Agenda Week 6


Review Homework 
Week 7 assignment
• Problems Ch 3: 2, 4 • Read chapter 4

Chapter 3: Problem Solving • Homework
• Desksides: 7 QC Tools problems: Ch 3
• Flow chart
- 11, 12, 23, 28(c)
• Run Chart
• Case Study: "How
• Pareto Diagram
We Slashed
• Histogram
Response Time"
• Cause and Effect
Diagram
• Check sheet

• Scatter diagram

• Control chart

Quality Improvement: Pro

Seven Quality Tools
Chapter 3: Problem
Solving

Quality Improvement: Problem So

lving
Seven Quality Control Tools
• Pareto Chart
• Histogram
• Process flow diagram
• Check sheet
• Scatter diagram
• Control chart
• Run Chart
• Cause and Effect Diagram
Quality Improvement: Pro
Pareto Principle

Vilfredo Pareto (1848-1923) Italian
economist
• 20% of the population has 80% of the
wealth

Juran used the term “vital few, trivial
many”. He noted that 20% of the quality
problems caused 80% of the dollar loss.

7 Quality Tools

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Pareto chart
30 28
% Complaints

25

20
16
15
12 12
10
6
5 4 3
0
Loose Stitching Button Material
Threads flaws problems flaws

7 Quality Tools

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 Chart
Pareto

Percent from each cause

10
20
30
40
50
60
70

0
Po
or
W De
ro s
n g ig
di n
(64)

m
De en
f ec
s io
ns
tiv
(13)

M e
ac pa
hi rts
ne

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(10)

ca
O lib
pe ra
ra t io
to
(6)

re ns
De rro
f ec rs
tiv
(3)

e
m
Causes of poor quality

Su at
rfa er
ce ia
ls
(2)

ab
ra
s io
n s
(2)
Histogram
25

20

15
Frequency

10

Category

7 Quality Tools

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Histogram

40
35
30
25
20
15
10
5
0 1 2 6 13 10 16 19 17 12 16 20 17 13 5 6 2 1

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Flowcharts

Flowcharts
• Graphical description of how work is done.
• Used to describe processes that are to be
improved.

7 Quality Tools

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Flow Diagrams
" Draw a flowchart for whatever you do.
Until you do, you do not know what you
are doing,
you just have a job.”

-- Dr. W. Edwards Deming.

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Flowchart
Flowchart
Activity

Yes
Decision

No

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Flowchart

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Flow Diagrams

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Flow Diagrams

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Process Chart Symbols
Operations
Inspection

Transportation

Delay

Storage

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Process Chart
Date: 9-30-00 Location: Graves Mountain
Analyst: TLR Process: Apple Sauce

Distance
Operation
Transport Description

Storage
Inspect

(feet)
(min)
Time
Delay
Step

of
process

1 Unload apples from truck 20

2 Move to inspection station 100 ft
3 Weigh, inspect, sort 30
4 Move to storage 50 ft
5 Wait until needed 360
6 Move to peeler 20 ft
7 Apples peeled and cored 15
8 Soak in water until needed 20
9 Place in conveyor 5
10 Move to mixing area 20 ft
11 Weigh, inspect, sort 30
Page 1 0f 3 Total 480 190 ft

Quality Improvement: Pro

Quality Improvement: Pro
Check
Check Sheet
Sheet

Shifts

   

Defect Type

 

 

 

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Check Sheet
COMPONENTS REPLACED BY LAB
TIME PERIOD: 22 Feb to 27 Feb 1998
REPAIR TECHNICIAN: Bob

TV SET MODEL 1013

Integrated Circuits ||||
Capacitors |||| |||| |||| |||| |||| ||
Resistors ||
Transformers ||||
Commands
CRT |

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Cause-and-Effect
Cause-and-Effect Diagrams
Diagrams

Show the relationships between a
problem and its possible causes.

Developed by Kaoru Ishikawa (1953)

Also known as …
• Fishbone diagrams
• Ishikawa diagrams

7 Quality Tools

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Cause
Cause and
and Effect
Effect
“Skeleton”
“Skeleton”
Materials Procedures

Quality
Problem

People Equipment
7 Quality Tools

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Fishbone Diagram
Measurement Human Machines

Faulty testing equipment Poor supervision Out of adjustment

Incorrect specifications Lack of concentration Tooling problems

Improper methods Inadequate training Old / worn

Quality
Inaccurate Problem
temperature Poor process
control Defective from vendor
design
Ineffective quality
Not to specifications management
Dust and
Dirt Material- Deficiencies
handling problems in product
design
Environment Materials Process

Quality Improvement: Pro

Cause and effect diagrams

Advantages
• making the diagram is educational in itself
• diagram demonstrates knowledge of
problem solving team
• diagram results in active searches for
causes
• diagram is a guide for data collection

Quality Improvement: Pro

Cause and effect diagrams
To construct the skeleton, remember:

For manufacturing - the 4 M’s
 man, method, machine, material

For service applications
 equipment, policies, procedures, people

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Scatter Diagram

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Run Charts

Run Charts (time series plot)
• Examine the behavior of a variable over
time.
• Basis for Control Charts

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Control Chart 27

24
UCL = 23.35
21
Number of defects

18 c = 12.67

15

12

6
LCL = 1.99
3

2 4 6 8 10 12 14 16
Sample number
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Control Charts

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“Stem and leaf” displays
Data
Integrated Circuit Response Time (ps)

4.6 4.0 3.7 4.1 4.1 5.6 4.5 6.0 6.0 3.4
3.4 4.6 3.7 4.2 4.6 4.7 4.1 3.7 3.4 3.3
3.7 4.1 4.5 4.6 4.4 4.8 4.3 4.4 5.1 3.9

Quality Improvement: Pro

“Stem and leaf” displays

Integrated Circuit Response Time (ps)

3 7 4 4 7 7 4 3 7 9

4 6 0 1 5 6 2 6 7 1 1 5 6 4 8 3 4

5 6 1

6 0 0

Quality Improvement: Pro

Dot diagrams

Integrated Circuit Response Time (ps)

3 4 5 6
Plant A

Plant B

Quality Improvement: Pro