7 QC Tools TATA Motors PDF

Commercial Vehicle Business Unit 7 QC Tools
Tata Motors Limited

Commercial Vehicle Business Unit
Pune, Maharashtra
Welcome
7 QC Tools & 8D
1
7 Tools for Quality Control
2
What are 7 QC Tools ?

QC tools are the means for Colleting data
, analyzing data , identifying root causes and
measuring the results.
USER HAS TO ARRIVE AT THE

SOLUTION & IMPLEMENT
3
Ishikawa’s Basic Tools of Quality
• Kaoru Ishikawa developed seven basic visual tools of

quality so that the average person could analyze and
interpret data.
• These tools have been used worldwide by

companies, managers of all levels and employees.
4
Problem Solving Tools

1. Simple Tools for Problem Analysis
1.1 Why -Why Analysis
1.2 What If Analysis
2 Simple 7 QC Tools (Statistical Tools)
•Stratification
•Pareto Diagram
•Cause and Effect Diagram
•Check Sheet
•Control Chart/Graph
•Histogram
•Scatter Diagram
5
What is a “Problem “?
“Problem is an undesirable event” or ..
Any Gap between what is expected and what is

obtained , can be called as a Problem, and any effort to
reduce this gap can be called as “Problem Solving”
Expected
(Gap ?) A Problem!
Obtained
6
Why - Why analysis - An Example
Purpose : It is the simple tool used by the team to

find out the cause of the problem / Accident /
Breakdown at the Workplace.
7

Why - Why
Library analysisSolving
of Problem - An Example
Tools
Water Dripping in Substation 1
WHY ?
Water accumulated at the roof
WHY ?
Outlet drain chocked
WHY ?
Atmospheric dust & dirt
WHY ?
Periodic cleaning of drain not done
Action
Proper scheduled procedure for roof cleaning is to be prepared
8
9 April 2012 Revision : 0

9
Step 4:Factor Analysis
5 Why analysis :
Probable Cause 1 Cause 2 Cause 3
Oil pattern marks on

Cause's
component
1 WHY ? Excess oil on the blank
Presence of oil on Blank

2 WHY ?
in Perpendicular
direction of material flow
w.r.t Die.
Blank was passing in

3 WHY ? that direction through the
oiling machine
Wrong blank orientation on

4 WHY ?
the stack table
5 WHY ? Blank orientation

to be modified
10
What-IfofAnalysis
Library Problem Solving Tools
Purpose : It is the simple Pro active tool

used by the team to identify problems before
hand and take appropriate counter measures
to prevent such problems .
11

What-IfofAnalysis
Library Problem- Solving
An Example
Tools
Area : Equipment :Compressor
Team :
SL. What If Results Countermeasures
1. There is no Water in The Engine heats • Inspect the
the Radiator of an up and Piston may Temperature of
Automobile ? And it get seized. outlet water .
is not noticed. • Provide the temp.
Indictor for the
driver
12
Seven QC tools
1. Pareto diagrams
2. Cause & Effect diagram – Ishikawa diagram –
Fishbone diagram Check sheet
3. Stratification
4. Check sheets
5. Histogram & frequency distributions
6. Scatter diagrams (concept of correlations)
7. Graph & control charts
13
1. Pareto diagrams
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.
Pareto’s 80/20 Rule

80% Of: Are Produced by 20% of:
• Company profits • Company Products
• Car Accidents • Drivers
• Farm Goods • Farmers
• Delayed Shipments • Shipping Sites
• Company Sales • Customers
14
Pareto Diagram
1. What is Pareto diagram ?
A Pareto diagram is a combination of bar and line graphs of
accumulated data, where data associated with a problem are
divided into smaller groups by cause or by phenomenon and
sorted.
2. When is it used and what results will be obtained?
It is mainly used to prioritize matters.
15
15
Pareto Diagram
Method Usage Result
Used to identify and
prioritize a problem. Allows identification
Pareto Diagram of a starting point
(No. of Occurrences) Used to review the effects of (which task to start
an action taken. with).
Allows projection of
the effects of a measure
Used to prioritize actions. to be taken
(Used to monitor the
situation, analyze causes,
and review effectiveness of
an action.)
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16
Pareto diagram
17
Rejection Trend of Press Parts on Line 1

