used for

checking results of work

verifying and collecting data

Q7T/PPT- 8

Slide : 8

Check sheet

Types of Check Sheet

Discrete value such as no. Of
recording errors, no. of Item sold
& Rejections etc.

Indiscrete value such as height,

weight, length, time & temp., Etc.

Measured
Data

Point Scale
Data

1 Point, 2 Point
etc.

Counted
Data

Check
Sheet
Ordered
Data

Primary
Data

YES / NO or
/ X - Type

1st, 2nd Order

Very Good, Good, No Good
- Type
Q7T/PPT- 9

Slide : 9

Check sheet

Check points for check sheets preparation

Below items can be added , as necessary
1. The purpose of the checks

2. The items being checked

3. The methods of the checks

4. The dates and times of the checks

5. The person to perform the checks
6. The results
Q7T/PPT- 10

Slide : 10

Check sheet

Example of check sheet

Defect check sheet
Month ,day
Component

4/1

1
2
3
4
5
6
7
8
9
10

No. of
defects
Q7T/PPT- 11

Slide : 11

Check sheet

Make a check list of all the expenses

in your home & the amount you
spend on these expenses

Q7T/PPT- 12

Slide : 12

Check sheet

Sl.No

Q7T/PPT- 13

Expense

Amount

House Rent

1500

Electricity & Water Bill

250

Cable TV Bill

150

News paper bill

100

Milk

400

Maid servant

150

Groceries

2000

Entertainment & Lifestyle

200

Travel

200

10

Educational

1000

11

Hospital

200

12

Loan repayment

1000

13

Clothes

200

14

Petrol

300

15

Others

300
Slide : 13

Pareto

Pareto diagram

Q7T/PPT- 14

Slide : 14

Pareto

Do you remember this? (14th March 2001 - Eden gardens )

Q7T/PPT- 15

Slide : 15

Pareto

Lets look at the second innings score board:

India
SS Das

hit wicket b Gillespie

39

S Ramesh

c ME Waugh b Warne

30

VVS Laxman

c Ponting b McGrath

281

SR Tendulkarc Gilchrist b Gillespie

10

SC Ganguly

c Gilchrist b McGrath

48

R Dravid

run out

180

N R Mongia

b McGrath

Zaheer Khan

not out

23

Harbhajan Singh

not out

Total
Q7T/PPT- 16

657
Slide : 16

Pareto

Do you remember this? (14th March 2001 - Eden gardens )

Q7T/PPT- 17

Slide : 17

Pareto

Who got the wickets?

Zaheer Khan

30

V Prasad

Harbhajan Singh

30.3

73

V Raju

15

58

S Tendulkar

11

31

S Ganguly

Q7T/PPT- 18

Slide : 18

Pareto

Who got the maximum runs?

Laxman & Dravid 461 / 657 runs.
22% of the 9 batsmen who batted got 70% of the runs!

Who got the maximum wickets?

Harbhajan & Tendulkar 9 / 11 wickets.
30% of the 6 bowlers who bowled got 80% of the wickets!

This illustrates the Pareto principle

Q7T/PPT- 19

Slide : 19

Pareto

Pareto
Vilfredo Pareto was an Italian engineer in the 19th Century
who studied the number of people in various income classes &
declared
20% of the people own 80% of the countrys wealth;

80% of the people own 20% of the countrys wealth

Q7T/PPT- 20

Slide : 20

Pareto

Pareto Principle
Pareto principle holds good to the present day in various
applications
A few causes lead to many defects;
many causes lead to few defects.

The few causes that lead to many defects are the vital few.

The many causes that lead to few defects are the trivial many.

Q7T/PPT- 21

Slide : 21

Pareto

Get to the biggest problems first

Solve the vital few

Q7T/PPT- 22

Slide : 22

Pareto
200

Creating a Pareto Diagram

100 100

99.5

98.5

97.5

95.5

93.5

91

88

175

84
79

150

55.5
100
75

50

66
33
45

50

25
20

25

15

12

10

Steps

1. Collect data

2. Arrange data in the descending order

3. Calculate the relative % for individual data

4. Calculate the cumulative % for individual data

5. Draw a graph with scales on both axis
6. Draw bar chart based on data
7. Using cumulative % data, draw cumulative curve
8. Identify the VITAL FEW (thumb rule > 70%)
Q7T/PPT- 23

Slide : 23

Quality

Factory
production

Manufacturing
Planning

Stores

Others

Information
Systems

Dept

Research &
Development

Service

Personnel

Finance

Production
Engineering

Plant
Maintenance

Materials

0
Marketing

In %

In nos

75

73
65.5

125

Pareto

Same problem, but different approach

You have to cut down your

house expenditure by 20% / month

How will you do it ?
Paret
o

Q7T/PPT- 24

Slide : 24

Pareto

Now take your check sheet.

