7 Quality Tools:
An overview of Seven Quality Tools Address purpose and applications Highlight benefits.
Why Do This?
1. The Continuous Chain
2. Improve Quality
3. Decrease Costs
4. Improve Productivity
5. Decrease Price
6. Increase Market
7. Stay in Business
8. Provide Jobs
9. Return on Investment
Six Problem Solving Steps
1. Identify : recognize the symptoms
2. Define : Agree on the problem and set boundaries
3. Investigate : Collect data
4. Analyze : Use quality tools to aid
5. Solve : Develop the solution and implement
6. Confirm : Follow up to ensure that the solution is effective
Seven Quality Tools
1. Cause and Effect Diagrams:
Purpose: Graphical representation of the trail leading to the root cause of a problem.
Benefits:
1. Breaks problems down into bite-size pieces to find root cause
2. Team work
3. Common understanding of factors causing the problem
4. Road map to verify picture of the process
5. Follows brainstorming relationship
2. Flow Charts: A flow chart is a pictorial representation showing all of the steps of a process.
Purpose:
1. Visual illustration of the sequence of operations required to complete a task
2. Schematic drawing of the process to measure or improve. Starting point for process improvement
3. Potential weakness in the process are made visual.
Benefits:
1. Identify process improvements Understand the process
2. Shows duplicated effort and other non-value-added steps Clarify working relationships between Shop floor people
3. Target specific steps in the process for improvement.
4. Show what actually happens at each step in the process
5. Show what happens when non-standard events occur
6. Graphically display processes to identify redundancies and other wasted effort
Toolbox
How is it done?
Write the process
Implement in Shop f loor for easy Process Flow.
Benefits
Simplest of all flowcharts
Used for planning new processes or examining existing one
Keep people focused on the whole process
How is it done?
List major steps
Write them acrossof the chart
List sub-steps under each in order they occur
Run Charts Defined: Run charts are used to analyze processes according to time or order.
An Example of Using a Run Chart
An organizations desire is to have their product arrive to their customers on time, but they have noticed that it doesnt take the same amount of time each day of the week. They decided to monitor the amount of time it takes to deliver their product over the next few weeks.
3. Checksheets:
Purpose: Tool for collecting and organizing measured or counted data
Data collected can be used as input data for other quality tools.
Benefits: Collect data in a systematic and organized manner
To determine source of problem
To facilitate classification of data (stratification)
4. Histograms:
Purpose: To determine the spread or variation of a set of data points in a graphical form.
Collect data
Determine the range of the data
Calculate the size of the class interval Divide data points into classes.
Benefits:
1. Allows you to understand at a glance the variation that exists in a process
2. The shape of the histogram will show process behavior
3. The shape and size of the dispersion will help ide ntify otherwise hidden sources of variation
4. Used to determine the capability of a process
5. Starting point for the improvement process
5. Pareto Charts:
Purpose: Prioritize problems.
How is it done?
1. Create a preliminary list of problem classifications.
2. Tally the occurrences in each problem classification.
3. Arrange each classification in order from highest to lowest
4. Construct the bar chart.
Benefits:
Pareto analysis helps graphically display results so the significant few problems emerge from the general background. It tells you what to work on first.
6. Control Charts: Control charts are used to determine whether a process will produce a product or service with consistent measurable properties.
Purpose:
The primary purpose of a control chart is to predict expected product outcome.
Benefits:
Predict process out of control and out of specification limits
Distinguish between specific, identifiable causes of variation
Can be used for statistical process control.
What does it look like?
1. Adding the element of time will help clarify your understanding of the causes of variation in the processes.
2. A run chart is a line graph of data points organized in time sequence and centered on the median data value.
7. Scatter Diagrams:
Scatter Diagrams are used to study and identify the possible relationship between the changes observed in two different sets of variables.
How is it done?:
1. Decide which paired factors you want to examine. Both factors must be measurable on some incremental linear scale.
2. Collect 30 to 100 paired data points.
3. Find the highest and lowest value for both variables.
4. Draw the vertical (y) and horizontal (x) axes of a graph.
5. Plot the data
6. Title the diagram
The Concept of Consistency:
Who is the Better Target Shooter
Not just the mean is important, but also the variance
Need to look at the distribution function
The Impact of Variation on Quality: The Xootr Case
Variation is (again) the root cause of all evil.
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