7 quality tools by krishna heda

The Basic Seven (B7) The Basic Seven (B7) Tools of QualityTools of Quality

A PowerPoint Training PresentationA PowerPoint Training Presentation

By KRISHNA HEDABy KRISHNA HEDA"As much as 95% of quality related problems in the factory can be solved "As much as 95% of quality related problems in the factory can be solved

with seven fundamental quantitative tools." - Kaoru Ishikawawith seven fundamental quantitative tools." - Kaoru Ishikawa

What are the Basic Seven What are the Basic Seven Tools of Quality?Tools of Quality?

• Fishbone DiagramsFishbone Diagrams• HistogramsHistograms• Pareto AnalysisPareto Analysis• FlowchartsFlowcharts• Scatter PlotsScatter Plots• Run ChartsRun Charts• Control ChartsControl Charts

Where did the Basic Seven Where did the Basic Seven come from?come from?

Kaoru IshikawaKaoru Ishikawa• Known for “Democratizing Statistics”Known for “Democratizing Statistics”

• The Basic Seven Tools made statistical analysis The Basic Seven Tools made statistical analysis less complicated for the average personless complicated for the average person

• Good Visual Aids make statistical and quality Good Visual Aids make statistical and quality control more comprehendible.control more comprehendible.

The Basic Seven (B7) The Basic Seven (B7) Tools of QualityTools of Quality

Fishbone DiagramsFishbone Diagrams

• No statistics involvedNo statistics involved

• Maps out a process/problemMaps out a process/problem

• Makes improvement easierMakes improvement easier

• Looks like a “Fish Skeleton”Looks like a “Fish Skeleton”

Constructing a Fishbone Constructing a Fishbone DiagramDiagram

• Step 1 - Identify the ProblemStep 1 - Identify the Problem• Step 2 - Draw “spine” and “bones”Step 2 - Draw “spine” and “bones”

Example: Example: High Inventory Shrinkage at local Drug StoreHigh Inventory Shrinkage at local Drug Store

Shrinkage

Constructing a Constructing a Fishbone DiagramFishbone Diagram

• Step 3 - Identify different areas where Step 3 - Identify different areas where problems may arise fromproblems may arise from

Ex. : Ex. : High Inventory Shrinkage at local Drug StoreHigh Inventory Shrinkage at local Drug Store

Shrinkage

employees

shoplifters

Constructing a Constructing a Fishbone DiagramFishbone Diagram

• Step 4 - Identify what these specific causes Step 4 - Identify what these specific causes could becould be

Ex. : Ex. : High Inventory Shrinkage at local Drug StoreHigh Inventory Shrinkage at local Drug Store

Shrinkage

shoplifters

Anti-theft tags poorly designedExpensive merchandise out in the open

No security/ surveillance

Constructing a Fishbone Constructing a Fishbone DiagramDiagram

• Ex. : Ex. : High Inventory Shrinkage at local Drug StoreHigh Inventory Shrinkage at local Drug Store

Shrinkage

shoplifters

Anti-theft tags poorly designedExpensive merchandise out in the open

No security/ surveillance

employeesattitude

new traineetraining

benefits practices

Constructing a Fishbone Constructing a Fishbone DiagramDiagram

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

The Basic Seven (B7) The Basic Seven (B7) Tools of QualityTools of Quality

HistogramsHistograms

• Bar chartBar chart

• Used to graphically represent groups of Used to graphically represent groups of datadata

ConstructingConstructing a Histogram a Histogram

From a set of data computeFrom a set of data compute• sumsum• mean (x)mean (x)• MaxMax• MinMin• Range (max-min)Range (max-min)

ConstructingConstructing a Histogram a Histogram

• Use range to estimate beginning Use range to estimate beginning and end and end

• Calculate the width of each column Calculate the width of each column by dividing the range by the by dividing the range by the number of columnsnumber of columns

