THE BASIC SEVEN (B7)

TOOLS OF QUALITY

TOTAL QUALITY
MANAGEMENT
BY
DR. ASIF MAHMOOD

Institute of Business & Management

University of Engineering and Technology,

Lahore

"As much as 95% of quality related problems

in the factory can be solved with seven
fundamental quantitative tools.
Kaoru Ishikawa

BASIC SEVEN TOOLS OF QUALITY (OR)

OLD SEVEN TOOLS

Flowcharts
Check

Sheets
Histograms
Stratification or
Scatter Plots
Fishbone Diagrams
Pareto Analysis
Control Charts

LOGICAL ORDER FOR B7 TOOLS

Big
Picture

Flow
Flow
Chart
Chart

Data
Collection

Check
Check
Sheet
Sheet

Data
Analysis

Histograms
Histograms

Scatter
Scatter
Diagrams
Diagrams

Control
Control
Charts
Charts

Problem
Identification

Cause
Cause
&
&
Effect
Effect

Priortization

Pareto
Pareto
Analysis
Analysis

FLOWCHART
A diagram that uses graphic symbols to depict the
nature and flow of the steps in process

Promote process understanding

Provide tool for training

Identify problem areas and improvement

opportunities

Depict customer-supplier relationships

BASIC FLOW CHART SYMBOLS

Start/End
Bookends
Activity:

Operation/Inspection

Decision

Wait/Delay
Flow Lines

LEVELS OF FLOWCHART

KEYS TO SUCCESS
Start

with the big picture

Observe
Record

process steps

Arrange
Draw

the current process

the sequence of steps

the flow chart

TYPES OF FLOWCHART

Linear Flowchart

A Linear Flowchart is a diagram that displays the

sequence of work steps that make up a process.

Deployment Flowchart

A Deployment Flowchart shows the actual process flow

and identifies the people or groups involved at each step.

Opportunity Flowchart

An Opportunity Flowcharta variation of the basic linear

typedifferentiates process activities that add value from
those that add cost only.

LINEAR FLOWCHART

EXAMPLE: PLAN OF THE DAY

DEPLOYMENT FLOWCHART
EXAMPLE: PLAN OF THE DAY

OPPORTUNITY FLOWCHART
EXAMPLE: PLAN OF THE DAY

MAKING A CUP OF TEA

EXERCISE

CHECK SHEETS
What is a check sheet?
A form or sheet used to record data

WHAT IS IT FOR?
To manually collect data in a reliable, organised
way.

To present the facts for further investigation.

For recording and presenting direct observations
and facts about a process.

CHECK SHEET - HOW DO WE USE IT? - COMMON

DESIGNS

TABULAR FORMATEQUIPMENT
BREAKDOWN DATA

LOCATION PLOT/FORMAT
A Location Plot/Format uses a picture of the
item to mark defect positions.
Reject shirts Check Sheet

Shirts rejected

= flaw
= tear
= mark

Front

Date:

Batch:

Back

GRAPHIC FORMAT

PROCESS DISTRIBUTION CHECK

SHEET

It measures the frequency of a single item across a

range of measures - produces a histogram.
Pin diameter Check Sheet

Sheet No:

Date:
Lathe number:
Cutter type:

Operator:
Remarks:
Low er Spec. Limit

mm:

25

Upper Spec. Limit

1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4

20
15
10
5

Total:

7 10 14 18 19 15 13

DEFECTIVE ITEM CHECK SHEET

It counts and classifies defects by type

Typing test analysis

Date:

Typist:

Test:

Examiner:
Type of error

Count

Score

Reversed letters
Missing letters
Extra letters
Wrong letters
Total errors:

CHECKLIST

It contains a list of actions which are ticked off as

they are done..
Design Complete check list
Design fully documented
To AS31 standard
Filed in DVCS system
Reviews completed
... vs. design standard
... vs. specification
Costing completed
Resource costs
Material costs
Schedule updated
Business team approval
Signed:
Date:

WHAT IS A HISTOGRAM?
A bar graph that shows the distribution of data
A snapshot of data taken from a process

WHEN ARE HISTOGRAMS USED?

Summarize large data sets graphically

Compare measurements to specifications

Communicate information to the team

Assist in decision making

PARTS OF HISTOGRAM

HOW TO CONSTRUCT A HISTOGRAM

Step 1 Count the total number of data points

Number

of yards long (+data) and yards short (-data)

that gun crew missed its target

HOW TO CONSTRUCT A HISTOGRAM

Step 2 Summarize the data on a tally sheet

HOW TO CONSTRUCT A HISTOGRAM

Step 3 Compute the range for the data set

Largest value = +410 yards past target

Smallest value = -180 yards short of target
Range of values = 590 yards
Calculation: +410 - (-180) = 410+180 = 590

HOW TO CONSTRUCT A HISTOGRAM

Step 4 Determine the number of intervals

required
Data points
Less than 50
50 to 99
100 to 250
More than 250

No. of Intervals
5 to 7
6 to 10
7 to 12
10 to 20

HOW TO CONSTRUCT A HISTOGRAM

Step 5 Compute the interval width

HOW TO CONSTRUCT A HISTOGRAM

Step 6 Determine the starting point of each interval
Step 7 Count the number of points in each interval

HOW TO CONSTRUCT A HISTOGRAM

Step 8 Plot the data
Step 7 Add the title and legend

INTERPRETING HISTOGRAMS:
LOCATION AND SPREAD OF DATA

INTERPRETING HISTOGRAMS:
IS PROCESS WITHIN SPECIFICATION LIMITS?

