7qc tools nokia.ppt

8/10/2019 7QC tools nokia.ppt

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7 QC TOOLS


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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.

Objective


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7QC tools

Check Sheet

Pareto Diagram

Cause & Effect diagram

Scatter Diagram

Flow chart

Graph &Control charts

Histogram

7 QC Tools

Types


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Check sheet

Check sheet


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What is a check sheet?

Why is a check sheet necessary?

Check sheet


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Check sheet

Example:



Check sheets are forms used for

checking results of work

verifying and collecting data

Check sheet

Check sheet



CheckSheet

MeasuredData

CountedData

PrimaryData

Point ScaleData

OrderedData

Indiscrete value such as height,weight, length, time & temp., Etc.

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

YES / NO or/ X - Type

1st, 2ndOrder

Very Good, Good, No Good - Type

1 Point, 2 Point etc.

Types of Check Sheet

Check sheet


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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

Check points for check sheets preparation

Check sheet


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Defect check sheet

Check sheet

Example of check sheet

Month ,day

Component

1

2

3

4

5

6

7

8

9

10

4/1 2 3 4

No. of

defects


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Make a check list of all the expenses

in your home & the amount youspend on these expenses

Check sheet


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Sl.No Expense Amount

1 House Rent 1500

2 Electricity & Water Bill 250

3 Cable TV Bill 150

4 News paper bill 100

5 Milk 400

6 Maid servant 1507 Groceries 2000

8 Entertainment & Lifestyle 200

9 Travel 200

10 Educational 1000

11 Hospital 200

12 Loan repayment 1000

13 Clothes 200

14 Petrol 300

15 Others 300

Check sheet


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Pareto diagram

Pareto


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

Pareto

P t


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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 Tendulkar c Gilchrist b Gillespie 10SC Ganguly c Gilchrist b McGrath 48

R Dravid run out 180

N R Mongia b McGrath 4

Zaheer Khan not out 23

Harbhajan Singh not out 8

Total 657

Pareto

P t


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

Pareto

P t


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Who got the wickets?

O M R W

Zaheer Khan 8 4 30 0

V Prasad 3 1 7 0

Harbhajan Singh 30.3 8 73 6

V Raju 15 3 58 1

S Tendulkar 11 3 31 3

S Ganguly 1 0 2 0

Pareto

P t


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Who got the maximum runs?

Laxman & Dravid461 / 657 runs.22% of the 9 batsmen who batted got 70% of the runs!

Pareto

Who got the maximum wickets?Harbhajan & Tendulkar9 / 11 wickets.

30% of the 6 bowlers who bowled got 80% of the wickets!

This illustrates the Pareto principle

P t


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Vilfredo Pareto was an Italian engineer in the 19thCentury

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

Pareto

Pareto


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Pareto


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Get to the biggest problems first

Solve the vital few

Pareto

Pareto


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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%)

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2015 12 10 8 6 5 4 4 2 2 1

33

55.5

65.5

73

79

8488

91 93.5

95.5 97.5 98.5

99.5 100

0

25

50

75

100

125

150

175

200

Materials

Marketing

Plant

Maintenance

Finance

Service

Production

Engineering

Personnel

Information

Systems

Stores

Research&

Development

Others

Quality

Factory

production

Manufacturing

Planning

Dept

Innos

0

25

50

75

100

In%

Pareto

Creating a Pareto Diagram

Steps

Pareto


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You have to cut down yourhouse expenditure by 20% / month

How will you do it ?

Pareto

Same problem, but different approach

Paret

o

Pareto


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Now take your check sheet.

Arrange these expenses & amounts in anorder, with the highest expense being

the first & lowest expense being the last

Pareto

Pareto


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Sl.No Expense Amount

1 Groceries 2000

2 House rent 1500

3 Educational 1000

4 Loan repayment 1000

5 Milk 400

6 Petrol 300

7 Others 3008 Electricity & water bill 250

9 Hospital 200

10 Travel 200

11 Entertainment & lifestyle 200

12 Clothes 200

13 Maid Servant 150

14 Cable TV bill 150

7850

Pareto

Pareto


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Calculate the percentage contribution of each of these

expenses.

