By: Maruti Center for Excellence (MACE) On 20th June2008

ULTIMATE GOAL OF AN ORGANIZATION

- Making Profits - Survival & - Growth

SURVIVAL AND GROWTH: HOW?

- Products & Services must be preferable to Customers over Competitors.
- Organization must continually meet Needs & Expectations of Customers i.e. Voice of Customers also called QUALITY
4

WHAT IS A PROBLEM?
A problem is the gap between the present Situation And the ideal situation or objective Control characteristic Ideal situation or objective
Good Gap Problem = (ideal situation or objective) (present level) Present Level

PROBLEM DEFINED
Deviation from the expectation - In maintaining the status quo. - In improving the status quo

An opportunity for improvement

The Problem-Solving Process

Grasp problem Set target Identify gap between existing situation and target

Expose problem

Expose problem

Experience, intuition, nerve, inspiration

Analyze causes

Investigate cause

Implement countermeasures
1. The conventional problem solving approach

Implement countermeasures

Plan countermeasures Implement countermeasures Institutionalize

2. The QC problem-solving approach

8

WHAT ARE SEVEN QC TOOLS :

TOOLS ARE USED TO IDENTIFY, ANALYSE AND RESOLVE PROBLEMS
TOOLS ARE SIMPLE, VERY POWERFUL AND HELP TO IDENTIFY THE CAUSES FOR WORK RELATED PROBLEMS AND TO FIND SOLUTIONS FOR THE SAME IN A

SYSTEMATIC MANNER.

1 Cause and Effect Diagram 2 Graphs / Flowcharts 3 Pareto analysis 4 Checksheets 5 Control charts 6 Scatter diagram 7 Histogram
10

PARETO DIAGRAM
Prioritisation Tool It tells where to concentrate first. 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.

11

PRINCIPLE OF PARETO
Isolate vital few from trivial many. 80/20 principle. 80% improvement can be achieved by

working on 20% of the causes.

12

WHAT IS PARETO DIAGRAM :

It is a column graph. Differentiating major
factors contributing to problem from other factors which have less contribution. Thus it helps fixing priority to take first. OR A technique to segregate vital few from trivial many

13

DATA TALLY SHEET

DEFECT TALLY Total

A
B C D E F
TOTAL No. of defects

////
//// //// //// //// ////

////
////

////
////

.......
//// ////

////
////

150
60 45 30 9 6 300

//// . //// . //// /

Total No. of defectives : //// //// //// . ////

150

14

What is a defective : A unit that contains at least one defect.

What is a defect : An output of a process that does not meet a defined specification.

15

DATA SHEET FOR PARETO DIAGRAM

S.No Defect . No. of defects Cumulative total Percentage of overall total Cumulative percentage

1)
2) 3) 4)

A
B C D

150
60 45 30

150
210 255 285

50
20 15 10

50
70 85 95

5)
6)

E
F Total

9
6 300

294
300 -

3
2 100

98
100 16

Pareto diagram
No. of defects Cummulative %
17

200 150 100 50 0 A B

150 50 60 70

85

95

98

100

45

30

100 80 60 40 20 0

Type of defect

DATA TALLY SHEET

DEFECT
Flow mark Sink Mark Warpage Silver streak Crack

TALLY

Total

//// //// //// //// ////

//// //// //// //// ////

//// //// . . ////

....... //// ////

//// ////

200 100 50 25 15

Flash

////

////

10 400

TOTAL

Total No. of defectives : //// //// //// . ////

250

18

DATA SHEET FOR PARETO DIAGRAM

S.No Defect . No. of defects Cumulative total Percentage of overall total Cumulativ e percentag e

1) 2)

Flow mark Sink mark Warpag e Silver streak Crack

200 100

200 300

50 25

50 75

3)
4)

50
25

350
375

12.5
6.25

87.5
93.75

5) 6)

15 10
400

390 400
-

3.75 2.5
100

97.5 100
19

Flash

Total

Pareto diagram
250 200 150 100 50 0
200 50 87.5 93.75 97.5 100

75 100

50

25

15

10

100 80 60 40 20 0

ar W k ar pa Si ge lv er st re ak C ra ck

Fl ow

Si nk

Type of defect
20

Fl as h

ar k

Cummulative %

No. of defects

CAUSE AND EFFECT DIAGRAM

Shows the relationship between a problem and its possible causes. Developed by Kaoru Ishikawa (1953)
Also known as Fishbone diagram Ishikawa diagram
21

WHAT IS CAUSE AND EFFECT DIAGRAM :

A systematic arrangement of all possible causes

which give rise to the effect are made. The

causes are first divided into major sources (4Ms) i.e., MAN, MACHINE, METHOD & MATERIAL. Then each source is divided into sub-sources and so on. It helps to find out the root cause of the
22

problem.