Pareto Analysis for TL1 Rejection
1000 98.9 99.6 99.8 99.9 100.0 100.0 100.0 100.0 100.0 100.0 100.00
91.8
900 90.00
800 80.00
74.0
700 70.00
Constituent ratio
600 60.00
Rejection Qty
500 50.00
400 40.00
300 30.00
200 20.00
100 10.00
0 0.00
Hole shift
Damage
Checking
imbalance
Oil mark
Crack
Dents
Chip mark
Depth less
Rust
Side cut
Wrinkle
Comp Name
18
2. Cause & Effect diagrams
Man Machine
Quality
Problem
Method Material
19
Cause & Effect diagrams

•Show the relationships between a problem and its
possible causes.
•Developed by Kaoru Ishikawa (1953)
•Also known as …
Fishbone diagrams or
Ishikawa diagrams
20

What is Effect ?
EFFECT = A Result or an outcome
EFFECT is What happens
21
What is cause ?
CAUSE = Reason or Factor contributing to the EFFECT

CAUSE is WHY it happens
22

Measurement Man Method
Cause Effect
Material Machine Environment
• If there are no clues to indicate the cause, Write a cause and effect
diagram.
• List down the possible and probable causes by brain storming.
• Group them under 6M category.
• Then by observation eliminate causes which do not contribute to the
problem.
23

To construct the skeleton, remember:
• For manufacturing - the 4 M’s / 5 M’s / 6 M’s
man, method, machine, material, measurement,
Environment.
Constructing a Cause and Effect Diagram

• First, clearly identify and define the problem or effect for which the
causes must be identified. Place the problem or effect at the right
or the head of the diagram.
• Identify all the broad areas of the problem.
• Write in all the detailed possible causes in each of the broad areas.
• Each cause identified should be looked upon for further more
specific causes.
• View the diagram and evaluate the main causes.
• Set goals and take action on the main causes
24
Cause & Effect diagrams - Brainstorming

Definition -
Brain storming is a Team approach to generate creative ideas in a short time
Brain storming plays an important role to build a Cause and Effect Diagram
Why
Brain
storming
?
Brainstorming is used to establish common method for a team to creatively

and efficiently generate high volume of ideas on any topic
Brainstorming encourages open thinking
Gets the involvement of all the team members without the dominance of
anyone team member
Allows team members to build on each others creativity while staying focus
on the joint mission
25
Cause & Effect diagrams - Brainstorming
26
Brainstorming sheet
Brainstorming
Brainstorming Subject _____________________ Session Date: ___/___/___
Present__________________________________ Session number __________
Sr Brain storming Points 5 M category Sr Brain storming Points 5 M category
27

Fishbone Diagram
Man Machine
Poor supervision Out of adjustment
Lack of concentration Tooling problems
Inadequate training Old / worn
Quality
Problem
Defective from vendor Poor process
design
Ineffective quality
Not to specifications management
Material- Deficiencies
handling problems in product
design
Materials Method
28
Step 4:Factor Analysis
ISHIKAWA DIAGRAM FOR REJECTION DUE TO OIL PATTERN
MACHINE MATERIAL
Oil nozzle not OK Excess oil in the blanking stage
O' ring not cleaned
O' ring condition not OK

Oil on Brass plate Oil viscosity not ok
Oil Pr. Not OK

O' ring cleaning attachment not OK
Rejection due
to oil pattern
marks.
O' ring not cleaned
streatching direction not OK
Training not given to operator Orientation of blank not OK
O' ring cleaning frequency not maintained Improper oil pattern
MAN METHOD
29

