Seven Quality Tools

The Seven Tools

Histograms, Pareto Charts, Cause and Effect Diagrams, Run Charts, Scatter Diagrams, Flow Charts, Control Charts

Ishikawas Basic Tools of Quality

Kaoru Ishikawa developed seven basic visual tools of quality so that the average person could analyze and interpret data.
These tools have been used worldwide by companies, managers of all levels and employees.

Histograms
Slide 1 of 3

Histogram Defined
A histogram is a bar graph that shows frequency data. Histograms provide the easiest way to evaluate the distribution of data.

 Histograms
Bar chart Used to graphically represent groups of data

 Description A frequency distribution shows how often each different value in a set of data occurs. A histogram is the most commonly used graph to show frequency distributions. It looks very much like a bar chart, but there are important differences between them.

When to Use a Histogram

When the data are numerical. When you want to see the shape of the datas distribution, especially when determining whether the output of a process is distributed approximately normally. When analyzing whether a process can meet the customers requirements. When seeing whether a process change has occurred from one time period to another. When determining whether the outputs of two or more processes are different. When you wish to communicate the distribution of data quickly and easily to others.

Constructing a Histogram
From a set of data compute sum mean (x) Max Min Range (max-min)

 Use range to estimate beginning and end Calculate the width of each column by dividing the range by the number of columns

Range
# of Columns

= Width

 Lets say the owner wants a distribution of Acmes Thursday Night Sales Data Set from last Thursday(slices) 0212241312122434143223 212212214221212212121212 121222121211222314223222 123224224412223221224212 421721223121121222122121 222424

Mean = 2.032258 Max = 7 Min = 0 Range = 7

Question For 7 columns what would the width be?

Range/Columns=7/7=1 slice

Histogram
70 60 50 40 30 20 10 0 1 2 3 4 5 6 7 8 12 0 0 1 33 65

Slices of Pizza

 How is this helpful to Acme? 2 slices of pizza most common order placed Distribution of sales useful for forecasting next Thursdays late night demand

Histograms
Slide 3 of 3

Examples of How Histograms Can Be Used

Histograms can be used to determine distribution of sales. Say for instance a company wanted to measure the revenues of other companies and wanted to compare numbers.

 Histogram Analysis Before drawing any conclusions from your histogram, satisfy yourself that the process was operating normally during the time period being studied. If any unusual events affected the process during the time period of the histogram, your analysis of the histogram shape probably cannot be generalized to all time periods. Analyze the meaning of your histograms shape.

 Amount of variation in the process The distribution represented in a histogram can be normal or skewed It indicates whether the spread of the curve falls within specification or not

Pareto Chart
Also called: Pareto diagram, Pareto analysis Variations: weighted Pareto chart, comparative Pareto charts

 Description A Pareto chart is a bar graph. The lengths of the bars represent frequency or cost (time or money), and are arranged with longest bars on the left and the shortest to the right. In this way the chart visually depicts which situations are more significant.

Pareto Charts
Slide 1 of 4

Pareto Chart Defined

Pareto charts are used to identify and prioritize problems to be solved. They are actually histograms aided by the 80/20 rule adapted by Joseph Juran.
Remember the 80/20 rule states that approximately 80% of the problems are created by approximately 20% of the causes.

 When to Use a Pareto Chart When analyzing data about the frequency of problems or causes in a process. When there are many problems or causes and you want to focus on the most significant. When analyzing broad causes by looking at their specific components. When communicating with others about your data.

Pareto Chart Procedure

Decide what categories you will use to group items. Decide what measurement is appropriate. Common measurements are frequency, quantity, cost and time. Decide what period of time the Pareto chart will cover: One work cycle? One full day? A week? Collect the data, recording the category each time. (Or assemble data that already exist.) Subtotal the measurements for each category. Determine the appropriate scale for the measurements you have collected. The maximum value will be the largest subtotal from step 5. (If you will do optional steps 8 and 9 below, the maximum value will be the sum of all subtotals from step 5.) Mark the scale on the left side of the chart.

 Construct and label bars for each category. Place the tallest at the far left, then the next tallest to its right and so on. If there are many categories with small measurements, they can be grouped as other. Steps 8 and 9 are optional but are useful for analysis and communication. Calculate the percentage for each category: the subtotal for that category divided by the total for all categories. Draw a right vertical axis and label it with percentages. Be sure the two scales match: For example, the left measurement that corresponds to one-half should be exactly opposite 50% on the right scale. Calculate and draw cumulative sums: Add the subtotals for the first and second categories, and place a dot above the second bar indicating that sum. To that sum add the subtotal for the third category, and place a dot above the third bar for that new sum. Continue the process for all the bars. Connect the dots, starting at the top of the first bar. The last dot should reach 100 percent on the right scale.