METHODOLOGY : How to reach to root cause of the problem

Step 1 : Make fish bone diagram and write all possible causes in 4 Ms after brainstorming session.
Step 2 : Find out suspect or potential causes from the possible causes. Highlight it. Step 3 : Validate all the suspect or potential causes and write the judgement. All the NG judgements are the main causes of the problem. Step 4 : Do the why why analysis of the main causes and find out the root causes of the problem.
23

METHODOLOGY :

Step 1 : Possible causes

Step 2 : Suspect or Potential causes

Step 3 : Main causes

Step 4 : Root causes

24

Cause & Effect diagram - Major and subsidiary causes

Material
Assemblies

Methods
Procedures

Environment
Noise level Temperature

Consumables Components Suppliers Accounting Policies Lighting

Humidity

Quality
Variability Training Experience Technology Tooling Attitude Skill Fixtures Gauging Counting Instruments Tests

Men

Machine

Measurement

25

P D

CAUSE & EFFECT DIAGRAM

METHOD MATERIAL
PROCESS TIME RUBBING CLOTH LAYOUT

PROCESS SEQUENCE

CAR SHAMPOO WATER BRUSHES

POLISH QUALITY

POOR WASHING QUALITY

NOZZLE DIA VACUUM CLEANER PUMP PRESSURE WORK LOAD JOB SKILL EXPERIENCE TRAINING

MACHINE

MAN
26

VALIDATION OF POTENTIAL CAUSES

S. Potential Cause No. Validation Conclusion

27

SAMPLE SIZE FOR VALIDATION

Formulae : np = 5 or n= 5 / p

Where n= number of sample size p= no. of defects coming out of 100 Example : Suppose 1% defect is there, then sample size will be n= 5*100 / 1 = 500

28

5 WHY FOR ROOT CAUSE

ASK WHY FIVE TIMES. When a problem has just been discovered, think about it by asking the question why? five times. A haphazard idea of the cause cannot be counted on. Thinking it over repeatedly will discover the root cause. For example , imagine that a bracket has broken from a pipe. 1. Why did the bracket broken? ( It was not welded properly)

2. Why wasnt it welded properly? ( The bracket wasnt set in the proper position when it was welded)
3. Why wasnt the bracket placed in the proper position for welding? ( The welding jig was loose) 4. Why was the welding jig loose? ( The welding jig is worn) 5. Why is the welding worn? ( The material specification of the jig was not proper)
29

WHAT IS A SCATTER DIAGRAM :

A graphical technique to show the dependency of two variables.

It is used to study the variation of two

corresponding variables. For example, what extent surface finish of a machined part be varied by the change in speed of a lathe.
30

SCATTER DIAGRAM - Example of Positive Correlation

15
Y - Axis

10 5 0 0 5
X - Axis
31

10

15

SCATTER DIAGRAM - Example of Negative Correlation

15
Y - Axis

10 5 0 0 5
X - Axis
32

10

15

Scatter Diagram
variation of strength with varying air pressure
1.8
Strength

1.6 1.4 1.2 1 3.5 4 03-Mar 06-Mar 4.5 04-Mar

02-Mar 05-Mar

5 5.5 Air pressure

6
33

EXAMPLE OF SCATTER DIAGRAM :

Two variables : a) Speed of the car in kms / Hr. b) Petrol consumption in kms / Lt.
EFFECT Speed of the car in kms / Hr.
30 35 40 45 50 55 60 65 70 75

Petrol consumptio n in kms / Lt.

15, 15.5 16, 16.5 17, 17.5 18, 18.5 19, 19.5 20, 20.5 22, 22.5 21, 21.5 20, 20.4 19, 19.6

CAUSE
Here Cause : Speed of the car in kms / Hr. Effect : Petrol consumption in kms / Lt.