30

31
Factor Analysis
Factor and Cause –Distinction

All conditions that
potentially contribute to
the phenomenon
Factors
Cause Effect
The condition that will

always produce the
phenomenon
32
3 Stratification
1. What is Stratification ?
Stratification means to “divide the whole into smaller portions

according to certain criteria.”
Stratification generally means to divide data into several groups

according to common factors or tendencies (e.g., type of defect
and cause of defect).
33
33
3 Stratification

The “common and basic principle” of quality control is
stratification, i.e., to think a matter out by breaking it
into smaller portions.
Stratification has a number of useful purposes.
34
34
3 Stratification
Item Method of Stratification
Hour, a.m ., p.m ., imm ediately after start of work,
Elapse of tim e
shift, daytim e, nighttim e, day, week, m onth
W orker, age, m ale, fem ale, years of experience,
Variations am ong workers
shift, team , newly em ployed, experienced worker
Processing m ethod, work m ethod, working
Variations am ong work
conditions (tem perature, pressure, and speed),
m ethods
tem perature
Variations am ong Measurem ent tool, person perform ing
m easurem ent/inspection m easurem ent, m ethod of m easurem ent, inspector,
m ethods sam pling, place of inspection
35
35
Defects/1000
0
1
2
0.5
1.5
2.5
Cp dia u/c u/s

2.29
Commercial
Cp dia u/c flat mark width o/s c
CL 242
1.81
machine
CP Grinding
CP Width Over Size Grinding
0.96
CP Dia Radius Step / dia flat mark

0.84
analysis
CP dia uc & Width Over Size
Crank
CL 251
Landies
machine.
Grinding
MB dia u/s & step
1.04 1.04
Vehicle Business Unit
Machine wise defects
CL 92
Mb dia flat mark dia u/s c
machine
1.22
MB Grinding
Mb dia u/s
0.44
CL 07
MB dia Flat Mark / Step
grinding
1.56
semi finish
Multi wheel Mb dia u/s
0.26
Mb 2dia width o/s dia u/s

CL 6
0.66
machine
Mb 2 dia width o/s

MB2 Grinding
0.44
15
Mb 2 dia u/s
0.33
7 QC Tools
No. of defects :
CL 113
CP Dia Unclean Grinding

machine
1.04
36
CP Grinding
Cp dia u/s
0.39
Check Sheet
1. What is Check sheet ?
A check sheet is “a sheet designed in advance to allow easy
collection and aggregation of data.”
By just entering check marks on a check sheet, data can be
collected to extract necessary information, or a thorough
inspection can be performed in an efficient manner,
eliminating a possibility of skipping any of the required
inspection items.
37
37
Check Sheet
It is frequently used in daily business operations.
38
38
Check Sheet
Method Usage Result
Used to collect Ensures collection of
Check Sheet data. required data.
Day
Process Allows a thorough
Process 1
inspection of all check
Process 2
items.
Process 3
39
39
Check Sheet
A check sheet used to identify defects
Date
Total
Defect
Vertical Scratch
Scratch
Dent
40
40
Check sheet
Types of check sheets
• Process distribution check sheet

• Defective cause wise check sheet
• Defect location check sheet
• Defective cause check sheet
41
CHECK SHEET
Process distribution Check Sheet

(Continuous data use) No._____
Product Name __________________ Date ___________________
Usage _________________________ Dept. Name ____________
Specification ____________________ Section Name ____________
No. of Inspectors ________________ Data Collector ____________
Total Number ___________________ Group Name _____________
Lot Number ____________________ Remarks ________________
Dimensions 2 2 2 2 2 2.0 2 2 2 2 3 3 3 3 3 3.0 3 3

25
L S L
U S L
20
15
10
0
Total Frequency 1 2 6 13 10 16 19 17 12 16 20 17 13 8 5 6 2 1
42
Defective Cause wise check sheet
Product : _________________ Date : _______________

Manufacturing stage : Final insp. Factory : _____________
Type of defect : Scar , incomplete , mishappen Section : _____________
Total no. inspected : 2530 Inspector's name : _____
Remarks : All items inspected Lot No. ______________
Order No. ____________
Type Check Sub Total