Arrange these expenses & amounts in an
order, with the highest expense being
the first & lowest expense being the last

Q7T/PPT- 25

Slide : 25

Pareto
Sl.No

Expense

Amount

Groceries

2000

House rent

1500

Educational

1000

Loan repayment

1000

Milk

400

Petrol

300

Others

300

Electricity & water bill

250

Hospital

200

10

Travel

200

11

Entertainment & lifestyle

200

12

Clothes

200

13

Maid Servant

150

14

Cable TV bill

150
7850

Q7T/PPT- 26

Slide : 26

Pareto

Calculate the percentage contribution of each of these

expenses.

Percentage can be calculated by the formula

Individual expense

X 100

Total expense

Q7T/PPT- 27

Slide : 27

Pareto
Sl.No

Department

Nos.

Relative %

Groceries

2000

25.47

House rent

1500

19.10

Educational

1000

12.74

Loan repayment

1000

12.74

Milk

400

5.10

Petrol

300

3.83

Others

300

3.83

Electricity & water bill

250

3.19

Hospital

200

2.54

10

Travel

200

2.54

11

Entertainment & lifestyle

200

2.54

12

Clothes

200

2.54

13

Maid Servant

150

1.92

14

Cable TV bill

150

1.92

7850

100

Q7T/PPT- 28

Slide : 28

Pareto
Sl.No

Q7T/PPT- 29

Department

Nos.

Relative %

Cumulative %

Groceries

2000

25.47

25.47

House rent

1500

19.10

44.57

Educational

1000

12.74

57.31

Loan repayment

1000

12.74

70.05

Milk

400

5.10

75.15

Petrol

300

3.83

78.98

Others

300

3.83

82.81

Electricity & water bill

250

3.19

86.00

Hospital

200

2.54

88.54

10

Travel

200

2.54

91.08

11

Entertainment & lifestyle

200

2.54

93.62

12

Clothes

200

2.54

96.16

13

Maid Servant

150

1.92

98.08

14

Cable TV bill

150

1.92

100

7850

100

100

Slide : 29

Pareto
Sl.No

Department

Nos.

Relative %

Cumulative %

Groceries

2000

25.47

25.47

House rent

1500

19.10

44.57

Educational

1000

12.74

57.31

Loan repayment

1000

12.74

70.05

Milk

400

5.10

75.15

Petrol

300

3.83

78.98

Others

300

3.83

82.81

Electricity & water bill

250

3.19

86.00

Hospital

200

2.54

88.54

10

Travel

200

2.54

91.08

11

Entertainment & lifestyle

200

2.54

93.62

12

Clothes

200

2.54

96.16

13

Maid Servant

150

1.92

98.08

14

Cable TV bill

150

1.92

100

7850

100

100

Q7T/PPT- 30

VITAL FEW

TRIVIAL
MANY

Slide : 30

Pareto

100

100

7500

VITAL FEW
75

57.31

5000
44.57

2500

50

25.47

Trivial
Many
0

Cumulative(%)

Amount

70.05

25

0
Groceries

House Rent

Educational

Loan
Repayment

Others

Expenses

Q7T/PPT- 31

Slide : 31

Pareto

Why pareto ?
To Clearly prioritise the magnitude of the problem.
To identify the vital few and trivial many problems.

To find 80/20 rule which states that 80% of the

problems are created by 20% of the causes.

Q7T/PPT- 32

Slide : 32

Pareto
84
79

150

75

73
65.5

125

In nos

100 100

99.5

98.5

97.5

95.5

93.5

91

88

175

55.5

100
75

50

66
33
45

50

25
20

25

15

12

10

1. The most important problem

2. The rate of each problem to the whole
3. The degree of improvement action
4. The comparison of improvement level
5. Before & after remedial action taken

Q7T/PPT- 33

Slide : 33

Quality

Factory
production

Manufacturing
Planning

Stores

Others

Information
Systems

Dept

Research &
Development

Service

Personnel

Finance

Production
Engineering

Plant
Maintenance

Materials

0
Marketing

In %

Pareto diagram is used to find out

200

Relation between Pareto diagram & Cause & effect diagram

The biggest problem has been found. What next?