80
85 90 95 100

18, 18.6
18, 18.5 17, 17.4 16, 16.2 16, 16.1 34

EXAMPLE OF SCATTER DIAGRAM :

Positive and negative co-relation

24

22.5 19.5 15.5 15 16.5 16 17.5 17 18.5 18 19 20.5 20 22

FUEL AVERAGE IN KMS / LT

22 20 18 16 14 12 10 20 30 40 50

21.5 20.4 21 20 19 19.6 18.6 18 18.5 17.4 18 17 16.2 16.1 16 16

60

70

80

90

100

110

SPEED IN KMS / HR.

35

OTHER EXAMPLES OF SCATTER DIAGRAM :

In machining process : 1) Cause : Speed of the machine and effect : surface finish of the component. 2) Cause : Feed of the machine and effect : surface finish of the component

36

WHAT ARE CONTROL CHARTS :

Control charts serve to detect abnormal trends with the help of line graphs.

Control charts differ from standard line graphs as they have control limit lines at the center, top and bottom levels.
37

CONTROL CHARTS FOR VARIABLES

The variable control charts that are most commonly used are average or X-bar-charts, range or Rcharts and sigma-standard deviation charts.

38

WHAT IS X CHART
X chart shows the centering of the process,i.e. it shows the variation in the average of samples. It is the most commonly used variable chart.

39

WHAT IS R CHART
R chart shows the uniformity or consistency of the process i.e. it shows the variation in the range of samples.

40

Diameter of Shaft: 23.75 + 0.1 mm

No. of samples per : day 6 : 6 The diameter of shafts are as given below :
1st day 2nd day 3rd day 4th day 5th day 6th day 7th day 8th day 23.77 23.80 23.78 23.73 23.76 23.75 23.80 23.78 23.76 23.70 23.81 23.77 23.77 23.78 23.77 23.77 23.80 23.74 23.79 23.76 23.79 23.74 23.82 23.76 23.75 23.78 23.78 23.77 23.76 23.79 23.78 23.76 23.73 23.76 23.74 23.78 23.76 23.78 23.75 23.76 23.81 23.80 23.76 23.79 23.77 23.72 23.78 23.78
41

Construct the X and R chart:

Average diameter for the first day X1 = X1+X2+X3+X4+X5+X6

6
= 23.77+23.80+23.78+23.73+23.76+23.75 6 = 23.765 Similarly, the averages for each day are calculated: X1
23.765

X2
23.77

X3
23.771 6

X4
23.776 7

X5
23.771 7

X6
23.758 3

X7
23.776 7

X8
23.766 7
42

Now X = Ranges : R1
.07

X = 190.1567 = 23.7696 8

R2
.11

R3
.06

R4
.08

R5
.04

R6
.05

R7
.06

R8
.07

R=
For X chart :

R = 0.0675

UCLX =X + A2R
=23.7696 + 0.48 x 0.0675 (A2= 0.48 for subgroup of from table)
43

= 23.7696 + 0.0324 = 23.802 LCLX =X - A2R

= 23.7696 0.0324 = 23.7322

For R chart : UCLR = D4R

= 2 x 0.0675 = 0.1350
LCRR = D3R = 0 (D3 = 0 for subgroup of 6 or less) Process capability : Sigma = R / d2 = 0.0675 / 2.534 = 0.0266 ( for subgroup of 6, d2 = 2.534

Xmax = (USL) upper specification limit, Xmin= (LSL) lower specification limit

44

 Xmax Xmin = 0.2 mm from data Process capability Cp = (USL LSL)/ 6 sigma Cp= 0.2 / 6* 0.0266 = 0.2 / 0.15982 = 1.25 Cpk = (USL X ) / 3 sigma or (X LSL) / 3 sigma Cpk = (23.85 23.7696)/ 3*0.0266=1.0 Cpk = (23.7696 23.65)/ 3*0.0266 = 1.49 Cpk = 1.0 or 1.49 ( 1.0 is minimum )
45