Surface scar 32
Cracks 23
Incomplete 48
Mishappen 4
Others 8
115
Grand Total :
Total Rejects
86
43
Defect location Check Sheet Bubble Investigation Check Sheet
Remark
Date :
Product Type :
44

45
Defective cause check sheet
Monday Tuesday Wednesday Thursday Friday Saturday
Equipment Worker am pm am pm am pm am pm am pm am pm
Machine 1 A χχθζ χθ χχχ χθθ χχχθ χχχχ χχχχ χθθ χχχχ χχ χ θθζ
€ € € θθζ θθθ θζζ € € € € €
B χθθζ χχχθ χχχχ χχχθ χχχχ χχχχ χχχχ χχχθ χχθθ χχχχ χ θθζ
€ θχ χχθθ θ χχθθ χχθζ χθ ζζ ζ χ € €
Machine 2 C χχθ χθ χχ ζ χχχχ χχχχ χχ χζ χχυ χχο οχ χο
€ € € € χ χχθ € € € € € €
D χχθ χθ χχ χχχζ χχχζ χχχχ χχχ χχυ χχυυ χζζ οχχθ θθο
€ € € € υ χθ € € ο € € €
χ Surface Scratch
θ Blow hole
υ Defective finishing
ζ Improper Shape
ο Others
46
What is Histogram ?
A histogram is a bar graph that shows frequency

data
Histograms provide the easiest way to evaluate the

distribution of data
47
47

When is it used and what results will be obtained?
A histogram is mainly used to analyze a process by
examining the location of the mean value in the
graph or degree of variations, to find a problem point
that needs to be improved.
48
48
Method Usage Result

•Used to assess the actual
conditions. •Can identify the
Histogram •Used to analyze a process to location of the mean
Standard
Range identify a problem point that needs (central) value or
to be improved by finding the degree of variations.
location of the mean value or •Can find out the scope
degree of variations in the graph.
of a defect by inserting
X Axis (Values
Actually
standard values.
Range of Measured)
Variations
49
49
•A histogram is a bar graph that shows frequency data
•Histograms provide the easiest way to evaluate the

distribution of data
50
Histogram
LSL USL
30
Number of times
n = 100
Frequency -
x = 28.016
20 s = 0.295
10
（mm） 27.0 27.2 27.4 27.6 27.8 28.0 28.2 28.4 28.6 28.8 29.0
51
HISTOGRAM
NORMAL, NATURAL DISTRIBUTION

Bell - Shaped
TWO DISTINCT PROCESSES AT WORK

Double - Peaked
ONE SIDED SPECIFICATONS

Skewed
52
HISTOGRAM
MANY PROCESSES OR
NO DEFINED PROCESSES
Plateau
MEASUREMENT ERRORS OR
DATA GROUPING WRONG
Comb
DISTINCT ABNORMALITY
Isolated- Peaked
53
HISTOGRAM
SCREENED
Truncated
INACCURATE DATA RECORDING

Edge - Peaked
54
HISTOGRAM
LIMITS OF ACCEPTABILITY
Limit Nominal Limit
Acceptable now, but the slightest change will

make it unacceptable. Should reduce the variability.
55
HISTOGRAM
Limit Nominal Limit
Unacceptable, process needs adjustment

back to center range
56
HISTOGRAM
Limit Nominal Limit
Unacceptable, need to
reduce the variability
57
6 Scatter Diagram
1. What is Scatter Diagram ?
A scatter diagram is used to “examine the relationship between