Percentage can be calculated by the formula

Individual expense

Total expenseX 100

Pareto

Pareto


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Sl.No Department Nos. Relative %

1 Groceries 2000 25.47

2 House rent 1500 19.103 Educational 1000 12.74

4 Loan repayment 1000 12.74

5 Milk 400 5.10

6 Petrol 300 3.83

7 Others 300 3.83

8 Electricity & water bill 250 3.19

9 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

Pareto

Pareto


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Sl.No Department Nos. Relative % Cumulative %

1 Groceries 2000 25.47 25.47

2 House rent 1500 19.10 44.57

3 Educational 1000 12.74 57.31

4 Loan repayment 1000 12.74 70.05

5 Milk 400 5.10 75.15

6 Petrol 300 3.83 78.98

7 Others 300 3.83 82.81

8 Electricity & water bill 250 3.19 86.00

9 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

Pareto

Pareto


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Sl.No Department Nos. Relative % Cumulative %

1 Groceries 2000 25.47 25.47

2 House rent 1500 19.10 44.573 Educational 1000 12.74 57.31

4 Loan repayment 1000 12.74 70.05

5 Milk 400 5.10 75.15

6 Petrol 300 3.83 78.98

7 Others 300 3.83 82.81

8 Electricity & water bill 250 3.19 86.00

9 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

TRIVIAL

MANY

VITAL FEW

Pareto

Pareto


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25.47

44.57

57.31

70.05

100

0

2500

5000

7500

Groceries House Rent Educational Loan

Repayment

Others

Expenses

Amount

0

25

50

75

100

Cumu

lative(%)

Trivial

Many

Pareto

VITAL FEW

Pareto


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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.

Pareto

Why pareto ?

Pareto


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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

Pareto

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91 93.5

95.5 97.5 98.5

99.5 100

0

25

50

75

100

125

150

175

200

Materials

Marketing

Plant

Maintenance

Finance

Service

Production

Engineering

Personnel

Information

Systems

Stores

Research&

Development

Others

Quality

Factory

production

Manufacturing

Planning

Dept

Innos

0

25

50

75

100

In%Pareto diagram is used to find out


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Cause & effect diagram


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Pareto chart

Cause-and-effect

diagram

Cause & Effect diagram

derived from pareto




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Cause & Effect

diagram




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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.

Why Cause & Effect ?




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What is Effect ?

EFFECT= A Result or an outcome

EFFECTis What happens


EffectTyre puncture



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What is cause ?

CAUSE= Reason or Factor contributing to the EFFECT

CAUSE is WHY it happens




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The analysis of

why?

for

what?

iscause and effect

diagram




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In 1953, Kaoru Ishikawa, Professor of the

University of Tokyo, used the Cause & effectdiagram for the first time.

A cause & effect diagram is also called a fish

bone diagram since it looks like the skeleton

of a fish.


http://sol.brunel.ac.uk/~jarvis/gallery/ishikawa.gif


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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



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& g

2

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.



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Cause & effect diagram for identifying the causes

g



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In this type of cause & effect diagram:

Write all causes.

Don't classify them.

g



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Brainstorming!

g

How to obtain most number of causes?



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Remember

All the ideas/causes should be noted.

Dont label any ideas good or bad.Encourage free flow of ideas.

g

DURING BRAINSTORMING:



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Effect

Causes

1

g

HOW TO DO IT?



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g

Dimensional

Variation

Poor operator skill

Machine

vibration

Wrong inspection method

Wrong

inspection

instrument

Improper

clamping on

jig or fixtureOperator

fatigue

Wrong setting of job on locator

Insufficie

nt training

Too much

tightening of job

Improper material storage

No inbound

inspection of

raw material Raw material

dimension too

close to final

dimension

Improper / warped shape of raw material

Wrong spindle speed

Wrong

feed

Example

1



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Cause & effect diagram for systematically listing causes

Use these steps to make a successful Cause & effect diagram

for systematically listing causesStep 1

List all the causes that have been suggested by team

members as a part of brain storming.



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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.

Step 2

Connect the sub causes to the main causes. The maincauses should then be connected to the effect.



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2

Effect

Causes

Graph&control charts


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Graph & Control charts



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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



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Types of Graphs & Its applicationBar graphs, line graphs, pie charts, and band graphs.