X CHART
UCL23.802

x23.7696

LCL
23.7322

46

R chart
UCL 0.1350
R1 R2 R3 R4 R5 R6 R7 R8

R 0.0675

LCL 0
47

No.
1 2 3 4 5 6 7 8 9 10

I
1.38 1.38 1.41 1.36 1.36 1.38 1.40 1.40 1.40 1.41

II
1.42 1.39 1.41 1.45 1.42 1.45 1.40 1.41 1.40 1.41

III
1.42 1.42 1.39 1.41 1.46 1.39 1.41 1.38 1.40 1.39

IV
1.4 1.41 1.38 1.39 1.37 1.40 1.39 1.39 1.39 1.38
DIMENSION : 1.4 + / - 0.3

Draw X bar and R chart

11 12 13 14 15 16 17 18 19 20

1.41 1.44 1.37 1.38 1.39 1.37 1.38 1.39 1.38 1.32

1.40 1.34 1.43 1.44 1.46 1.47 1.42 1.39 1.44 1.40

1.39 1.36 1.41 1.42 1.40 1.40 1.45 1.39 1.46 1.41

1.42 1.38 1.38 1.40 1.40 1.40 1.37 1.45 1.37 1.40
48

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

I
1.38 1.38 1.41 1.36 1.36 1.38 1.40 1.40 1.40 1.41 1.41 1.44 1.37 1.38 1.39 1.37 1.38 1.39 1.38 1.32

II
1.42 1.39 1.41 1.45 1.42 1.45 1.40 1.41 1.40 1.41 1.40 1.34 1.43 1.44 1.46 1.47 1.42 1.39 1.44 1.40

III
1.42 1.42 1.39 1.41 1.46 1.39 1.41 1.38 1.40 1.39 1.39 1.36 1.41 1.42 1.40 1.40 1.45 1.39 1.46 1.41

IV
1.4 1.41 1.38 1.39 1.37 1.40 1.39 1.39 1.39 1.38 1.42 1.38 1.38 1.40 1.40 1.40 1.37 1.45 1.37 1.40

X
1.405 1.4 1.3975 1.4025 1.4025 1.405 1.4 1.395 1.3975 1.3975 1.405 1.38 1.3975 1.41 1.4125 1.41 1.405 1.405 1.4125 1.3825
49

Now we calculate the Range:Range:- Highest value of sample Smallest value of sample For example:R1 1.42 1.38 0.04

Similarly we calculate for all the samples.

50

No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

I
1.38 1.38 1.41 1.36 1.36 1.38 1.40 1.40 1.40 1.41 1.41 1.44 1.37 1.38 1.39 1.37 1.38 1.39 1.38 1.32

II
1.42 1.39 1.41 1.45 1.42 1.45 1.40 1.41 1.40 1.41 1.40 1.34 1.43 1.44 1.46 1.47 1.42 1.39 1.44 1.40

III
1.42 1.42 1.39 1.41 1.46 1.39 1.41 1.38 1.40 1.39 1.39 1.36 1.41 1.42 1.40 1.40 1.45 1.39 1.46 1.41

IV
1.4 1.41 1.38 1.39 1.37 1.40 1.39 1.39 1.39 1.38 1.42 1.38 1.38 1.40 1.40 1.40 1.37 1.45 1.37 1.40

X
1.405 1.4 1.3975 1.4025 1.4025 1.405 1.4 1.395 1.3975 1.3975 1.405 1.38 1.3975 1.41 1.4125 1.41 1.405 1.405 1.4125 1.3825

R
0.04 0.04 0.03 0.09 0.1 0.07 0.02 0.03 0.01 0.03 0.03 0.01 0.06 0.06 0.07 0.1 0,08 0.06 0.09 0.09
51

X N X1 + X2 + X3+ X4 + X5 + X6..X19 +X20 20 1.405 + 1.4 + 1.3975 + 1.4025 + 1.4025 + 1.4.1.4125 + 1.3825 20

Now Calculate

1.4011 M

R N R1+ R2+R3+R4.R19+R20 20 0.04 + 0.04 + 0.03 + 0.09..0.06 + 0.09 + 0.09 20

Now Calculate R

0.06

52

Calculation For Average (X-bar) Chart

Upper Control Limit (UCL) = X +A2 R = 1.4011+0.73*0.06 = 1.4449 = 1.44
Lower Control Limit (LCL) = X - A2 R = 1.4011 - 0.73 *0.06 = 1.3573 = 1.36