the two, paired, interrelated data types, ” such as “height and
weight of a person.”
A scatter diagram provides a means to find whether or not
these two data types are interrelated. It is also utilized to
determine how closely they are related to identify a problem
point that should be controlled or improved.
58
58
Scatter Diagram
The table on next slide shows some examples of
scatter diagram’s usage. If, for example, there is a
relationship where “an increase in the number of
rotations (x) causes an increase in abrasion (y),” there
exists “positive correlation.” If, on the other hand, the
existence of a relationship where “an increase in the
number of rotations (x) causes a decline in abrasion
(y)” indicates that there is “negative correlation.”
59
59
Scatter Diagram
Method Usage Result
•Used to identify a relationship •Can identify cause
Scatter Diagram between two matters.
ｙAxis and effect relation.
•Used to identify a relationship
Abrasion
between two matters and establish •Can understand the

countermeasures based on their
cause and effect relation. relationship
x Axis Example Usage between two
Number of
Rotations
1.Relationship between thermal results.
treatment temperature of a steel
material and its tensile strengths
2.Relationship between visit made
by a salesman and volume of sales
3.Relationship between the number
of persons visiting a department
store and volume of sales
4 Others
[Used during phases to monitor the
situation, analyze causes, and review
effectiveness of an action.]
60
60
Scatter Diagrams are used to study and identify the

possible relationship between the changes observed in
two different sets of variables
61
Positive Coorelation Positive Coorelation No Coorelation

may be present
Negative Coorelation Negative Coorelation

may be present
62
7. Graph & Control Charts

Graphs and charts are pictorial representation of the data,
making it easy to spot trends, ratios and comparisons
among different groups of data.
The more common types of graphs and charts are Line

graphs, Bar charts and Pie charts.
63

Line Graph
LINE GRAPHS ARE USED TO DEPICT CHANGE OR VARIATION OVER TIME.
Example
Variation of temperature
30
Temperature C
25
0
20
18 17
15 15 16 15
14 13
10
5
0
9:00am 10:00am 11:00am 12:00noon 1:00pm 2:00pm 3:00pm
Time
64

Bar graph
Bar graphs are used for comparing quantities between
persons, regions, time intervals etc.
30 28
25
20
16
15 12 12
10
6
4 3
5
0
Loose Incorrect Stitching Trim Errors Button Color Material
Threads hemming flaws problems mismatch flaws
65

Pie Chart
Pie charts are used to show percentages or proportions of different
components of a specific item.
3
4
6
Loose Threads
28
Incorrect hemming
Stitching flaws
12 Trim Errors
Button problems
Color mismatch
Material flaws
12
16
66
Control Chart (Control Chart / Graph 1)

1. What is Control Chart ?
A control chart is used to examine a process to see if
it is stable or to maintain the stability of a process.
This method is often used to analyze a process. To
do so, a chart is created from data collected for a
certain period of time, and dots plotted on the chart
are examined to see how they are distributed or if they
are within the established control limit. After some
actions are taken to control and standardize various
factors, this method is also used to examine if a
process is stabilized by these actions, and if so, to
keep the process in a stable state.
67
67
Control Chart
There are two types of control charts: one used for
managerial purposes and the other for analytical
purposes. A control chart is used to identify dots that
are outside the control limit, which indicate some
anomalies in a process. In addition, seven
consecutive dots showing values that are below or
above the mean (central) value, or an increasing or a
decreasing trend represented by seven consecutive
dots also indicate “a problem in a process.”
We need to examine what has caused such a

tendency.
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68
Control Chart
Method Usage Result
Used to observe a Can identify a change
Control Chart
caused by elapse of
change caused by
time.
elapse of time.
Can judge the
[Used during phases to
process if it is in its
monitor the situation,
normal state or there
x-R Control Chart analyze causes, review
are some anomalies
effectiveness of an
by examining the dots
action, perform
plotted on the chart.
standardization, and
implement a selected In the example “x bar ” -R
control chart, “X bar”
control measure represents the central value,
while “R” indicates the range.
Control Chart for Managerial Purposes: Extends the line indicating the control limit used for analytical purposes to
plot data obtained daily to keep a process in a good state.
Control Chart for Analytical Purposes: Examines a process if it is in a controlled state by collecting data for a certain
period of time. If the process is not controlled, a survey is performed to identify its cause and develop
countermeasures.
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69
Control Chart
78.40
UCL = 78.2789
78.30
x 78.20 CL = 78.1214
78.10
78.00 LCL = 77.9639
77.90
0.60
UCL = 0.493
0.50
0.40
R × × × ×
× ×
0.30
× × ×
× CL = 0.216
0.20 × × × × ×
× × × ×
× ×
0.10 × × ×
×
1 5 10 15 20 25
70