A combination of Pareto diagram & cause and effect

diagram is an ideal way to arrive at the main problem & its
causes.
Take the biggest problem from the pareto diagram & put it
on the right side in the cause & effect diagram.
Derive the causes for the same.

Q7T/PPT- 34

Slide : 34

Cause & effect diagram

Cause & Effect diagram
derived from pareto

Pareto chart

Cause-and-effect
diagram

Q7T/PPT- 35

Slide : 35

Cause & effect diagram

Cause & Effect

diagram

Q7T/PPT- 36

Slide : 36

Cause & effect diagram

Why Cause & Effect ?

To identify and systematically list the different causes
that can be attributed to a problem (or an effect)

To identify the reasons why a process goes out of

control
To decide which causes to investigate for process
improvement.

Q7T/PPT- 37

Slide : 37

Cause & effect diagram

What is Effect ?
EFFECT = A Result or an outcome
EFFECT is What happens

Effect Tyre puncture

Q7T/PPT- 38

Slide : 38

Cause & effect diagram

What is cause ?
CAUSE = Reason or Factor contributing to the EFFECT
CAUSE is WHY it happens

Q7T/PPT- 39

Slide : 39

Cause & effect diagram

The analysis of
why?
for

what?
is

cause and effect

diagram
Q7T/PPT- 40

Slide : 40

Cause & effect diagram

In 1953, Kaoru Ishikawa, Professor of the
University of Tokyo, used the Cause & effect
diagram for the first time.
A cause & effect diagram is also called a fish
bone diagram since it looks like the skeleton
of a fish.

Q7T/PPT- 41

Slide : 41

Cause & effect diagram

The EFFECT or PROBLEM is stated on the right side of

the diagram and the major INFLUENCES or CAUSES are

listed to the left.

Effect

Q7T/PPT- 42

Slide : 42

Cause & effect diagram

There are two steps of making cause & effect diagrams:

1. Identify all the causes in one cause & effect diagram.

2. Take all the identified causes & classify them systematically

in another cause & effect diagram.

Q7T/PPT- 43

Slide : 43

Cause & effect diagram

Cause & effect diagram for identifying the causes

Q7T/PPT- 44

Slide : 44

Cause & effect diagram

In this type of cause & effect diagram:

Write all causes.
Don't classify them.

Q7T/PPT- 45

Slide : 45

Cause & effect diagram

How to obtain most number of causes?

Brainstorming!

Q7T/PPT- 46

Slide : 46

Cause & effect diagram

Remember

DURING BRAINSTORMING:
All the ideas/causes should be noted.
Dont label any ideas good or bad.
Encourage free flow of ideas.

Q7T/PPT- 47

Slide : 47

Cause & effect diagram

HOW TO DO IT?

1
Effect

Causes
Q7T/PPT- 48

Slide : 48

Cause & effect diagram

Example
Poor operator skill

Wrong inspection method

Improper
clamping on
jig or fixture

Insufficie
nt training

Machine
vibration

Wrong setting of job on locator

Q7T/PPT- 49

Wrong
inspection
instrument

Too much
tightening of job

Wrong spindle speed

No inbound
inspection of
raw material

Improper material storage

Operator
fatigue
Wrong
feed

Dimensional
Variation

Raw material
dimension too
close to final
dimension
Improper / warped shape of raw material

Slide : 49

Cause & effect diagram

Cause & effect diagram for systematically listing causes

Use these steps to make a successful Cause & effect diagram

for systematically listing causes
Step 1

List all the causes that have been suggested by team

members as a part of brain storming.

Q7T/PPT- 50

Slide : 50

Cause & effect diagram

Step 2
Connect the sub causes to the main causes. The main
causes should then be connected to the effect.
Step 3
Assign an importance to each factor, & mark the particularly
important factors which seem to have a significant effect.

Step 4
Draw the diagram & continually look for improvement.