For future control it is advise to set the process at target value i.e., (USL + LSL)/2.
53

Calculation for Range(R) Chart

LCL

= D3 X R = 0 * 0.06 = 0

UCL = D4 X R = 2.28 * 0.06 = 0.1368 = 0.14

54

THE X-bar & R CHARTS

1.44 1.40 1.36 THE X-bar CHART 0.14

0.06

THE R CHART

55

The Control Chart

1.44

1.40

X-bar CHART

1.36 0.14

0.06

0 R CHART

56

TWO KINDS OF VARIATIONS

1) Variation due to chance causes 2) Variation due to assignable causes. 1) Variation due to chance causes: Variations due to chance causes are inevitable in any process or product. They are difficult to trace and difficult to control even under best conditions of production. Since these variations may be due to some inherent characterstic of the process or machine which functions at random. For example, a little play between nut and screw at random may lead to back-lash error and may cause a change in dimension of a machined part.
57

2) Variation due to assignable causes: These variations possess greater magnitude as compared to those due to chance causes and can be easily traced or detected. The variations due to assignable causes may be because of the following factors: a) Differences among machines. b) Differences among workers c) Differences among materials d) Change in working conditions
58

How to read CONTROL CHARTS :

Whether a process is in the controlled state or not is judged by the following criteria from the control chart. Process not in control : a) Point out of control limit. b) Seven points on one side of the average (run) c) Seven points in a row continously increasing and decreasing (trend). d) Points very close to control limits and close to average. e) When the curve repeatedly shows an up and 59 down trend for the same interval (periodicity).

WHAT IS HISTOGRAM :
A diagram that graphically depicts the
variability in a population.

60

WHAT IS HISTOGRAM :
The frequency data obtained from measurements display a peak around a certain value. The variation of quality characterstics is called distribution. The figure that illustrates frequency in the form a pole is referred to as a Histogram.

61

POPULATION AND SAMPLE

The entire set of items is called the Population.
The small number of items taken from the population to make a judgment of the population is called a Sample. The numbers of samples taken to make this judgment is called Sample size.

POPULATION

SAMPLE OF SIZE THREE

62

Histogram steps
1.Obtain a set of 50 ~ 100 observations as shown below:
Sample Numbe r
1-10 11-20 2.51 0 2.52 7 2.517 2.536 2.522 2.506

Results of Measurement

2.522 2.541

2.510 2.512

2.511 2.521

2.519 2.521

2.532 2.536

2.543 2.529

2.525 2.524

21-30
31-40 41-50 51-60 61-70

2.52 9
2.52 0 2.53 5 2.53 3 2.52

2.523
2.514 2.523 2.510 2.515

2.523
2.512 2.526 2.542 2.520

2.523
2.534 2.525 2.524 2.519

2.519
2.526 2.532 2.530 2.526

2.538
2.532 2.530 2.535 2.542

2.543
2.532 2.502 2.522 2.522

2.538
2.526 2.530 2.535 2.542

2.518
2.523 2.522 2.540 2.540

2.534
2.520 2.514 2.528
63

2.528

Histogram steps
2. Obtain the maximum value and minimum value:
Sample Number
1-10 11-20 21-30 31-40 2.510 2.527 2.529 2.520 2.5 17 2.5 36 2.5 23 2.5 14 2.5 22 2.5 06 2.5 23 2.5 12

Results of Measurement

Maximum value of the line

2.5 32 2.5 36 2.5 38 2.5 26 2.5 43 2.5 29 2.5 18 2.5 23 2.5 25 2.5 24 2.5 34 2.5 20 2.543 2.541 2.543 2.534