Range

# of Columns= Width

Acme Pizza ExampleAcme Pizza Example

• Let’s say the owner wants a Let’s say the owner wants a distribution of Acme’s Thursday distribution of Acme’s Thursday Night SalesNight Sales

Data Set from last Thursday(slices)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 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 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 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 42 2 3 1 2 1 1 2 1 2 2 2 1 2 2 1 2 1 2 2 2 4 2 4

Acme Pizza ExampleAcme Pizza Example

Mean = 2.032258 Mean = 2.032258

Max = 7 Max = 7

Min = 0 Min = 0

Range = 7 Range = 7

QuestionQuestion

For 7 columns what would the width be?For 7 columns what would the width be?

Range/Columns=7/7=1 slice

Acme Pizza ExampleAcme 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

# tim

es o

rder

edHistogram

Constructing a HistogramConstructing a Histogram

How is this helpful to Acme?How is this helpful to Acme?• 2 slices of pizza most common order 2 slices of pizza most common order

placedplaced• Distribution of sales useful for Distribution of sales useful for

forecasting next Thursday’s late night forecasting next Thursday’s late night demanddemand

If you were an Acme manager how could If you were an Acme manager how could you apply this information?you apply this information?

The Basic Seven (B7) The Basic Seven (B7) Tools of QualityTools of Quality

Pareto AnalysisPareto Analysis

• Very similar to HistogramsVery similar to Histograms

• Use of the 80/20 ruleUse of the 80/20 rule

• Use of percentages to show importanceUse of percentages to show importance

Acme Pizza (part 2)Acme Pizza (part 2)

SlicesSlices FrequencyFrequency %%

00 11 .3.3

11 33 33 13.09 13.09

22 65 65 25.79 25.79

33 88 3.17 3.17

44 12 12 4.76 4.76

55 00 00

66 00 00

77 11 .3 .3

Acme Pizza (part 2)Acme Pizza (part 2)

• The completed Pareto Analysis results in the following The completed Pareto Analysis results in the following graph:graph:

0

10

20

30

40

50

60

70

1 2 3 4 5 6 7

Slices of Pizza

# tim

es o

rder

ed

2 1 4 3 7 5 6

Acme Pizza (part 2)Acme Pizza (part 2)

Critical ThinkingCritical Thinking• How does the Pareto Analysis differ How does the Pareto Analysis differ

from the Histogram?from the Histogram?

• How can this be a useful tool to the How can this be a useful tool to the Acme boss?Acme boss?

The Basic Seven (B7) The Basic Seven (B7) Tools of QualityTools of Quality

FlowchartsFlowcharts

• A graphical picture of a PROCESSA graphical picture of a PROCESS

Process Decision

The process flow

FlowchartsFlowcharts

Don’t Forget to:Don’t Forget to:

• Define symbols before beginningDefine symbols before beginning

• Stay consistentStay consistent

• Check that process is accurateCheck that process is accurate

Acme Pizza Example Acme Pizza Example (Flowchart)(Flowchart)

WindowWindow Take CustomerTake Customer Money?Money?

(start)(start) Order Order

Get PizzaGet Pizza

LockupLockupPut More inPut More in OvenOven 2 Pies 2 Pies

Available?Available?

TimeTime

to close?to close? Take to CustomerTake to Customer

noyes

no

yesno

yes

How can we use the flowchart to How can we use the flowchart to analyze improvement ideas from the analyze improvement ideas from the

Histogram?Histogram?

WindowWindow Take CustomerTake Customer Money?Money?

(start)(start) Order Order

Get PizzaGet Pizza

LockupLockupPut More inPut More in OvenOven 2 Pies 2 Pies

Available?Available?

TimeTime

to close?to close? Take to CustomerTake to Customer

noyes

no

yesno

yes

Want some practice?Want some practice?

Make a flowchart for:Make a flowchart for:

• Taking a showerTaking a shower• Cooking dinnerCooking dinner• Driving a carDriving a car• Having a partyHaving a party• Creating a FlowchartCreating a Flowchart

Any other processes you can think of?Any other processes you can think of?

