11 lesson quality tools

8/3/2019 11 Lesson Quality Tools

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Lesson 11 - 7 Q-Tools - 1 1 Mar 05

Lesson 11

Quality Tools


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The Quality Toolbox

Flow Chart

Fishbone Diagram

Check Sheet

Control Chart

Pareto Chart

Scatter Diagram

Histogram


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Quality Tools

In his book Introduction to Quality Control,Kaoru Ishikawa identified seven basic tools

for quality control by combining his workwith the concept of variation and statisticalcontrol charts. These tools represent thefirst practical scientific tools in analyzing

and improving process performance.

Control without action is simply a hobby ~ Ishikawa


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Check Sheets


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Check Sheets

Used for organizing and collecting factsand data To make better decisions

To solve problems faster

Three common types of check sheets Recording check sheets (e.g. data sheets,

checkbook register)

Checklists (e.g. inspection checklist) Measles charts (e.g. rental car customers vehicle

inspection sheet)


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Check Sheets

Step #1: Identify data/information needsStep #2: Decide on check sheet format

Step #3: Design and produce the check

sheet

Step #4: Complete the check sheet


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Category 1 2 3 4 5 6 Total

A

B

C

D

E

F

Total

Days of Week

Com artment1-25-0-L

01-35-7-Q

3-120-0-E

01-141-0-M

05-200-1-E

1-45-6-Q

Electrical Ins ection Mechanical Ins ection Final Acce tance

XXX

Identify surface defectlocations with an X

Measles Chart example

Recording Check Sheet

Compartment Inspection Checklist

Step #3:Design & Produce Check Sheet



Category 1 2 3 4 5 6 Total

A III II IIII II I IIII 16B I II IIII IIII III IIII 18

C II I I I 5

D III I I I II 8

E III II I I 7

F I III I II IIII 11

Total 13 6 14 8 8 16 65

Days of Week

Step #4:Complete the Check Sheet



Histograms



Histograms

Used to analyze a problem when There is a data set of related values, either

attributes (counts) or variables data(measurements), and

It is important to visualize central location, shapeand spread of the data

Focuses attention on a distribution of

results A picture is worth a thousand words



Histograms

Step #1: Select logical categories foridentified topic

Step #2: Specify the time period

Step #3: Collect the data

Step #4: Construct a counts /

measurements table

Step #5: Draw the histogram chart


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Category Counts

A 1B 4

C 11

D 24

E 38

F 50

G 52

H 55

I 49

J 44

K 36

L 29

M 17

N 10

O 4

P 2

Q 1

Step #4: Construct a counts /measurements table


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Step #5: Draw the Histogram

0

10

20

30

40

50

60

A B C D E F G H I J K L M N O P Q

Counts


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Review Histogram Results

Step #6: Evaluate distribution

Step #7: Develop conclusions

Step #8: Develop an action plan


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Histogram Example

Frequency of Test Scores

1059585756555453525

40

30

20

10

0

Test Scores

Frequency


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Scatter Diagrams


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Used to determine whether or not arelationship exists between two factors Will not prove that a cause-and-effect relationship

exists

Enables teams to test hunches betweentwo factors

Scatter Diagrams


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Scatter Diagrams

Step #1: Determine factors to be comparedStep #2: Collect paired observations

(factors A & B) data

A check sheet containing the pairedobservation data might be used

Step #3: Plot the data


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Step #3: Plot the data

0

1

2

3

0 1 2 3

Factor A

FactorB


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Review Scatter Diagram Results

Step #4: Interpret the diagramLook for patterns (narrow band of points,

circular pattern, peaks or troughs, etc.)


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Step #4: Interpret the diagram

0

1

2

3

0 1 2 3

Factor A

FactorB

0

1

2

0 0.5 1

Factor A

FactorB

0

1

2

3

0 1 2 3

Factor A

Facto

rB

Narrow band, direct relationship Circular, no relationship

Wide band, inverse relationship


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Scatter Diagram Example

1.00.90.80.70.60.50.40.30.20.10.0

7

6

5

4

3

2

1

0

920N KMD

920N

Plot of 920N Defects per 1000 MDs


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Fishbone Diagrams*

*Also referred to as a Cause & Effect Diagram, or Ishikawa Diagram, after Dr.

Ishikawa, who was (incorrectly) credited with its invention.


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Fishbone Diagrams

Breaks problems down into bite-sized

pieces

Displays many possible causes in a

graphic manner Shows how causes interact

Follows brainstorming rules when

generating ideas

A.K.A Ishikawa diagram or cause &

effect diagram


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Fishbone Diagrams

Brainstorming Rules: Determine who will facilitate the session

Determine the length of the session

Each person, in turn:

Provides an idea (which the facilitator or scribe

captures on a white-board or easel pad), or

Says Pass (allowing next person to make a

suggestion) Suggestions are not discussed, merely captured


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Fishbone Diagrams

Step #1: Define problem and determine themain causes (I,II,III,...)

Use 5Ms: Man, Method, Machine, Material,Mother Nature

Main Cause IIMain Cause I

Main Cause VMain Cause IV

Main Cause III

Problem


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Fishbone Diagrams

Step #2: Pick one main cause and askWhy did the main cause occur?

Results in causes A, B, C, ...

Work onecategory at

a time

please!

Main Cause I

Why did the main cause occur?

C

A

B

Problem


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Fishbone Diagrams

Step #3: Pick one cause and ask Whydid cause A occur?

Results in causes A1, A2, A3,

Work one

category ata time

please!

Main Cause I

Why did cause A occur?

A

A1A2

A3

Problem


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Fishbone Diagrams

Step #4: Pick one cause and ask Why? 5timesEnd result is a probable cause

Ask Why?5 times?

Main Cause I

Why

A2A1?A

A2

Why

A?

A2A1A1A2A1

A2A

Why

A2A?

A2A1A

WhyA2A1A?

Probable

CauseProblem


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Fishbone Diagrams

Step #5: Repeat Steps #2 through #4 untilall causes have resulted in a

probable cause

Step #6: If one probable cause repeats,identify it as a root cause


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Review Fishbone Diagram


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Step #7: Develop an action plan to addressroot causes

Notes on Fishbone Diagrams: Can be used to conduct accident investigations

Can be used as a follow-on to Pareto (identifies

critical issues / problems)

Review Fishbone DiagramResults


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Fishbone Example

D/P Cell Project:

Materials

Man (People)Mother Nature(Environment)Machinery

Methods

Team todo the job

(Effect)

Project Teams

ImprovementSuggestion

Min. # of people

Contract NAVSEA

team

Expertise

Use other Corp methods

Consistency

Use of othersmachines/tools

Fewer critiques/problems

Mobile facilities

Teams trailer

with toolsStandardization

Kit materials you needprepared


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L 11 7 Q T l 34

Presentation Exercise

Spend 20 minutes developing yourpresentation

Use flip chart

10 minute presentation per group Each person at your table will present

Include an example or exercise

Incorporate what you learned inpresentation basics

11 lesson quality tools

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