Minimum value of the line

2.510 2.506 2.518 2.512

2.5 22 2.5 41 2.5 23 2.5 34

2.5 10 2.5 12 2.5 19 2.5 26

2.5 11 2.5 21 2.5 38 2.5 32

2.5 19 2.5 21 2.5 43 2.5 32

41-50
51-60

2.535
2.533

2.5 23
2.5 10

2.5 26
2.5 42

2.5 25
2.5 24

2.5 32
2.5 30

2.5 30
2.5 35

2.5 02
2.5 22

2.5 30
2.5 35

2.5 22
2.5 40

2.5 14
2.5 28

2.545
2.542

2.502
2.510

61-70
71-80 81-90

2.525
2.531 2.518

2.5 15
2.5 45 2.5 27

2.5 20
2.5 24 2.5 11

2.5 19
2.5 22 2.5 19

2.5 26
2.5 20 2.5 31

2.5 42
2.5 19 2.5 27

2.5 22
2.5 19 2.5 29

2.5 42
2.5 29 2.5 28

2.5 40
2.5 22 2.5 19

2.5 28
2.5 13 2.5 21

2.542
2.545 2.531 The largest value 2.545

2.515
2.513 2.511 The smallest value 2.502

64

Histogram- Steps
3. Determine the number of classes: Let these be between 5-12, Say it is K. Generally to decide the number of classes, divide the range by 1,2 or 5 (their fractions or multiples).
In this case, the range is 0.043 and if it divided by 0.002 or 0.005 or 0.010, we will get - 0.043 / 0.002 = 21.5 ~ 22 - 0.043 / 0.005 = 8.6 ~ 9 - 0.043 / 0.010 = 4.3 ~ 4 Therefore, number of interval of classes be taken as 9. 4. Determine class width rounded off to a convenient figure. So that it covers maximum and minimum value both C = Max- Min = 0.043 / 9 ~ 0.005
K

65

Histogram- Steps
5. Calculate the class boundaries so that it covers minimum and maximum value both. In the case, let the boundary be 2.5055. Note: First class boundary should contains smallest value and boundary value falls on half of the unit of measurement .
6. Calculate the mid point of first class by sum of upper and lower boundaries of first class i.e. (2.5005 + 2.5055)/2 = 2.503. Mid point of second class shall be (2.5055+2.5105)/2= 2.508 and so on.
66

Histogram Steps
7. Make a frequency table as given below:
Class
1 2 3 4 5 6 7 8 9 2.5005-2.5055 2.5055-2.5105 2.5105-2.5155 2.5155-2.5205 2.5205-2.5255 2.5255-2.5305 2.5305-2.5355 2.5355-2.5405 2.5405-2.5455 Total

Mid-Point of class x
2.503 2.508 2.513 2.518 2.523 2.528 2.533 2.538 2.543

Frequency
1 4 9 14 22 19 10 5 6 90

67

Histogram-Steps
8. Mark the horizontal axis with the class boundary values. 9. Mark the vertical axis with a frequency scale. 10. Erect the rectangles over the class interval having area proportion to the frequencies. 11 Draw a line on the Histogram to represent Mean, number of data points and standard deviation.
68

Types of Histogram
Histogram of shaft Dia
2.5247 25

N=90
20

Mean=2.5247 S.D=0.00906

15

Frequency

10

0 2.51 2.52 2.53 2.54

69

Shaft Dia

Normal Distribution
LSL USL

3o 99.7% 2o 95.4% o 68.3%

Out of Spec.
-3o -2o -o +o +2o +3o

Out of Spec.

70

Histogram for grade wise distribution in a class

35
No. of students

23 10

25 15 5

C-

B+

A+
71

Grade

WHAT IS CHECK SHEET :

A check sheet is a paper form on which items to be checked have been printed so that data can be collected easily and concisely. Its main purpose is twofold. To make data gathering easy To arrange data automatically so that they can be used easily later on. 72

EXAMPLE -1 OF CHECK SHEET

Shown a check sheet used in final inspection process of a certain molded plastic product. At the end of the day we can immediately calculate the total number and types of defects that have occurred.

73

Product:

Defective Item Check Sheet

Date Section

Manufacturing stage: final insp.

Type of defect: sink mark, silver Streak,flow mark, crack, flash Total no. inspected: 1525
Remarks: all items inspected
Type
Sink mark Silver streak Flow mark Crack Flash Total Rejects

Inspectors name Lot no:.

Order no:.
Subtota l
17 11 26 3 5 Total defects 62 42
74

Check
//// //// //// // //// //// / //// //// //// //// //// / /// //// //// //// //// //// //// //// //// //// //

CHECK SHEET
It is necessary to decide clearly how to record the defects. When these are found in a product. We should give proper instructions to the staff regarding the format in which the defects are to be gathered. In this case, 42 out of 1525 components were found defective. However the total nos of defects was 62 because two or more 75 defects were found on the same piece.

