Exercise Quality Management

Tools of Quality Management

Exercise Solution No.1

Contact:

Rebecca Lauther, M.Sc.

Phone: 0241/ 80-25814
Email: R.Lauther@wzl.rwth-aachen.de

© WZL/Fraunhofer IPT
The „Seven Q-Tools“
Exercise for Tally Sheet/ Histogram

Product: Fender W124 date: 2004/06/01

Lacquer: X5Z-Y8 colour: silver
number: 20 employee: Le Grand
9:00 a.m. 11:00 a.m. 2:00 p.m. 4:00 p.m.
Mo 1,25 1,42 1,27 1,30
Tu 1,44 1,35 1,31 1,25
We 1,32 1,30 1,45 1,39
Th 1,18 1,19 1,33 1,31
Fr 1,33 1,29 1,43 1,26

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The „Seven Q-Tools“
Exercise for Tally Sheet/ Histogram

Quantity

Class

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The „Seven Q-Tools“ ≤
Tally Sheet/ Histogram – Model Solution

Product: Fender W124 date: 2004/06/01

Lacquer: X5Z-Y8 colour: silver
number: 20 employee: Le Grand
9:00 a.m. 11:00 a.m. 2:00 p.m. 4:00 p.m.
Mo 1,25 1,42 1,27 1,30
Tu 1,44 1,35 1,31 1,25
We 1,32 1,30 1,45 1,39
Th 1,18 1,19 1,33 1,31
Fr 1,33 1,29 1,43 1,26

R Range Quantity Class

k= n H=
R = xmax - xmin 1,18 ≤ 1,234 2 A
k
R = 1,45 - 1,18 k = 20 1,234 ≤ 1,288 4 B
0,27
k = 4,47 H= 1,288 ≤ 1,342 8 C
R = 0,27 5
1,342 ≤ 1,396 2 D
⇒k = 5 H = 0,054
1,396 ≤ 1,45 4 E

© WZL/Fraunhofer IPT Slide 4

The „Seven Q-Tools“
Tally Sheet/ Histogram – Model Solution

n  20
Quantity
xmin  1,18
xmax  1,45
R  0,27
8 k  20  4,47  5
0,27
H  0,054
6 5

Range Quantity Class

4
1,18 ≤ 1,234 2 A
1,234 ≤ 1,288 4 B
2 1,288 ≤ 1,342 8 C
A B C D E 1,342 ≤ 1,396 2 D
1,396 ≤ 1,45 4 E
Class
© WZL/Fraunhofer IPT Slide 5
The „Seven Q-Tools“
Pareto-Analysis – Exercise

Failure Mo Tue We Thu Fr Sum Percent

Above upper tolerance A 3 2 2 2 4

Below under tolerance B 1 2 2 1 2

Missing screw C 6 6 7 5 8

Edges not completely

trimmed D 4 6 4 3 5

Lacquer failure on the

surface E 3 2 4 1 4

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The „Seven Q-Tools“
Pareto-Diagram – Exercise

Quantity Percent
50 100

40 80

30 60

20 40

10 20

Failure Type (Class)

© WZL/Fraunhofer IPT Slide 7

The „Seven Q-Tools“
Pareto-Analysis – Exemplary Solution

Failure Mo Tue We Thu Fr Sum Percent

Above upper tolerance A 3 2 2 2 4 13,0 14,6

Below under tolerance B 1 2 2 1 2 8,0 9,0

Missing screw C 6 6 7 5 8 32,0 36,0

Edges not completely

trimmed D 4 6 4 3 5 22,0 24,7

Lacquer failure on the

surface E 3 2 4 1 4 14,0 15,7

© WZL/Fraunhofer IPT Slide 8

The „Seven Q-Tools“
Pareto-Analysis – Model Solution

Quantity Percent,
50 100 added up
100,0 %
91,0 %
40 80

76,4 %
30 60
60,7 %
Failure
20 40 Mo Tue We Thu Fr Sum Percent
Above upper tolerance A 13,0 14,6
3 2 2 2 4
36,0 % Below under tolerance B1 8,0 9,0
2 2 1 2
10 20
Missing screw C6 6 7 5 8 32,0 36,0

32 22 14 13 8 Edges not completely

4 6 4 3 5
trimmed D 22,0 24,7

Failure Types (Class) Lacquer failure on the 3 2 4 1 4

surface E 14,0 15,7

© WZL/Fraunhofer IPT Slide 9

The „Seven Q-Tools“
Cause-Effect-Diagram

© WZL/Fraunhofer IPT Slide 10

The „Seven Q-Tools“
Cause-Effect-Diagram – Model Solution

Man Material

Wrong settings at Poor paper quality

printer
Wrong toner type
Wrong print options at
the pc Fixer is too old

Bad Printing
Results

Machine is overloaded Dirty rolls

Low toner status Defect heating element

Method Machine

© WZL/Fraunhofer IPT Slide 11

The „Seven M-Tools“
Affinity Diagram

What represents a
successful bicycle courier?

© WZL/Fraunhofer IPT Slide 12

The „Seven M-Tools“
Affinity Diagram – Model Solution

What represents a
successful bicycle courier?
fast absolute
transport reliability
fast small no loss Trans-
order queue of port
acceptance time sending insured
carefulness
small
with
transport time
sending

pricing
high
availability
adequate long
appropriate simple
amount of trading
price payment
drivers hours

fair telephonic
billing availability

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The „Seven M-Tools“
Relations Diagram – Exercise
Main Cause

Support by
take away
upper Further
employees
manage- education
fear
ment

Main Effect

Define Goals Successful Information

use of M7 material

Building a increase
launch team knowledge of
Individual
Aspect employees
To / From

© WZL/Fraunhofer IPT Slide 14

The „Seven M-Tools“
Relations Diagram – Exemplary Solution
Main Cause

Support by
take away
upper Further
employees
manage- education
fear
ment 0/5 3/3 3/1

Main Effect

Define Goals Successful Information

use of M7 material
2/1 6/0 0/3

Building a increase
launch team knowledge of
Individual
Aspect 1/3 employees
2/1
To / From

© WZL/Fraunhofer IPT Slide 15

The „Seven M-Tools“
Network Diagram – Exercise

Develop a Networking Plan with the help of the information given in the table!
Which activities are on the critical path?

Cycle Time Production Combination

Activity Description Length Predecessor Successor
Turn a shaft Turning 5 - S-harden
Milling a gear-wheel Milling 7 - C-harden
Found the Housing Founding 3 - Grinding
Harden the Shaft S-harden 10 Turning Sub Assembly
Harden the Gear Wheel C-harden 11 Milling Sub Assembly
Grinding the Housing Grinding 5 Founding Final Assembly
Install Shaft and Gear Wheel Sub Assembly 8 S-harden, C-harden Final Assembly
Final Housing Assembly Final Assembly 5 Grinding, Sub Assembly -

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The „Seven M-Tools“
Network Diagram – Exercise

Start

End

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The „Seven M-Tools“
Network Diagram – Model Solution

Turning S-Hardening Sub Assembly

0 5 5 15 18 26
5 10 8
3 8 8 18 18 26

Milling C-Hardening
Start 7
0 7
11
7 18
0 7 7 18

Founding Grinding Final Assembly

0 3 3 8 26 31
3
18 21
5
21 26
5
26 31
End

Path
Critical Path

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