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Spirit Proprietary 1
7 QC TOOLS
The term “7 QC tools for QC” is name after the 7 tools of the famous warrior , Benkai. Benkai owned 7 weapons, which he used to win all his battles. Similarly, from my own experience, you will find that you will able to solve 95% of the problems around you if you wisely use the 7 tools of QC.” ISHIKAWA KAORU, Professor Emeritus, University of Tokyo.
7 Quality Tools
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Page 2
IntroductionIn 1950, the Japanese Union of Scientists and Engineers (JUSE) invited legendary quality guru W. Edwards Deming to go to Japan and train hundreds of Japanese engineers, managers and scholars in statistical process control. Deming also delivered a series of lectures to Japanese business managers on the subject, and during his lectures, he would emphasize the importance of what he called the "basic tool" that were available to use in quality control.
One of the members of the JUSE was Kaoru Ishikawa, at the time an associate professor at the University of Tokyo. Ishikawa had a desire to 'democratise quality': that is to say, he wanted to make quality control comprehensible to all workers, and inspired by Deming’s lectures, he formalised the Seven Basic Tools of Quality Control.
Ishikawa believed that 90% of a company’s problems could be improved using these seven tools, and that –- with the exception of Control Charts -- they could easily be taught to any member of the organisation. This ease-of-use combined with their graphical nature makes statistical analysis easier for all.
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The Basic Seven (B7) Tools of Quality
A PowerPoint Training Presentation
"As much as 95% of quality related problems in the factory can be solved with seven fundamental quantitative tools." - Kaoru
Ishikawa
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What are the Basic Seven Tools of Quality?
1 – Fishbone/Ishikawa Diagrams 2 - Histograms 3 - Pareto Analysis 4 - Flowcharts 5 - Scatter Plots 6 - Run Charts 7 - Control Charts
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Where did the Basic Seven come from?
Kaoru Ishikawa Known for “Democratizing Statistics”
The Basic Seven Tools made statistical analysis less complicated for the average person
Good Visual Aids make statistical and quality control more comprehendible.
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The Basic Seven (B7) Tools of Quality
1] Fishbone Diagrams
No statistics involved
Maps out a process/problem
Makes improvement easier
Looks like a “Fish Skeleton”
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Constructing a Fishbone Diagram
Step 1 - Identify the Problem Step 2 - Draw “spine” and “bones”
Example: High Inventory Shrinkage at local Drug Store
Shrinkage
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Constructing a Fishbone Diagram
Step 3 - Identify different areas where problems may arise from
Ex. : High Inventory Shrinkage at local Drug Store
Shrinkage
employees
shoplifters
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Constructing a Fishbone Diagram
Step 4 - Identify what these specific causes could be
Ex. : High Inventory Shrinkage at local Drug Store
Shrinkage
shoplifters
Anti-theft tags poorly designedExpensive merchandise out in the open
No security/ surveillance
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Constructing a Fishbone Diagram
Ex. : High Inventory Shrinkage at local Drug Store
Shrinkage
shoplifters
Anti-theft tags poorly designedExpensive merchandise out in the open
No security/ surveillance
employeesattitude
new trainee
training
benefits practices
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Constructing a Fishbone Diagram
Step 5 – Use the finished diagram to brainstorm solutions to the main problems.
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The Basic Seven (B7) Tools of Quality
2] Histograms
Bar chart
Used to graphically represent groups of data
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Constructing a Histogram
From a set of data compute sum mean (x) Max Min Range (max-min)
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Constructing a Histogram
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
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Pak Mat Pizza Example
Let’s say the owner wants a distribution of Pak Mat’s Thursday Night Sales
Data Set from last Thursday(slices)0 2 1 2 2 4 1 3 1 2 1 2 2 4 3 4 1 4 3 2 2 3 2 1 2 2 1 2 2 1 4 2 2 1 2 1 2 2 1 2 1 2 1 2 1 2 1 2 1 2 2 2 1 2 1 2 1 1 2 2 2 3 1 4 2 2 3 2 2 2 1 2 3 2 2 4 2 2 4 4 1 2 2 2 3 2 2 1 2 2 4 2 1 2 4 2 1 7 2 1 2 2 3 1 2 1 1 2 1 2 2 2 1 2 2 1 2 1 2 2 2 4 2 4
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Acme Pizza ExampleMean = 2.032258 Max = 7 Min = 0 Range = 7
QuestionFor 7 columns what would the width be?
