7 quality tools by krishna heda
DESCRIPTION
As much as 95% of quality related problems can be solved with seven fundamental quantitative tools.... must seeTRANSCRIPT
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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
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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
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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.
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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”
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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
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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
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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
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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
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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.
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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
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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)
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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
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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
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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
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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
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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?
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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
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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
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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
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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?
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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
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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
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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
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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
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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?
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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
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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…
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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
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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
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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
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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
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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
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Control ChartsControl ChartsUpper LimitUpper Limit
Lower LimitLower LimitUnacceptable deviation
X
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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
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Acme example Acme example Control Control ChartsCharts
Upper LimitUpper Limit
17 inches17 inches
Lower LimitLower Limit15 Inches15 Inches
Small Pie
X16 inches=
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Acme example #50Acme example #50Control ChartsControl Charts
•Pies within specifications were acceptable
•One abnormally small pie is “uncommon”
•Should be examined for quality control
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SummarySummary
• Basic Seven Tools of QualityBasic Seven Tools of Quality
• Measuring dataMeasuring data
• Quality AnalysisQuality Analysis
• ““Democratized statistics”Democratized statistics”
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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.