Professional Documents
Culture Documents
on
Problem Solving
Tools
7 Q C Tools 1
What are 7 QC Tools ?
QC tools are the means for Colleting data
, analyzing data , identifying root causes and
measuring the results.
THESE TOOLS ARE RELATED TO
Numerical DATA processing
Expected
(Gap ?) A Problem!
Obtained
7 Q C Tools
Problem Solving Tools
Symptoms and the Root Causes
An undesirable end result is only a starting point
or Symptom.
7 Q C Tools
Problem Solving Tools
Four types of Problems
7 Q C Tools
Problem Solving Tools
Why - Why
Library analysisSolving
of Problem - An Example
Tools
7 Q C Tools
Problem Solving Tools
Why - Why
Library analysisSolving
of Problem - An Example
Tools
Water Dripping in Substation 1
WHY ?
Water accumulated at the roof
WHY ?
Outlet drain chocked
WHY ?
Atmospheric dust & dirt
WHY ?
Periodic cleaning of drain not done
Action
7 Q C Tools
Problem Solving Tools
Why - Why
Library analysisSolving
of Problem - Example-2
Tools
WHY WHY ANALYSIS ( ACCIDENT )
JANUARY’2001
LOCATION :- WOOL COMBING ACCIDENT
OCCURRED TO SRI K.N.PAUL
PROBLEM : Right hand fingers got
seriously injured
WHY ?
While fitting feed roller spiked
rings, his RH fingers got pressed
with the F/Roller
7 Q C Tools
Problem Solving Tools
Why - Why
Library analysisSolving
of Problem - Example-2
Tools (Contd..)
WHY ?
The F/R shaft was lifted from the m/c & placed about 2 ft.high
from the floor by means of a chain-pulley block & a supporting
device. Suddenly the belt fastener got slipped off causing the
feed roller to fall down
WHY ?
Since the job was being done for the first time,proper
fastening device suitable for the spiked feed roller could not
be designed
ACTION
Development of suitable fastening device being contemplated
and to be adopted for a repetitive jobs
7 Q C Tools
Problem Solving Tools
What-IfofAnalysis
Library Problem Solving Tools
7 Q C Tools
Problem Solving Tools
What-IfofAnalysis
Library Problem- Solving
An Example
Tools
Area : Equipment :Compressor
Team :
SL. What If Results Countermeasures
1. There is no Water in The Engine heats • Inspect the
the Radiator of an up and Piston may Temperature of
Automobile ? And it get seized. outlet water .
is not noticed. • Provide the temp.
Indictor for the
driver
7 Q C Tools
Pareto Diagram
1. What is Pareto diagram ?
A Pareto diagram is a combination of bar and line graphs of
accumulated data, where data associated with a problem
(e.g., a defect found, mechanical failure, or a complaint
from a customer) are divided into smaller groups by cause
or by phenomenon and sorted, for example, by the number
of occurrences or the amount of money involved. (The
name “Pareto” came from an Italian mathematician who
created the diagram.)
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Pareto Diagram
2. When is it used and what results will be obtained?
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Pareto Diagram
Method Usage Result
Used to identify and
prioritize a problem. Allows clarification of
Pareto Diagram important tasks.
(No. of Occurrences) Used to review the effects of
Allows identification
an action taken. of a starting point
(which task to start
with).
Used to prioritize Allows projection of
actions.(Used during the effects of a measure
phases to monitor the to be taken
situation, analyze causes,
and review effectiveness of
an action.)
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Pareto Diagram
Example
Improved
7 Q C Tools 16
Cause & Effect Diagram
1. What is Cause & effect Diagram ?
A cause and effect diagram is “a fish-bone diagram that
presents a systematic representation of the relationship
between the effect (result) and affecting factors (causes).”
Solving a problem in a scientific manner requires
clarification of a cause and effect relationship, where the
effect (e.g., the result of work) varies according to factors
(e.g., facilities and machines used, method of work, workers,
and materials and parts used). To obtain a good work result,
we must identify the effects of various factors and develop
measures to improve the result accordingly.
7 Q C Tools 17
Cause & Effect Diagram
2. When is it used and what results will be obtained?
7 Q C Tools 18
Cause & Effect Diagram
Method Usage Result
Used when Can obtain a clear
overall picture of causal
Cause and Effect clarifying a cause relation. (A change in
Diagram
Machine Man
and effect the cause triggers a
relationship.[Used variation in the
Effect
7 Q C Tools 19
Cause & Effect Diagram
Mechanism of Quality of
Copying Machine Copying Paper
Deterioration of
Error in
performance due
Keyboard handling placement of Dirt on the
to high
error paper (setting glass
temperatures
its face up) surface
Error in selecting a
Dust
scale of reduction Error in Nicotine-
selecting stained
shading
User Surrounding
Environment
7 Q C Tools 20
Stratification
1. What is Stratification ?
7 Q C Tools 21
Stratification
2. When is it used and what results will be obtained?
The “common and basic principle” of quality control is
stratification, i.e., to think a matter out by breaking it
into smaller portions. Stratification has a number of
useful purposes. The table below shows only a few
examples of these purposes.
7 Q C Tools 22
Stratification
Method Usage Result
Grouping by day, •Used to observe variations
•Allows observation
time, place, among strata.
of variations among
worker, or •Used to identify the
process strata.
relationship between cause
•By performing a
Number of Units
and effect.
cause analysis using
X ★★★★★★★ •Used to identify a purpose
the stratified data,
Y △△△△ and means to serve the
the following can be
purpose
Z ○○○ accomplished.