INTERPRETING HISTOGRAMS:
PROCESS VARIATION

INTERPRETING HISTOGRAMS:
COMMON HISTOGRAM SHAPES

HISTOGRAM: EXERCISE 1
A corpsman is responsible for the semiannual
Physical Readiness Test (PRT) screening for
percent body fat. Prior to one PRT, the corpsman
recorded the percent of body fat for the 80
personnel assigned to the command. These are the
data collected (next slide):

EXERCISE 1: PERCENT BODY FAT RECORDED

HISTOGRAM: EXERCISE 2
A Marine Corps small arms instructor was
performing an analysis of 9 mm pistol
marksmanship scores to improve training methods.
For every class of 25, the instructor recorded the
scores for each student who occupied the first four
firing positions at the small arms range. The
instructor then averaged the scores for each class,
maintaining a database on 105 classes. These are
the data collected:

EXERCISE 2: AVERAGE SMALL ARMS SCORES

CONTINUED

SCATTER PLOTS/DIAGRAM OR
STRATIFICATION
A graphical technique to analyze the relationship
between two variables.
Two sets of data are plotted on a graph, with the y-axis
being used for the variable to be predicted and the xaxis being used for the variable to make the prediction.
The graph will show possible relationships among
variables.

http://www.asq.org/learn-about-quality/cause-analysistools/overview/scatter.html

INTERPRETING DATA
Positive Correlation
If

the x-coordinates and

the y-coordinates both
increase, then it is
POSITIVE
CORRELATION.
This means that both are
going up, and they are
related.

INTERPRETING DATA
Negative Correlation
If

the x-coordinates and the

y-coordinates have one
increasing and one
decreasing, then it is
NEGATIVE CORRELATION.
This means that 1 is going up
and 1 is going down, making
a downhill graph. This means
the two are related as
opposites.

TYPES OF CORRELATIONS
Interpret the data
Scatter diagrams will generally show one of six
possible correlations between the variables

Types of correlations
Strong Positive Correlation
Strong Negative Correlation
Weak Positive Correlation
Weak Negative Correlation
Complex Correlation
Weak/No Correlation

TYPES OF CORRELATIONS

Strong Positive
Correlation
The value of Y
clearly increases as
the value of X
increases.

Strong Negative
Correlation
The value of Y clearly
decreases as the value of
X increases.

TYPES OF CORRELATIONS
Weak Positive
Correlation
The value of Y
increases slightly as
the value of X
increases.

Weak Negative
Correlation
The value of Y
decreases slightly as
the
value
of
X
increases.

TYPES OF CORRELATIONS

Complex
Correlation
The value of Y seems to be
related to the value of X,
but the relationship is not
easily determined.

Weak/No Correlation
There is no demonstrated
connection between the
two variables.

TYPES OF CORRELATIONS

Scatterplots
Which scatterplots below show a linear trend?
a)

c)

Negative
Correlation

e)
Positive
Correlation

b)

d)

f)
Constant
Correlation

Objective - To plot data points in the

coordinate plane and interpret scatter
plots.
y
5

Year Sales (in Millions)

1991
1992
1993
1994
1995
1996
1997
1998
1999

0.9
1.1
1.4
1.6
1.7
2.1
2.4
2.7
3.2

Vehicle Sales (Millions)

Sport Utility Vehicles

(SUVs) Sales in U.S.

3
2
1

1991 1993 1995 1997 1999

1992 1994 1996 1998 2000

Year

Scatterplot - a coordinate graph of data points.

y5

Trend is increasing.

Year
SUV Sales
Positive correlation.
Predict the sales in 2001.

Vehicle Sales (Millions)

Trend appears linear.

4
3
2
1

1991 1993 1995 1997 1999

1992 1994 1996 1998 2000

Year

Plot the data on the graph such that homework time

is on the y-axis and TV time is on the x-axis..
Time Spent Time Spent
Student Watching TV on Homework
Raza
Rizwan

30 min.

180 min.

45 min.

150 min.

Bilal

120 min.

90 min.

Gulraiz

240 min.

30 min.

Hafsa

90 min.

90 min.

Ramsha

150 min.

90 min.

Sohail

180 min.

90 min.

Plot the data on the graph such that homework time

is on the y-axis and TV time is on the x-axis.
TV

Homework

30 min. 180 min.

120 min. 90 min.
240 min. 30 min.
90 min. 120 min.
150 min. 120 min.
180 min. 90 min.

Time on
Homework

45 min. 150 min.

240
210
180
150
120
90
60
30
30

90

150
210
60
120
180
240
Time Watching TV

Describe the relationship between time spent on

homework and time spent watching TV.
Trend appears linear.
Trend is decreasing.
Time on
Homework

Time on TV
Time on HW

Negative correlation.

240
210
180
150
120
90
60
30
30

90

150
210
60
120
180
240
Time Watching TV