EXAMPLE -2
Check Sheet
Product : Manufacturing stage : Final Inspection Type of defect :scratch, dents, door gap uneven Total no. inspected : 1500 Remarks : all items inspected Type of defect Scratch Dents Door gap uneven Tally Mark IIII IIII IIII IIII IIII IIII Frequency 15 10 4 Date : Section : Inspector's name :

Others
Total No. Of Defects Total No. Of Defectives

III
IIII IIII IIII IIII

3
32 20
76

Check Sheet
Purpose of data recording : Variation in the Quality Characteristics of a proces
Applicable for Histogram, Run chart / Control Charts Difference between Groups/ Batches/ Machines Applicable for Pareto Diagram / Bar-chart. Relationship between two characteristics Applicable for Scatter Diagram
77

Flow Chart / Graphs

Flow Chart :
A Tool that graphically represents the steps of a process

78

Flow Chart
Different icons/symbols to indicate the different types of actions in the process. Start / End : Process Activities : Decision points : Movement : Storage :
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Flow Chart of annealing process:

Annealing Process :
Start

Rod receipt

Heating

Soaking

Inspection

Purging

Controlled cooling

End

Storage

Parameter setting

Unloading

Stora ge

Base & Batch Preparation

Furnace Loading

Controlled cooling

Testing

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GRAPH : It is one of the means of data stratification.

Bar Graph Line Graph Pie Graph Radar Graph
Purpose of Graph: A picture is worth more than thousand words

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BAR GRAPH : A graph to compare the difference in numeric quantity.

DENT ANALYSIS
25
% OF DENTS

21.6 14.8 13.6 9.8 8.6

20 18.8 15 10 5
REAR BODY CTR PLLR FRONT PANEL ROOF FR. DOOR RR.DOOR B.DOOR

12.8

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(Pie Chart) : A graph for the proportion of the different classifications

Others 10%

Spot Dent 20%

Handling Dents 45%

Gun Touch Dents 25%

AREA OMNI W/B PERIOD 05/01/2001 83 NO.OF.VEHICLE 150

LINE GRAPH : A graph to see the changes in condition of any numeric changes

Line graph
30 20 10 0 1 2 3 4 5 6 7 8 9 10 11 12
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SYSTEM AUDIT REPORT

Audit Points
1. Production preparation 2. Initial supply control 3. Initial control- Changed parts 4. Preventive measures for defects 5. Education and training

% Achieved
40% 60% 40% 70% 80%

6. Quality audit
7. Supplier control 8. Control of drawings and engg. Changes 9. Inspection standard & PCS 10. Operation standard 11. Observance of operation standard 12. Role of Manager/ Supervisor 13. Quality improvement of process 14. Control of Manufacturing machine/ jig 15. Control of Inspection equipment and Jig 16. Statistical method 17. Prevention of missing process/ wrong assembling 18. Control of non conforming product 19. Storage of product 20. First-in , First-out 21. History management of A parts 22. Implementation of inspection

80%
70% 100% 100% 100% 100% 100% 0% 50% 40% 100% 75% 100% 100% 100% 100% 100%

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Radar Graph : To see the total sharp image as a composite graph.

Radar Graph
1. Production preparation, 40% 22. Implementation of inspection, 100.0% 21. History management of A parts, 100.0% 20. First-in , First-out, 100.0% 100% 90% 80% 70% 60% 19. Storage of product, 100.0% 50% 40% 30% 18. Control of non conforming product, 100.0% 20% 10% 0% 17. Prev ention of missing process/ w rong assembling, 75.0% 7. Supplier control, 70.0% 6. Quality audit, 80.0% 5. Education and training, 80.0% 4. Prev entiv e measures for defects, 70.0% 2. Initial supply control, 60.0% 3. Initial control- Changed parts, 40.0%

Series1

16. Statistical method, 100.0% 15. Control of Inspection equipment and Jig, 40.0% 14. Control of Manufacturing machine/ jig, 50.0% 13. Quality improv ement of process, 0.0%

8. Control of draw ings and engg. Changes, 100.0% 9. Inspection standard & PCS, 100.0% 10. Operation standard, 100.0% 11. Observ ance of operation standard, 100.0% 12. Role of Manager/ Superv isor, 100.0%

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