[Used during phases to monitor
the situation, analyze causes, 1.Identification and control of a
review effectiveness of an action, problem
perform standardization, and 2.“Division of data (obtained by
implement a selected control using each QC tool) into several
measure.] groups”
7 Q C Tools 23
Stratification
Item Method of Stratification
Hour, a.m., p.m., immediately after start of work,
Elapse of time
shift, daytime, nighttime, day, week, month
Worker, age, male, female, years of experience,
Variations among workers
shift, team, newly employed, experienced worker
Processing method, work method, working
Variations among work
conditions (temperature, pressure, and speed),
methods
temperature
Variations among Measurement tool, person performing
measurement/inspection measurement, method of measurement, inspector,
methods sampling, place of inspection
7 Q C Tools 24
Check Sheet
1. What is Check sheet ?
A check sheet is “a sheet designed in advance to allow easy
collection and aggregation of data.” By just entering check
marks on a check sheet, data can be collected to extract
necessary information, or a thorough inspection can be
performed in an efficient manner, eliminating a possibility
of skipping any of the required inspection items.
A check sheet is also effective in performing stratification
(categorization).
7 Q C Tools 25
Check Sheet
2. When is it used and what results will be obtained?
7 Q C Tools 26
Check Sheet
Method Usage Result
Used to collect Ensures collection of
Check Sheet data. required data.
Day
Process
Used when Allows a thorough
Process 1
performing a inspection of all check
Process 2
Can understand
Used during phases to monitor tendencies and
the situation, analyze causes, variations.
review effectiveness of an Can record required
action, perform data.
standardization, and
implement a selected control
measure
7 Q C Tools 27
Check Sheet
A check sheet used to identify defects
Date
Total
Defect
Vertical Scratch
Scratch
Dent
7 Q C Tools 28
Control Chart (Control Chart / Graph 1)
1. What is Control Chart ?
A control chart is used to examine a process to see if
it is stable or to maintain the stability of a process.
This method is often used to analyze a process. To
do so, a chart is created from data collected for a
certain period of time, and dots plotted on the chart
are examined to see how they are distributed or if they
are within the established control limit. After some
actions are taken to control and standardize various
factors, this method is also used to examine if a
process is stabilized by these actions, and if so, to
keep the process in a stable state.
7 Q C Tools 29
Control Chart
2. When is it used and what results will be obtained?
There are two types of control charts: one used for
managerial purposes and the other for analytical
purposes. A control chart is used to identify dots that
are outside the control limit, which indicate some
anomalies in a process. In addition, seven
consecutive dots showing values that are below or
above the mean (central) value, or an increasing or a
decreasing trend represented by seven consecutive
dots also indicate “a problem in a process.”
7 Q C Tools 31
Control Chart
Examples of Values
Represented by Dots
Values above the
control
control limit
limit
represented
seven by
seven
Consecutive dots
x-Control Chart
A decline
represented
representedby
by
seven
consecutive dots
Group Number
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Graph
1. What is Graph ?
7 Q C Tools 33
Graph
2. When is it used and what results will be obtained?
A graph, although it is listed as one of the QC tools, is
commonly used in our daily life and is the most
familiar means of assessing a situation.
7 Q C Tools 34
Graph
Method Usage Result
120
Changes in a time-sequential Can observe changes in
100
3rd Qtr
57%
7 Q C Tools 35
Graph
[Bar Graph of Sales] [Band Chart of Expenses]
・ Survey Period: Dec. 1999
million) (¥million)
・ Prepared by: M/T
million)
Before
Sales
Sales Iwate
A Tokyo
B Osaka
C Shizuoka
D Electricity
Office (108)
7 Q C Tools 36
Histogram
1. What is Histogram ?
7 Q C Tools 37
Histogram
2. When is it used and what results will be obtained?
A histogram is mainly used to analyze a process by
examining the location of the mean value in the
graph or degree of variations, to find a problem point
that needs to be improved. Its other applications are
listed in the table below.
7 Q C Tools 38
Histogram
Method Usage Result
•Used to assess the actual
conditions. •Can identify the
Histogram •Used to analyze a process to location of the mean
Standard
Range identify a problem point that needs (central) value or
to be improved by finding the degree of variations.
location of the mean value or •Can find out the scope
degree of variations in the graph.
•Used to examine that the target
of a defect by inserting
X Axis (Values
Actually quality is maintained throughout standard values.
Range of
Variations
Measured)
the process. •Can identify the
•Others condition of
[Used during phases to distribution (e.g.,
monitor the situation, analyze whether there is an
causes, and review isolated, extreme
effectiveness of an action.] value).
7 Q C Tools 39
Scatter Diagram
1. What is Scatter Diagram ?
7 Q C Tools 40
Scatter Diagram
2. When is it used and what results will be obtained?
The table on next slide shows some examples of
scatter diagram’s usage. If, for example, there is a
relationship where “an increase in the number of
rotations (x) causes an increase in abrasion (y),” there
exists “positive correlation.” If, on the other hand, the
existence of a relationship where “an increase in the
number of rotations (x) causes a decline in abrasion
(y)” indicates that there is “negative correlation.”
7 Q C Tools 41
Scatter Diagram
Method Usage Result
•Used to identify a relationship •Can identify cause
Scatter Diagram between two matters.
y Axis
•Used to identify a relationship and effect relation.
Abrasion
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Scatter Diagram
yAxis
Abrasion (micron)
x Axis
Number of
Rotations
7 Q C Tools 43
Application of QC tools in Problem Solving
Graphs Check Stratifi Pareto Cause & Histogra Scatter Control
sheet cation Diagra Effect m Diagram Chart
m Diagram
Identification of
problem
Defining the
problem
Record of facts
Detecting causes of
problem
Develop
Improvement
method
( Solution )
Implementation
Evaluation of result
Process control
( Standardization )
Relation :-
7 Q C Tools Strong Normal 44
To sum up 7 QC tools (Numerical data ) are used as follow:
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Thank you
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