Q7T/PPT- 51

Slide : 51

Cause & effect diagram

2
Effect

Causes

Q7T/PPT- 52

Slide : 52

Graph&control charts

Graph & Control charts

Q7T/PPT- 53

Slide : 53

Graph&control charts

Graph
What is Graph?
When there are more than 2 interrelated data sets,you write
the datasets on a graph so as to clearly define the
relationships.

Why Graph?
The details of the data should be
Correctly understood
In their entirety
With just a one look

Q7T/PPT- 54

Slide : 54

Graph&control charts

Graph
Types of Graphs & Its application
Bar graphs, line graphs, pie charts, and band graphs.
There are also other specialty graphs such as radar
charts, Z charts and area graphs
Applications

Q7T/PPT- 55

To understand relative sizes of numbers

To understand trends over time

To understand percent-ages of totals

Slide : 55

Graph&control charts

Pie chart - Composition of sales turnover 2001-02

Export Sales
1%

Spare parts
sales
6%

Other
income
1%

Vehicle
sales
92%

Q7T/PPT- 56

Slide : 56

Graph&control charts

Bar chart - Sales performance

Plan for
2002-03

Rs Million x 100
300

262

250
184
162

200
133

150

104
83

100
50

194

62

14

17

19

27

91-92

92-93

93-94

41

0
90-91
Q7T/PPT- 57

94-95

95-96

96-97

97-98

98-99

99-00

00-01

'01-02

'02-03

Slide : 57

Graph&control charts

Line chart - Hourly output of Workmen

50
45
40

ACTUAL

40
38

45

47

41

44
42

Feb

Mar

42

44
42

43
41

Apr

May

Jun

PLAN

35
30
25
20
15
10
5
0
Jan

Q7T/PPT- 58

Slide : 58

Graph&control charts

Line chart
Cumulative Percentage
100

100

80
70.05
60

59.26
44.57

40
25.47
20

0
1

Q7T/PPT- 59

Slide : 59

Histogram

Histogram

Q7T/PPT- 60

Slide : 60

Histogram

In quality control, we try to discover facts by collecting data &

then take necessary action based on those facts.
The data is not collected as an end in itself, but as a means
of finding out the facts behind the data.

Data

Q7T/PPT- 61

FACTS

Slide : 61

Histogram

Example
Consider a sampling inspection.
We take a sample from a lot, carry out
measurements on it.
We decide whether we should accept
the whole lot or not.

The sample tells us the whether the lot

is OK or NOT OK.

The totality of items under

consideration is called the
population.
Q7T/PPT- 62

Slide : 62

Histogram

The data obtained from a

sample helps us to take a
decision on the population.
The larger the sample size
is, the more information we
get about the population.
But an increase of sample
size also means an increase
in the amount of data

Q7T/PPT- 63

Slide : 63

Histogram

It becomes difficult to understand the population from

these data even when they are arranged into tables.
In such a case we need a method which will enable us
to understand the population at a glance.
A histogram answers our needs.

Q7T/PPT- 64

Slide : 64

Histogram

What is histogram ?
Histogram is a bar chart.
25

20

15

The sizes of the

vertical bars reflects
the number of data

The horizontal axis

shows the values of
the characteristics

10

2.50

Q7T/PPT- 65

2.51

2.52

2.53

2.54

2.55
Slide : 65

Histogram

Application
To analyze processes and discover items to be improved
To research process capability
To control the process (in a time series)

To verify effects of an improvement

Q7T/PPT- 66

Slide : 66

Histogram

Overview of Histogram
The characteristics of the frequency distribution are

shown more clearly when results are plotted in form of

block diagram
The horizontal axis is divided into segments
corresponding to ranges of the group
On each segment a rectangle is constructed whose

height is proportional to the frequency in the group

Q7T/PPT- 67

Slide : 67

Histogram

Uses of Histogram
A Histogram can be used:

To display large amounts of data values in a relatively

simple chart form.
To tell relative frequency of occurrence.
To easily see the distribution of the data.
To see if there is variation in the data.
To make future predictions based on the data.

