Seven Quality Tools

• The Seven Tools

– Histograms, Pareto Charts, Cause and Effect
Diagrams, Run Charts, Scatter Diagrams, Flow
Charts, Control Charts
This was introduced by Dr. K. Ishikawa.
He used it in Kawasaki Iron Works in 1943.
 Ishikawa’s 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

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

• Creating a Histogram
– Collect data and sort it into categories.
– Then label the data as the independent set or the
dependent set.
• The characteristic you grouped the data by would be the
independent variable.
• The frequency of that set would be the dependent variable.
– Each mark on either axis should be in equal increments.
– For each category, find the related frequency and make
the horizontal marks to show that frequency.
 Example of Histogram :
Figure Skating

Yu-Na Kim 228.56

Mao Asada 205.5

Joanie Rochette 202.64

Mirai Nagasu 190.15

Miki Ando 188.86

Laura Lepisto 187.97

Rahail Flatt 182.49

Akiko Suzuki 181.44

Alena Leonova 172.46

Ksenia Makarova 171.91

 Scatter Diagrams
• 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
• 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.
 Example of Scatter Chart :
The local ice cream shop keeps track of how
much ice cream they sell versus the noon
temperature on that day. Here are their
figures for the last 12 days:
Ice Cream Sales vs Temperature
Temperature °C Ice Cream Sales
14.2° $215
16.4° $325
11.9° $185
15.2° $332
18.5° $406
22.1° $522
19.4° $412
25.1° $614
23.4° $544
18.1° $421
22.6° $445
17.2° $408
And here is the same data as a Scatter Plot
 Check Sheet
Definition: A simple data collection form
consisting of multiple categories with
definitions. Data are entered on the form with a
simple tally mark each time one of the
categories occurs.

Purpose: To facilitate the collection and analysis

of data.
 Creating a Check Sheet :

•Clearly define the objective of the data collection.

•Determine other information about the source of the data that
should be recorded, such as shift, date, or machine.
•Determine and define all categories of data to be collected
•Determine the time period for data collection and who will
collect the data.
•Determine how instructions will be given to those involved in
data collection.
•Design a check sheet by listing categories to be counted.
•Pilot the check sheet to determine ease of use and reliability of
results.
•Modify the check sheet based on results of the pilot
 Check Sheet Example :
The figure below shows a check sheet used to collect data
on telephone interruptions. The tick marks were added as data
was collected over several weeks.
 Pareto Charts
• 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.
 Pareto Charts
• 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 Chart Example:

Example shows how many complaints were

received in how to make one using excel and
open office file.
each of five categories.
Since the diagram looks like a fish bone it is
also called as fish bone diagram.
 Cause and Effect Diagrams

• 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
• 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
Diagram of the Variation in Test Results Example:
 Flow Charts

• Flow Charts Defined

– A flow chart is a pictorial representation showing
all of the steps of a process.
 Flow Charts
• 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 don’t in the process of simplifying the work.
 Flow charts
Benefits Linear
• Show what actually happens at
each step in the process
• Show what happens when non-
standard events occur Toolbox
• Graphically display processes to
identify redundancies and other
wasted effort
How is it done?
• Write the process step inside
each symbol
• Connect the Symbols with
arrows showing the direction of
flow
Example of Flow Chart :
 Control Charts

• Control Charts Defined

– Control charts are used to determine whether a
process will produce a product or service with
consistent measurable properties.
 Control Charts
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
 Control Charts
• 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.
 Basic Principles
• Basic components of control charts
– A centerline, usually the mathematical
average of all the samples plotted;
– Lower and upper control limits defining the
constraints of common cause variations;
– Performance data plotted over time.
Control Charts

Upper Control Limit

Central Line

Lower Control Limit

Control charts tell you when a process measure is

exhibiting abnormal behavior.
An example may help to illustrate the construction of control limits
for counts data. We are inspecting 25 successive wafers, each
containing 100 chips. Here the wafer is the inspection unit. The
observed number of defects are

Wafer Number Wafer Number

Number of Defects Number of Defects

1 16 14 16 From this table we have

c¯=total number of defects total number of
2 14 15 15 samples=40025=16
3 28 16 13
4 16 17 14
UCL = c¯ + 3 c¯√ = 16 +
5 12 18 16 3 16−−√ = 28
6 20 19 11 LCL = c¯ - 3 c¯√ = 16 -
7 10 20 20
8 12 21 11 3 16−−√ = 4
9 10 22 19
10 17 23 16
11 19 24 31
12 17 25 13
13 14
 Summary
This presentation provided learning material for each of Ishikawa’s seven
basic tools of quality.

Each tool was clearly defined with definitions, a step-by-step process and
an example for each tool.

As seen through the presentation, these tools are rather simple and
effective.
 Works - Cited
• Histograms and Bar Graphs.
<http://www.shodor.org/interactivate/lessons/sm3.html>
• Your MBA: The Business Study Reference Site.
http://yourmba.co.uk/pareto_diagram.htm
• Hci Home Services. Cause and Effect Diagram.
http://hci.com.au/hcisite/toolkit/causeand.htm
• Scatter Diagram. http://sytsma.com/tqmtools/Scat.html
• Flowchart.
<http://http://deming.eng.clemson.edu/pub/tutorials/qctools/flowm.htm>
• Run Charts/Time Plot/ Trend Chart.
<http://www.deming.edu.clemson.edu/pub/tutorials/qctools/runm.htm>
• Foster Thomas S. Managing Quality An Integrative Approach. New Jersey:
Prentice Hall, 2001