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Total Quality ManagementbyDr. Asif MahmoodInstitute of Business & ManagementUniversity of Engineering and Technology, LahoreThe Basic Seven (B7) Tools of Quality"As much as 95% of quality related problems in the factory can be solved with seven fundamental quantitative tools.Kaoru Ishikawa Basic Seven Tools of Quality (Or)Old Seven Tools

FlowchartsCheck SheetsHistogramsStratification or Scatter PlotsFishbone DiagramsPareto AnalysisControl Charts3Logical Order for B7 ToolsFlowChartCheckSheetHistogramsScatterDiagramsControlChartsCause&EffectParetoAnalysisBig PictureData CollectionData AnalysisProblemIdentificationPriortization

FlowchartA diagram that uses graphic symbols to depict the nature and flow of the steps in processPromote process understandingProvide tool for trainingIdentify problem areas and improvement opportunitiesDepict customer-supplier relationships

Basic Flow Chart SymbolsActivity:Operation/InspectionDecisionStart/EndBookendsWait/DelayFlow Lines6These symbols are in Microsoft Power PointLevels of Flowchart

Keys to SuccessStart with the big pictureObserve the current processRecord process stepsArrange the sequence of stepsDraw the flow chartTypes of Flowchart Linear FlowchartA Linear Flowchart is a diagram that displays the sequence of work steps that make up a process.Deployment FlowchartA Deployment Flowchart shows the actual process flow and identifies the people or groups involved at each step.Opportunity FlowchartAn Opportunity Flowcharta variation of the basic linear typedifferentiates process activities that add value from those that add cost only.Linear FlowchartExample: Plan of the Day

Deployment FlowchartExample: Plan of the Day

Opportunity FlowchartExample: Plan of the Day

Making a Cup of Tea

ExerciseCheck SheetsWhat is a check sheet?

A form or sheet used to record data

What is it for?

To manually collect data in a reliable, organised way.To present the facts for further investigation.For recording and presenting direct observations and facts about a process.

Check Sheet - How do We use it? - Common designs

Tabular FormatEquipment breakdown data

A Location Plot/Format uses a picture of the item to mark defect positions.

Location Plot/FormatGraphic Format

It measures the frequency of a single item across a range of measures - produces a histogram.

Process Distribution Check SheetIt counts and classifies defects by type

Defective Item Check SheetIt contains a list of actions which are ticked off as they are done..

ChecklistWhat is a Histogram?A bar graph that shows the distribution of dataA snapshot of data taken from a process

When are Histograms Used?Summarize large data sets graphicallyCompare measurements to specificationsCommunicate information to the teamAssist in decision makingParts of Histogram

How to Construct a histogramStep 1 Count the total number of data pointsNumber of yards long (+data) and yards short (-data) that gun crew missed its target

Step 2 Summarize the data on a tally sheetHow to Construct a histogram

Step 3 Compute the range for the data set

Largest value = +410 yards past targetSmallest value = -180 yards short of targetRange of values = 590 yardsCalculation: +410 - (-180) = 410+180 = 590How to Construct a histogramHow to Construct a HistogramStep 4 Determine the number of intervals requiredData pointsLess than 5050 to 99100 to 250More than 250

No. of Intervals5 to 76 to 107 to 1210 to 20How to Construct a HistogramStep 5 Compute the interval width

How to Construct a HistogramStep 6 Determine the starting point of each intervalStep 7 Count the number of points in each interval

How to Construct a HistogramStep 8 Plot the dataStep 7 Add the title and legend

Interpreting Histograms:Location and Spread of Data

Interpreting Histograms:Is Process Within Specification Limits?

Interpreting Histograms:Process Variation

Interpreting Histograms:Common Histogram Shapes

Histogram: Exercise 1A corpsman is responsible for the semiannual Physical Readiness Test (PRT) screening for percent body fat. Prior to one PRT, the corpsman recorded the percent of body fat for the 80 personnel assigned to the command. These are the data collected (next slide):Exercise 1: Percent Body Fat Recorded

A Marine Corps small arms instructor was performing an analysis of 9 mm pistol marksmanship scores to improve training methods. For every class of 25, the instructor recorded the scores for each student who occupied the first four firing positions at the small arms range. The instructor then averaged the scores for each class, maintaining a database on 105 classes. These are the data collected:Histogram: Exercise 2Exercise 2: AVERAGE SMALL ARMS SCORESContinued

Scatter Plots/Diagram or StratificationA graphical technique to analyze the relationship between two variables.Two sets of data are plotted on a graph, with the y-axis being used for the variable to be predicted and the x-axis being used for the variable to make the prediction.The graph will show possible relationships among variables.http://www.asq.org/learn-about-quality/cause-analysis-tools/overview/scatter.html42Interpreting DataIf the x-coordinates and the y-coordinates both increase, then it is POSITIVE CORRELATION.This means that both are going up, and they are related.

Positive CorrelationIf the x-coordinates and the y-coordinates have one increasing and one decreasing, then it is NEGATIVE CORRELATION.This means that 1 is going up and 1 is going down, making a downhill graph. This means the two are related as opposites.

Interpreting DataNegative CorrelationTypes of correlationsInterpret the dataScatter diagrams will generally show one of six possible correlations between the variablesTypes of correlationsStrong Positive CorrelationStrong Negative CorrelationWeak Positive CorrelationWeak Negative CorrelationComplex CorrelationWeak/No Correlation

Strong Positive Correlation The value of Y clearly increases as the value of X increases.

Types of correlationsStrong Negative Correlation The value of Y clearly decreases as the value of X increases.

Weak Positive Correlation The value of Y increases slightly as the value of X increases.

Types of correlationsWeak Negative Correlation The value of Y decreases slightly as the value of X increases.

Complex Correlation The value of Y seems to be related to the value of X, but the relationship is not easily determined.

Weak/No Correlation There is no demonstrated connection between the two variables.

Types of correlationsScatterplotsWhich scatterplots below show a linear trend?a)c)e)b)d)f)NegativeCorrelationPositiveCorrelationConstantCorrelationTypes of correlationsYearSport Utility Vehicles(SUVs) Sales in U.S. Sales (in Millions) 1991199219931994199519961997199819990.91.11.41.61.72.12.42.73.21991 1993 1995 1997 1999 1992 1994 1996 1998 2000xyYearVehicle Sales (Millions)54321Objective - To plot data points in the coordinate plane and interpret scatter plots.1991 1993 1995 1997 1999 1992 1994 1996 1998 2000xyYearVehicle Sales (Millions)54321Trend is increasing.Scatterplot - a coordinate graph of data points.Trend appears linear.Positive correlation.

Predict the sales in 2001.Plot the data on the graph such that homework timeis on the y-axis and TV time is on the x-axis..StudentTime SpentWatching TVTime Spenton HomeworkRazaRizwanBilalGulraizHafsaRamshaSohail30 min.45 min.120 min.240 min.90 min.150 min.180 min.180 min.150 min.90 min.30 min.90 min.90 min.90 min.Plot the data on the graph such that homework timeis on the y-axis and TV time is on the x-axis.TVHomework30 min.45 min.120 min.240 min.90 min.150 min.180 min.180 min.150 min.90 min.30 min.120 min.120 min.90 min.Time Watching TVTime onHomework30 90 150 210 60 120 180 240240210180150120 90 60 30Describe the relationship between time spent onhomework and time spent watching TV.Time Watching TVTime onHomework30 90 150 210 60 120 180 240240210180150120 90 60 30Trend is decreasing.Trend appears linear.Negative correlation.