Q7T/PPT- 68

Slide : 68

Histogram

Types of distribution
The shape of the distribution gives a more clear concept
than mean or standard deviation

From the distribution we can deduce the peak value of

frequency and symmetry of the data range
(i) Normal distribution
Normal distribution is commonly used
type.Here the values are symmetric
about the center and area gives the
value of probability

Q7T/PPT- 69

Slide : 69

Histogram - Interpretation

(ii) Positively skewed

Values are more concentrated in one
side nearer to origin of x line.
Here most of the values lies in the
lower part of the values of histogram

(iii) Negatively skewed

Values are more concentrated in one
side far from the origin
Values lies in the higher part of the
values of histogram

Q7T/PPT- 70

Slide : 70

Histogram - Interpretation

(iv) Bi modal distribution

In this type of distribution, there are
two peak values of frequency

(v) Multi modal distribution

There are number of peak values of
frequency

Q7T/PPT- 71

Slide : 71

Stratification

Flow chart

Q7T/PPT- 72

Slide : 72

Stratification

Q7T/PPT- 73

Slide : 73

Stratification

Flow chart
A pictorial representation describing a process being
studied or even used to plan stages of a project.
Flow charts tend to provide people with a common

language or reference point when dealing with a project or

process.

Q7T/PPT- 74

Slide : 74

Stratification

Why Flow chart?

Clarity in process

Flow is clear
Helps to maintain standard

Q7T/PPT- 75

Slide : 75

Scatter diagram

Scatter diagram

Q7T/PPT- 76

Slide : 76

Scatter diagram

Scatter diagram

It is often essential to study the relation of two corresponding

variables.
For example, how does the speed of driving a two wheeler
affect its fuel efficiency?

Q7T/PPT- 77

Slide : 77

Scatter diagram

To study the relation of two variables such as the speed of

the two wheeler & the fuel efficiency we can use what is
called a Scatter diagram.

Q7T/PPT- 78

Slide : 78

Scatter diagram

A scatter diagram is a type of a Graph.

The X & Y axes contain the the two variables.

Speed of the two wheeler

Q7T/PPT- 79

Slide : 79

Scatter diagram

Based on the data available, dots are marked on the graph &
the distribution of the dots is observed.

..
..
...
.. .
Speed of the two wheeler

How to read scatter diagrams

You can grasp the correlation between pairs of data just by

looking at the shape of a scatter diagram.
Q7T/PPT- 80

Slide : 80

Scatter diagram

5 examples are given

350
300
250
200
150
100
50
0

35
30
25
20
15
10
5
0
0

10

15

20

Positive correlation
Q7T/PPT- 81

100

200

300

400

Negative correlation
Slide : 81

Scatter diagram

500

40

400

30

300

20

200

10

100

10

15

20

Positive correlation may be present

Q7T/PPT- 82

100

200

300

400

Negative correlation may be present

Slide : 82

Scatter diagram

700
600
500
400
300
200
100
0
0

100

200

300

400

No correlation

Q7T/PPT- 83

Slide : 83

Scatter diagram

Why Scatter Diagram?

As illustrated in the figure if two
characteristics are correlated, & their
correlation can be represented as a
line or a curve:
The scope of action can be
determined easily.
In the diagram, Action on Sector A1
will get more significant results than
on Sector A3

Q7T/PPT- 84

Slide : 84

Scatter diagram

Let us do an exercise !
Let us say you are not satisfied
with the marks that your
son/daughter is scoring.
So, you want him/her to study
more.
But does studying more really
help?
How to find out?

Q7T/PPT- 85

Slide : 85

Scatter diagram

Percentage of marks

Try a scatter diagram !

90
80
70

60
50
0.5 1.0 1.5 2.0 2.5

No. of hours of study/day

Q7T/PPT- 86

Slide : 86

There is another tool which we

use as a part of all the 7 QC
tools

Which is it?

Q7T/PPT- 87

Slide : 87

CONCLUSION

Q7T/PPT- 88

Slide : 88

Conclusion

Remember that the 7 QC Tools help in Problem Solving.

Problems can be solved through

Intuition / Experience
Statistical tools
Experimental research

By using the QC story methodology

for solving problems we are adapting
a scientific approach.
Q7T/PPT- 89

Slide : 89

Conclusion

CONCLUSION

Application of Tools
QC story
TOOLS

Problem
Observation
Identification

Analysis Action

Check

Standardization

HD

Check sheet
Pareto diagram
Stratification
Cause & effect diagram
Histogram
Scatter diagram
Control chart,graphs

DOE
Test of significance
Why, why analysis
PM analysis
Gantt chart

Q7T/PPT- 90

Slide : 90

Q7T/PPT- 91

Slide : 91