There are also other specialty graphs such as radar

charts, Z charts and area graphs

Applications

To understand relative sizes of numbers

To understand trends over time

To understand percent-ages of totals

Graph



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Pie chart - Composition of sales turnover 2001-02

Vehicle

sales

92%

Export Sales

1%

Spare parts

sales

6%

Other

income

1%



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Bar chart - Sales performance

1417 19 27

41

62

83

104

133

162

184 194

262

0

50

100

150

200

250

300

90-91 91-92 92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 '01-02 '02-03

Rs Million x 100

Plan for

2002-03



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Line chart - Hourly output of Workmen

40

45

42 42 42 43

38

41

44

47

44

41

0

5

10

15

20

25

30

35

40

45

50

Jan Feb Mar Apr May Jun

PLAN

ACTUAL



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Cumulative Percentage

25.47

44.57

59.26

70.05

100

0

20

40

60

80

100

1 2 3 4 5

Line chart

Histogram


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Histogram

Histogram


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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.

DataFACTS

Histogram


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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.

Example

Histogram


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The data obtained from a

sample helps us to take a

decision on the population.

The larger the sample size

is, the more information weget about the population.

But an increase of sample

size also means an increase

in the amount of data

Histogram


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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.

Histogram


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0

5

10

15

20

25

2.50 2.51 2.52 2.53 2.54 2.55

What is histogram ?Histogram is a bar chart.

The horizontal axis

shows the values of

the characteristics

The sizes of the

vertical bars reflects

the number of data

Histogram


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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

Application

Histogram


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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

Overview of Histogram

Histogram


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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.

Uses of Histogram

Histogram


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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 thevalue of probability

Types of distribution

Histogram - Interpretation


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(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 oneside far from the origin

Values lies in the higher part of thevalues of histogram

Histogram - Interpretation


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(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

Stratification


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Flow chart

Stratification


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Stratification


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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 commonlanguage or reference point when dealing with a project or

process.

Flow chart

Stratification


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Why Flow chart?

Clarity in process

Flow is clear

Helps to maintain standard


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Scatter diagram Scatter diagram


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It is often essential to study the relation of two corresponding

variables.

For example, how does the speed of driving a two wheeleraffect its fuel efficiency?

Scatter diagram


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To study the relation of two variables such as the speed ofthe two wheeler & the fuel efficiency we can use what is

called a Scatter diagram.

Scatter diagram


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A scatter diagram is a type of a Graph.

The X & Y axes contain the the two variables.

Speed of the two wheeler

Scatter diagram


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Speed of the two wheeler

Based on the data available, dots are marked on the graph &

the distribution of the dots is observed.

........... .

How to read scatter diagrams

You can grasp the correlation between pairs of data just bylooking at the shape of a scatter diagram.

Scatter diagram


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0

5

10

15

20

25

30

35

0 5 10 15 20

0

50

100

150

200

250

300

350

0 100 200 300 400

Positive correlation Negative correlation

5 examples are given

Scatter diagram


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0

10

20

30

40

0 5 10 15 20

0

100

200

300

400

500

0 100 200 300 400

Positive correlation may be present Negative correlation may be present

Scatter diagram


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0

100

200

300

400

500

600

700

0 100 200 300 400

No correlation

Scatter diagram


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Why Scatter Diagram?

As illustrated in the figure if twocharacteristics 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

Scatter diagram


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Let us do an exercise !

Let us say you are not satisfied

with the marks that yourson/daughter is scoring.

So, you want him/her to study

more.

But does studying more really

help?

How to find out?

Scatter diagram


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Try a scatter diagram !

No. of hours of study/day0.5 1.0 1.5 2.0 2.5

Percentage

ofmarks

50

60

70

80

90


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There is another tool which weuse as a part of all the 7 QC

tools

Which is it?


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CONCLUSION

Conclusion


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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.

CONCLUSION

Conclusion


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CONCLUSION

Application of ToolsProblem

IdentificationObservation Analysis Action Check Standardization HD

Check sheet

Pareto diagram

StratificationCause & effect diagram

Histogram

Scatter diagram

Control chart,graphs

DOE

Test of significance

Why, why analysis

PM analysis

Gantt chart

QC storyTOOLS


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