Range/Columns=7/7=1 slice
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Pak Mat Pizza Example
33
65
812
0 0 10
10
20
30
40
50
60
70
1 2 3 4 5 6 7
Slices of Pizza
Histogram
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Constructing a HistogramHow is this helpful to Pak Mat? 2 slices of pizza most common order placed Distribution of sales useful for forecasting
next Thursday’s late night demand
If you were an Pak Mat manager how could you apply this information?
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The Basic Seven (B7) Tools of Quality
3] Pareto Analysis
Very similar to Histograms
Use of the 80/20 rule
Use of percentages to show importance
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Pak Mat Pizza (part 2)
Slices Frequency %0 1 .31 33 13.092 65 25.793 8 3.174 12 4.765 0 06 0 07 1 .3
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Pak Mat Pizza (part 2)
The completed Pareto Analysis results in the following graph:
0
10
20
30
40
50
60
70
1 2 3 4 5 6 7
Slices of Pizza
2 1 4 3 7 5 6
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Pak Mat Pizza (part 2)
Critical Thinking How does the Pareto Analysis differ
from the Histogram?
How can this be a useful tool to the Pak Mat boss?
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The Basic Seven (B7) Tools of Quality
4] Flowcharts
A graphical picture of a PROCESS
Process Decision
The process flow
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FlowchartsDon’t Forget to:
Define symbols before beginning
Stay consistent
Check that process is accurate
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Pak Mat Pizza Example (Flowchart)
Window Take Customer Money?(start) Order
Get PizzaLockup
Put More inOven 2 Pies
Available?
Timeto close?
Take to Customer
noyes
no
yesno
yes
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How can we use the flowchart to analyze improvement ideas from the Histogram?
Window Take Customer Money?(start) Order
Get PizzaLockup
Put More inOven 2 Pies
Available?
Timeto close?
Take to Customer
noyes
no
yesno
yes
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Want some practice?
Make a flowchart for:
Taking a shower Cooking dinner Driving a car Having a party Creating a Flowchart
Any other processes you can think of?
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The Basic Seven (B7) Tools of Quality
5] Scatter Plots
2 Dimensional X/Y plots Used to show relationship between
independent(x) and dependent(y) variables
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Pak Mat Pizza (Scatter Diagram)
Minutes Cooking Defective Pies10 145 830 575 2060 1420 425 6
In this simple example, you can find the existing relationship without much difficulty but…
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Scatter Diagrams
0
5
10
15
20
25
0 20 40 60 80
•Easier to see direct relationship
Time Cooking (minutes)
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Scatter Diagrams
As a quality tool What does this tell Pak Mat
management about their processes? Improvements?
0
5
10
15
20
25
0 20 40 60 80
Time Cooking (minutes)
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The Basic Seven (B7) Tools of Quality
6] Run charts Time-based (x-axis)
Cyclical
Look for patterns
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Run Charts
8 9 10 11 12 1 2 3 4
8 9 10 11 12 1 2 3 4
8 9 10 11 12 1 2 3 4PM- AM PM- AM PM- AM
Thursday
Week 1
Thursday
Week 2
Thursday
Week 3
Slices/hour
Time
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The Basic Seven (B7) Tools of Quality
7] Control Charts Deviation from Mean
Upper and Lower Spec’s
Range
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Control ChartsUpper Limit
Lower Limit
Unacceptable deviation
X
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Control Charts
Pak Mat Pizza Management wants to get in on the control chart action
•Average Diameter = 16 inches
•Upper Limit = 17 inches
•Lower Limit = 15 inches
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Acme example Control Charts
Upper Limit17 inches
Lower Limit15 Inches
Small Pie
X16 inches=
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Pak Mat example #50Control Charts
•Pies within specifications were acceptable
•One abnormally small pie is “uncommon”
•Should be examined for quality control
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Summary Basic Seven Tools of Quality
Measuring data
Quality Analysis
“Democratized statistics”
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Bibliography
Foster, Thomas. Managing Quality. An Integrative Approach. Upper Saddle River : Prentice Hall, 2001.
Stevenson, William. “Supercharging Your Pareto Analysis.” Quality Progress October 2000: 51-55.
“Dr Kaoru Ishikawa.” Internet “http://www.dti.gov.uk/mbp/bpgt/m9ja00001/m9ja0000110.html.” 16 February 2001.
“Chemical and Process Engineering.” Internet. “http://lorien.ncl.ac.uk/ming/spc/spc8.htm.” 17 February 2001.