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7QC Tools
Check Sheets
Pareto Diagram
Cause and Effect Diagram.
Stratification.
Scatter Diagram.
Histogram.
Graphs and Control Charts.
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Check Sheet
Purpose
• How often are certain events happening
• Translating ‘Opinion’ into ‘Fact’
• Aid to the limited memory
• Making information collection easy from data
(Format)
• Good point to start most problem solving tools
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Types of Check Sheet
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Pareto Diagram
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How to make Pareto Diagram?
• Define a problem and collect data on the factors that
contribute to it.
• Historical records generally provide sufficient
information.
• Classify the data by type, cost , percent, number of
occurrences, or whatever is appropriate for the
situation.
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How to make Pareto Diagram?
• Arrange the data in descending order
• Calculate % contribution of each item
• Calculate cumulative % of each item
Rejection details of Pinion
Defect Defect Qty % Cum
Code description Rej Contribution %age
A Drill Broken 70 46.60% 46.60%
B Serration Mismatch 45 30% 76.60%
C Runout more 25 16.60% 93.20%
D Dia U/S 6 4% 97.20%
E Dia O/S 4 2.80% 100%
Total 150
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How to make Pareto Diagram……
75%
76.6%
50%
Nos. 70 46.6%
45
25 25%
6 4
A B C D E 8
Types of Pareto Diagrams
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Hints on Making Pareto Diagrams
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Hints on Using Pareto Diagrams
1. If an item is expected to be amenable to a simple
solution, it should be tackled right away even if it is of
relatively small importance.
It will serve as an example of efficient problem solving, and
the experience, information and incentives to morale
obtained through this will be of great assets for future
problem solving.
2. Do not fail to make Pareto diagram by causes
After identifying the problem by making a Pareto diagram
by phenomenon, it is necessary to identify the causes in order
to solve the problem. It is therefore vital to make a Pareto
diagram by causes if any improvements are to be effected.
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Cause and Effect Diagram
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How to make Cause & Effect
Diagram?
• Define the problem or effect clearly and explicitly.
• Generate the potential causes of the problem
through brain storming.
• Encourage wild ideas
• ‘Quantity’ rather than ‘Quality’ of ideas
• Suspend judgment on ‘Good’ or ‘Bad’
• Ride on another’s idea
• Do not interrupt
• Record all responses
• Categorize all causes into major causes and give
suitable names
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How to make Cause & Effect
Diagram?
• Construct the cause and effect diagram by:
– Place problem statement in a box on right hand side
– Draw the major cause category boxes on the left
hand side. Commonly used categories are man,
machine, method, material and measurement
– Put all brainstorming ideas at respective major cause
category in Cause and Effect Diagram
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Hints on Using Cause and Effect Diagrams
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Stratification
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How to use Stratification
• Regroup original data as per the source of data
(e.g. Machine wise, shift-wise, model-wise, supplier-
wise)
• If required collect data afresh after making the
source from which they come.
• Recreate histogram, Pareto charts and graphs on
classified data
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Stratification
Month Model A Mode B
Apr 10 50
90
May 8 32
Jun 80 15 65
Jul 10 50
Aug 70 8 42
Sep 7 28
60
Rej Nos
50 Mode B
Model A
40
30
20
10
0
Apr May Jun Jul Aug Sep
Month
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Stratification
V
V i
i s
s c
c o
o s
s i
i t
t y
y
Impurity Amount Impurity Amount
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Scatter Diagram
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How to make Scatter Diagram
• Collect 50 to 100 paired samples of data
believed to be related.
• Construct a data sheet.
• Draw the horizontal and vertical axis of the
diagram.
• Label the axes.
• “Cause”is usually plotted on the horizontal axis
and the “effect” variable on the vertical axis.
• Plot the data on the diagram. If values repeat,
circle that point.
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Interpretation
A B C
n=15 r=0.06 n=18 r=0.54 n=14 r=0.96
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Interpretation
D E
n=22 r=- 0.5 n=18 r=-0.92
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Correlation Coefficient
S(xy)
r= If r=0 No correlation
S(xx).S(yy)
n
If r=1 Very strong correlation
2
S(xx) = (xi -x) If r=-1 Very strong negative
i=1 correlation
n 2
S(yy) = (yi -y) If 0<r>1 Possible correlation
i=1
n
S(xy) = (xi -x) (yi –y)
i=1
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Significance of ‘r’
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Notes on Correlation Analysis
1. Coordinate Axes:
Effect of choosing scale of axes
2. Stratification:
Stratify the data and then see the
correlation
3. Range of variables:
Select range of variables carefully as it
affects correlation
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Regression Analysis
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Regression Analysis
Calculations:
1. Calculate x and y
2. Calculate S(xx) and S(xy)
3. Calculate b
b=S(xy)/S(xx)
4. Calculate a
a=y-b x
Then, equation of line is y=a+bx
Note: For both Correlation and Regression
Analysis, draw scatter diagram first
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Histogram
• A bar chart that displays the variation within the
process
• Also called a frequency distribution because the
frequency of occurrence of any given value is
represented by the height of the bars
• Allows one to quickly visualize what’s going on within
a large amount of data
• Provides clues to causes of problems
• May be used to show the relationship between the
engineering tolerance and the capabilities of the
process
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How to make Histogram?