Pareto Charts
Slide 2 of 4

Constructing a Pareto Chart First, information must be selected based on types or classifications of defects that occur as a result of a process. The data must be collected and classified into categories. Then a histogram or frequency chart is constructed showing the number of occurrences.

Pareto Charts
Slide 3 of 4

An Example of How a Pareto Chart Can Be Used

Pareto Charts are used when products are suffering from different defects but the defects are occurring at a different frequency, or only a few account for most of the defects present, or different defects incur different costs. What we see from that is a product line may experience a range of defects. The manufacturer could concentrate on reducing the defects which make up a bigger percentage of all the defects or focus on eliminating the defect that causes monetary loss.

Pareto Charts
Slide 4 of 4

 Pareto Analysis
Very similar to Histograms Use of the 80/20 rule Use of percentages to show importance

Acme Pizza (part 2)

Slices 0 1 2 3 4 5 6 7 Frequency 1 33 65 8 12 0 0 1 % .3 13.09 25.79 3.17 4.76 0 0 .3

 The completed Pareto Analysis results in the following graph:

70 60 50 40 30 20 10 0 1 2 3 4 5 6 7

Slices of Pizza

Fishbone Diagram
Also Called: Cause-and-Effect Diagram, Ishikawa Diagram Variations: cause enumeration diagram, process fishbone, time-delay fishbone, CEDAC (cause-and-effect diagram with the addition of cards), desired-result fishbone, reverse fishbone diagram

Cause and Effect Diagram

Used to find problem sources/solutions Other names
Fish-bone diagram, Ishikawa diagram

Steps
Identify problem to correct Draw main causes for problem as bones Ask What could have caused problems in these areas? Repeat for each sub-area.

 Description The fishbone diagram identifies many possible causes for an effect or problem. It can be used to structure a brainstorming session. It immediately sorts ideas into useful categories. When to Use a Fishbone Diagram When identifying possible causes for a problem. Especially when a teams thinking tends to fall into ruts.

Fishbone Diagram Procedure Materials needed: flipchart or whiteboard, marking pens. Agree on a problem statement (effect). Write it at the center right of the flipchart or whiteboard. Draw a box around it and draw a horizontal arrow running to it. Brainstorm the major categories of causes of the problem. If this is difficult use generic headings:
Methods Machines (equipment) People (manpower) Materials Measurement Environment

Write the categories of causes as branches from the main arrow. Brainstorm all the possible causes of the problem. Ask: Why does this happen? As each idea is given, the facilitator writes it as a branch from the appropriate category. Causes can be written in several places if they relate to several categories. Again ask why does this happen? about each cause. Write sub -causes branching off the causes. Continue to ask Why? and generate deeper levels of causes. Layers of branches indicate causal relationships. When the group runs out of ideas, focus attention to places on the chart where ideas are few.

 Fishbone Diagram Example This fishbone diagram was drawn by a manufacturing team to try to understand the source of periodic iron contamination. The team used the six generic headings to prompt ideas. Layers of branches show thorough thinking about the causes of the problem.

 Fishbone Diagrams

No statistics involved
Maps out a process/problem Makes improvement easier Looks like a Fish Skeleton

 Step 1 - Identify the Problem Step 2 - Draw spine and bones

Example: High Inventory Shrinkage at local Drug Store
Shrinkage

 Step 3 - Identify different areas where problems may arise from Ex. : High Inventory Shrinkage at local Drug Store
employees

Shrinkage

shoplifters

 Step 4 - Identify what these specific causes could be

Ex. : High Inventory Shrinkage at local Drug Store

Shrinkage
Expensive merchandise out in the open No security/ surveillance

Anti-theft tags poorly designed

shoplifters

employees
employees
attitude training new trainee benefits practices

Shrinkage
Expensive merchandise out in the open

Anti-theft tags poorly designed

No security/ surveillance

shoplifters

 Step 5 Use the finished diagram to brainstorm solutions to the main problems.

Cause and Effect Diagrams

Slide 1 of 4

Cause and Effect Diagram Defined

The cause and effect diagram is also called the Ishikawa diagram or the fishbone diagram. It is a tool for discovering all the possible causes for a particular effect. The major purpose of this diagram is to act as a first step in problem solving by creating a list of possible causes.

Cause and Effect Diagrams

Slide 2 of 4

Constructing a Cause and Effect Diagram

First, clearly identify and define the problem or effect for which the causes must be identified. Place the problem or effect at the right or the head of the diagram. Identify all the broad areas of the problem. Write in all the detailed possible causes in each of the broad areas. Each cause identified should be looked upon for further more specific causes. View the diagram and evaluate the main causes. Set goals and take action on the main causes.