Control charts are used to determine whether a process will produce a
product or service with consistent measurable properties
Control charts –P chart
71

Control charts –X bar R
72
Why do we need the 7 QC tools?
• Quality Management is data driven: data are impersonal;

opinions are not
• Experience is gained quickest by collecting and analyzing data
• The 7 QC tools provide common methods of analysis to help

problem solving teams operate effectively
73
Why do we need the 7 QC tools?
Application of QC tools in Problem Solving
Graphs Check Stratifi Pareto Cause & Histogra Scatter Control
sheet cation Diagra Effect m Diagram Chart
m Diagram
Identification of
problem
Defining the
problem
Record of facts
Detecting causes of
problem
Develop
Improvement
method
( Solution )
Implementation
Evaluation of result
Process control
( Standardization )
74
To sum up 7 QC tools (Numerical data ) are used as follow:
• Stratification Basic processing performed when collecting data

• Pareto Diagram To identify the current status and issues
• Cause & Effect Diagram
To identify the cause and effect relationship
• Histogram To see the distribution of data

• Scatter Diagram To identify the relationship between two things
• Check Sheet To record data collection
• Control Chart/Graph To find anomalies and identify the current status
75
76

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Commercial Vehicle Business Unit 7 QC Tools

Tata Motors Limited

7 Tools for Quality Control

What are 7 QC Tools ?

USER HAS TO ARRIVE AT THE

Ishikawa’s Basic Tools of Quality

• Kaoru Ishikawa developed seven basic visual tools of

• These tools have been used worldwide by

Problem Solving Tools

Any Gap between what is expected and what is

Problem Solving Tools

Why - Why analysis - An Example

Purpose : It is the simple tool used by the team to

Problem Solving Tools

Proper scheduled procedure for roof cleaning is to be prepared

9 April 2012 Revision : 0

Oil pattern marks on

1 WHY ? Excess oil on the blank

Presence of oil on Blank

Blank was passing in

Wrong blank orientation on

5 WHY ? Blank orientation

Problem Solving Tools

Purpose : It is the simple Pro active tool

Problem Solving Tools

Pareto’s 80/20 Rule

2. When is it used and what results will be obtained?

It is mainly used to prioritize matters.

Rejection Trend of Press Parts on Line 1

2. Cause & Effect diagrams

Cause & Effect diagrams

•Developed by Kaoru Ishikawa (1953)

Cause & Effect diagrams

Cause & Effect diagrams

CAUSE = Reason or Factor contributing to the EFFECT

Cause & Effect diagrams

Material Machine Environment

Cause & Effect diagrams

Constructing a Cause and Effect Diagram

Cause & Effect diagrams - Brainstorming

Brainstorming is used to establish common method for a team to creatively

Cause & Effect diagrams - Brainstorming

Sr Brain storming Points 5 M category Sr Brain storming Points 5 M category

Cause & Effect diagrams

Poor supervision Out of adjustment

Lack of concentration Tooling problems

Inadequate training Old / worn

Oil nozzle not OK Excess oil in the blanking stage

O' ring not cleaned

O' ring condition not OK

Oil Pr. Not OK

Training not given to operator Orientation of blank not OK

O' ring cleaning frequency not maintained Improper oil pattern

9 April 2012 Revision : 0

9 April 2012 Revision : 0

Factor and Cause –Distinction

The condition that will

Stratification means to “divide the whole into smaller portions

Stratification generally means to divide data into several groups

2. When is it used and what results will be obtained?

Stratification has a number of useful purposes.

Cp dia u/c u/s

Product : ___ Date : _