The Basic Seven (B7) The Basic Seven (B7) Tools of QualityTools of Quality

Scatter PlotsScatter Plots• 2 Dimensional X/Y plots2 Dimensional X/Y plots• Used to show relationship Used to show relationship

between independent(x) and between independent(x) and dependent(y) variablesdependent(y) variables

Acme Pizza (Scatter Acme Pizza (Scatter Diagram)Diagram)

Minutes CookingMinutes Cooking Defective Pies Defective Pies

1010 11

4545 88

3030 55

7575 20 20

6060 14 14

2020 44

2525 66

In this simple example, you can find the existing In this simple example, you can find the existing relationship without much difficulty but…relationship without much difficulty but…

Scatter DiagramsScatter Diagrams

0

5

10

15

20

25

0 20 40 60 80

•Easier to see direct relationship

Time Cooking (minutes)

Def

ecti

ve P

izza

s

Scatter DiagramsScatter Diagrams

As a quality toolAs a quality tool• What does this tell Acme What does this tell Acme

management about their management about their processes?processes?

• Improvements?Improvements?

0

5

10

15

20

25

0 20 40 60 80

Time Cooking (minutes)

Def

ecti

ve P

i zza

s

The Basic Seven (B7) The Basic Seven (B7) Tools of QualityTools of Quality

Run chartsRun charts• Time-based (x-axis)Time-based (x-axis)

• CyclicalCyclical

• Look for patternsLook for patterns

Run ChartsRun 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

5 10

15

2 0 2

5 3 0

35

40 4

5 50

55

60 6

5 70

75

8 0 8

5 9 0

95

1 00

Slices/hour

Time

The Basic Seven (B7) The Basic Seven (B7) Tools of QualityTools of Quality

Control ChartsControl Charts• Deviation from MeanDeviation from Mean

• Upper and Lower Spec’sUpper and Lower Spec’s

• RangeRange

Control ChartsControl ChartsUpper LimitUpper Limit

Lower LimitLower LimitUnacceptable deviation

X

Control ChartsControl Charts

Acme Pizza Management wants to get in on the control chart action

•Average Diameter = 16 inches

•Upper Limit = 17 inches

•Lower Limit = 15 inches

Acme example Acme example Control Control ChartsCharts

Upper LimitUpper Limit

17 inches17 inches

Lower LimitLower Limit15 Inches15 Inches

Small Pie

X16 inches=

Acme example #50Acme example #50Control ChartsControl Charts

•Pies within specifications were acceptable

•One abnormally small pie is “uncommon”

•Should be examined for quality control

SummarySummary

• Basic Seven Tools of QualityBasic Seven Tools of Quality

• Measuring dataMeasuring data

• Quality AnalysisQuality Analysis

• ““Democratized statistics”Democratized statistics”

BibliographyBibliography

• Foster, Thomas. Foster, Thomas. Managing Quality. An Integrative Managing Quality. An Integrative ApproachApproach. Upper Saddle River : Prentice Hall, . Upper Saddle River : Prentice Hall, 2001.2001.

• Stevenson, William. “Supercharging Your Pareto Stevenson, William. “Supercharging Your Pareto Analysis.” Analysis.” Quality ProgressQuality Progress October 2000: October 2000: 51-55.51-55.

• ““Dr Kaoru Ishikawa.” Internet Dr Kaoru Ishikawa.” Internet “http://www.dti.gov.uk/mbp/bpgt/m9ja00001/m9j“http://www.dti.gov.uk/mbp/bpgt/m9ja00001/m9ja0000110.html.” 16 February 2001.a0000110.html.” 16 February 2001.

• ““Chemical and Process Engineering.” Internet. Chemical and Process Engineering.” Internet. “http://lorien.ncl.ac.uk/ming/spc/spc8.htm.” 17 “http://lorien.ncl.ac.uk/ming/spc/spc8.htm.” 17 February 2001.February 2001.