Cause and Effect Diagrams

Slide 3 of 4

An Example of When a Cause and Effect Diagram Can Be Used

This diagram can be used to detect the problem of incorrect deliveries.
Diagram on next slide
Diagram obtained from: <http://www.hci.com.au/hcisite/toolkit/causeand.htm>

When a production team is about to launch a new product, the factors that will affect the final product must be recognized. The fishbone diagram can depict problems before they have a chance to begin.

Cause and Effect Diagrams

Slide 4 of 4
Diagram of the Incorrect Deliveries Example:

Cause and Effect Diagram Example

Problem
Too many defects

Cause and Effect Diagram Example

Method Main Cause Too many defects Manpower

Material

Machinery
Main Cause

Cause and Effect Diagram Example

Method Drill Manpower Overtime Too many defects Wood Steel Material Lathe

Machinery
Sub-Cause

Method Drill Slow

Cause and Effect Diagram Example

Manpower Tired Overtime Too many defects

Wood Steel Material

Old
Lathe

Machinery

Fishbone Chart - Problems with Airline Customer Service

Scatter Diagrams
Slide 1 of 4

Scatter Diagrams Defined

Scatter Diagrams are used to study and identify the possible relationship between the changes observed in two different sets of variables.

Scatter Diagrams
Slide 2 of 4

Constructing a Scatter Diagram First, collect two pieces of data and create a summary table of the data. Draw a diagram labeling the horizontal and vertical axes.
It is common that the cause variable be labeled on the X axis and the effect variable be labeled on the Y axis.

Plot the data pairs on the diagram. Interpret the scatter diagram for direction and strength.

Scatter Diagrams
Slide 3 of 4

An Example of When a Scatter Diagram Can Be Used

A scatter diagram can be used to identify the relationship between the production speed of an operation and the number of defective parts made.

Scatter Diagrams
Slide 4 of 4

An Example of When a Scatter Diagram Can Be Used (cont.)

Displaying the direction of the relationship will determine whether increasing the assembly line speed will increase or decrease the number of defective parts made. Also, the strength of the relationship between the assembly line speed and the number of defective parts produced is determined.
Example obtained from: <http://www.sytsma.com/tqmtools/Scat.html>

Flow Charts
Slide 1 of 3

Flow Charts Defined

A flow chart is a pictorial representation showing all of the steps of a process.

Flow Charts
Slide 2 of 3

Creating a Flow Chart

First, familiarize the participants with the flow chart symbols. Draw the process flow chart and fill it out in detail about each element. Analyze the flow chart. Determine which steps add value and which dont in the process of simplifying the work.

Flow Charts
Slide 3 of 3

Examples of When to Use a Flow Chart

Two separate stages of a process flow chart should be considered:
The making of the product The finished product

Run Charts
Slide 1 of 3

Run Charts Defined

Run charts are used to analyze processes according to time or order.

Run Charts
Slide 2 of 3

Creating a Run Chart

Gathering Data
Some type of process or operation must be available to take measurements for analysis.

Organizing Data
Data must be divided into two sets of values X and Y. X values represent time and values of Y represent the measurements taken from the manufacturing process or operation.

Charting Data
Plot the Y values versus the X values.

Interpreting Data
Interpret the data and draw any conclusions that will be beneficial to the process or operation.

Run Charts
Slide 3 of 3

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.

Control Charts
Slide 1 of 3

Control Charts Defined

Control charts are used to determine whether a process will produce a product or service with consistent measurable properties.

Control Charts
Slide 2 of 3

Steps Used in Developing Process Control Charts

Identify critical operations in the process where inspection might be needed. Identify critical product characteristics. Determine whether the critical product characteristic is a variable or an attribute. Select the appropriate process control chart. Establish the control limits and use the chart to monitor and improve. Update the limits.

Control Charts
Slide 3 of 3

An Example of When to Use a Control Chart

Counting the number of defective products or services
Do you count the number of defects in a given product or service? Is the number of units checked or tested constant?

Activity
Process Flow Chart for Finding the Best Way Home
Construct a process flow chart by making the best decisions in finding the best route home. Refer to the prior notes on flowcharts.
Remember: Define and analyze the process, build a step-by step picture of the process, and define areas of improvement in the process.
Answer is on the next slide Example obtained from: <http://deming.eng.clemson.edu/pub/tutorials/qctools/flow m.htm#Example>

Summary
This presentation provided learning material for each of Ishikawas seven basic tools of quality.
Each tool was clearly defined with definitions, a step-by-step process and an example of how the tool can be used. As seen through the presentation, these tools are rather simple and effective.