• Collect measurements(variable data)from a process or
key characteristic.
• Thirty or more measurements are preferred.
• Construct check sheet to record the data.
• Find the range by subtracting the smallest
measurements from the largest.
• Using this guide determine the proper number of class
intervals.
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How to make Histogram……
K=R/h +1 (R = Range)
Select h such that K is between 5~8
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How to make Histogram……
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How to make Histogram……
• Taking the class interval on horizontal axis, draw the
height of the bar corresponding to frequencies in
interval on the vertical axis.
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20
15
10
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Types of Histogram
Isolated Peak
Type
Left-hand Plateau Type Twin Peak Type
Precipice Type
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READING HISTOGRAMS
A. General Type
Shape symmetrical (Bell shaped). If your vendor has less variability but
centre is shifting you can help him to do right setting.
B. Bimodal or Twin Peak Type
Two Distributions with widely different mean values mixed.
C. Comb Type Multimodel
Number of units of data included in class varies from class to class.
Rounding off. Incorrect least count of measurement system
D. Positive Skew
Occurs when lower limit is controlled either theoretically or by
specification value or when values lower than certain value do not occur
E. Left Hand Precipice Type
100% screening has been done because of low process capability or when
positive skewness becomes more extreme. (Check your vendor if in receipt
supply having such pattern)
F. Plateau Type
Mixture of several distributions having different mean values, or 100%
screening on both sides
Normal Distribution
f(x)
•Frequency is the highest in the middle and becomes gradually lower towards the tail.
•It is symmetrical
It is denoted by N (
: The centre of the distribution (the mean)
x
: The spread of the distribution(the standard deviation)
To obtain a probability in a normal distribution, we standardize by transforming x to a
variable, u= x-
, We then have a standard measure u, which is distributed as the
standard normal distribution N(0, 12). The normal distribution table gives probabilities in the
standard normal distribution.
:- 68.3% of area
2 :- 95.4% of area
3 :- 99.7% of area
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Process Capability Index
After Histogram shows that it follows normal distribution, a study of
process capability is often undertaken. This is to find out whether the process
can meet specifications or not
Both-sided specifications (SU and SL)
CP = SU - SL/6s
CP = SU - x /3s
Evaluation of process:
3) CP 1.00 Inadequate
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DIFFERENCE BETWEEN Cp & Cpk
1 9 89 0
6 5 0
1 9 9 7 4 5
6 0
1 9 9 8 7 0
4 0
2 0
0
1 9 9 6 1 9 9 7 1 9 9 8
Y e a r
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Graphs……
Trend Chart
M o n th Rej
Rejection %age
A pr 0 .8 0 .2
M ay 0 .6 0 .6
Ju n 0 .4 0 .2 Rej
Ju l 0 .2
0 .2
A ug 0 .1 5
0
S ep 0 .2
Apr May Jun Jul Aug S ep
M o nth
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Graphs…….
R&P ASSY.
AXLE ASSY. 17.62%
28.67%
PROP.SHAFT
COLUMN
ASSY.
ASSY.
6.15%
26.25
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Control Charts
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How to make Control Charts
• Define process parameter to be measured.
• Define wherein the process the control characteristics
will be measured.
• Select where control chart is to be used.
• Determine sample size and frequency.
• Take measurements.
• Plot measurements on graph.
• Connect dots.
• After 20 plot points calculate center-line and control
limits.
• Analyze pattern for special cause of variation
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Control Charts
• Chance Cause
• Assignable Cause
• Upper Control Limit
• Lower Control Limit
• Upper Specification Limit
• Lower Specification Limit
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Control Charts
x – R Chart:
50
UCL ( x + A2R )
40
x
30 x
20
LCL ( x - A2R )
0
60
UCL ( D4 R )
40
R
20 R
LCL ( D3 R )
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Coefficients for x-R Charts
n A2 D3 D4 d2
2 1.880 - 3.267 1.128
3 1.023 - 2.575 1.693
4 0.729 - 2.282 2.059
5 0.577 - 2.115 2.326
6 0.483 - 2.004 2.534
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Other Charts
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How to Read Control Charts
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How to Read Control Charts
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