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Data gathering Check sheet Stratification Pareto diagram Brain Storming Cause and Effect Diagram Histogram Scatter diagram Graphs and Charts
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In problem solving
What is a problem ?
A problem could be
nonconformance scrap chronic rework recurring accepted on deviation poor yield customer complaint machine breakdown low process capability loosing customers reducing market share late delivery, etc.
What is solving ?
To identify a state where the above symptoms do not occur.
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Known approaches for problem solving ... In problem solving by approach B , Simple QC tools play a role
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Role Play
Tool
Data gathering
Role Play
To quantify the current status or magnitude of the problem To facilitate data gathering To identify and segregate different sources of the problem
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Role Play.
Tool
Pareto diagram
Role Play
To prioritize the problems/causes for taking action Generating many ideas for solving a specific problem Generate ideas in a structured way for possible causes of a problem
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Brain storming
Role Play.
Tool
Histogram Scatter diagram
Role Play
To study the pattern of variation in a set of data. To study the relationship between two sets of values
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DATA GATHERING
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Data Collection
What is Data ? Data is a numerical expression of an activity
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Conclusions based on facts and data are necessary for any improvement. K. Ishikawa If you are not able to express a phenomenon in numbers, you do not know about it adequately Lord Kelvin
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Types of Data
Quantitative
Measurable e.g. :Length, Temperature Countable e.g. :Number of defects
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Qualitative
Subjective assessment e.g. :Score in a beauty contest
Lot
Random Sampling
Sample Action
Measurement / Observation
Data
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CHECK SHEET
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Areas of application
Production
Measurements on process parameters, No. of defects in products, Location of defect.
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Areas of application
Maintenance
Maintenance time, down time, machine wise break down, causes of break down.
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Inspect machines or equipment or check the Inspection and validation operating procedure check sheet
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STRATIFICATION
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The method of grouping data by common points or characteristics to better understand similarities and characteristics of data is called stratification.
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Such classification helps in obtaining vital information by distinguishing and comparing data in different class or strata. It also identifies the key strata to concentrate on
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The stratification may be based on machines, operators, shifts or any other source of variation.
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The purpose of stratification is to ascertain the difference between different categories and to analyse the reasons behind abnormal distribution.
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You can also stratify the data you collect by different QC tools such as graphs, Pareto diagrams, check sheets, histograms, scatter diagrams, and control charts.
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Areas of application
Raw material
Quantity supplied, Delivery time, Rejection % - supplier wise and batch wise.
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Areas of application
Production
Stratification of rejection percentage with respect to r Machine, Shift, operator, raw material, tool, jig and so on.
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Areas of application
Engineering and design
Stratification of drawing errors draftsman wise.
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PARETO DIAGRAM
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The Pareto Principal is generally used to prioritize quality improvement projects to get most returns for the resources invested. It is one of the most powerful tools and is widely used as means of attacking bulk of the problems with the optimal utilization of resources.
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The basic principle of Pareto is Around 80% of overall effect is contributed by 20% of causes & vice versa
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Safety
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D e fe c t
C ount P ercent C um %
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. .
La
p cu
. .
m u G
pot
ea
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a L
be. m
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. .
. .
Pe r c e n t
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C ount
No. of complaints
Refund
Fares
others
Cum. percentage
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. . . .
Cum Percentage
No. of complaints
Bread Stale
Cashier Rude
Eggs rotten
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Stains
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. .
No. of Defectives
Bubbles Rough finish Scratches Damaged packaging Weak corners Cracks Stains Others
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. . .
Pentosan
S Ash content .
Acid insolubles
others
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No. of stoppages A B C D E F G H I J K LM N O P Q R S
Cumulative %
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BRAIN STORMING
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What is Brainstorming ?
Brainstorming is a simple but effective technique for generating many ideas of a group of people within a short span of time to solve a given problem
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Defer Evaluation
Put critical faculties in cold storageeven constructive criticism. This is to ensure a proper climate of acceptance of all sorts of ideas. No idea should be treated as stupid.
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Fantasize Freely
Dont operate with your brakes on. The participants are encouraged, urged to let themselves go and generate ideas, no matter how fanciful these ideas are.
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Generate Quantity
Generate as many ideas as possible. A pearl diver will be more successful in finding pearls, perhaps the pearl, when he brings up 200 oysters than when he surfaces only 15-20 oysters.
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Build on ideas
Idea of one participant is more effectively built up by another participant.
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Principles of Brainstorming
Deferment of evaluation develops the
appropriate psychologically safe climate for ideation The uniqueness of each participants knowledge is tapped to develop new insights
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Principles of Brainstorming
.Contd
Ideas of one participant tend to trigger off ideas in the brains of other group members Free association encourages fruitful ideation The pressure of time bound sessions in a non-threatening atmosphere is conductive to a high productivity of ideas
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Steps to Brainstorming
Choose the topic Each member, in rotation, is asked for ideas Each member offers only one idea per turn, regardless of how many he or she has in mind This continues until all the ideas have been exhausted Ideas are to be recorded and displayed on transparent sheets
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Key Points
Acquaint the participants with the technique of Brainstorming. A warmup session of the nature developed later helps. Obtain the commitment of the management to encourage the development and implementation of worthwhile ideas.
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Benefits of Brainstorming
Individual is limited in generating ideas and that group produces more ideas Ideas are improved upon by members Presence of others increases creativity Pooling of ideas and resources is made possible by coming together as a group
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To generate in a structured manner, maximum number of ideas regarding possible causes for a problem by using brainstorming technique.
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Draw the cause and effect chart Check for missing information Determine importance of significance of causes
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Problem
Material
Method
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Driver
Vehicle
Heavy Body Shape Inexperience High H.P Engine Cylinders Spark plugs Contacts Life Technical details Fuel mix Carburetor
Bad attitude
High Petrol
Crossings Traffic
Spares
Spurious
Consumption
Impurities Incorrect Octane no.
Road
Tyres Inferior Frequent Petrol Faulty stops Negligence pressure Speed Breakers Additives Ignorance Potholes Irregular Incorrect viscosity Low pressure servicing Poor Clogged Oil condition filters False Steep Not changed economy Low level
Maintenance
Materials
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MATERIALS
QTY OF WATER WOOD QLTY (OLD/FRESH) VARIATION IN PENTOSANS IN FINAL PULP
TRAINED
UNTRAINED
INSTRUMENT ACCURACY
PERSONNEL
EQUIPMENTS
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MACHINE
IMPROPER MIXING UNCALIBRATED INSTRUMENT HYPO PULP VISCOSITY
HIGH/LOW DOSAGE
ALKALI cP VARIATION
METHOD
MATERIAL
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HISTOGRAM
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Frequency Table
Class no. Class Boundaries . . . . . . . . . . . . . . . . . . Mid-value . . . . . . . . . Frequency
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Frequency
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Applications of Histograms
Study the pattern of variation Comparison to Specification limits Comparison to Sources of Variability Outlier Detection Before and After Comparison
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Types of Histograms
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Types of Histograms
Bell shaped
Symmetrical shape with a peak in middle representing a normal histogram
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Types of Histograms
Double peaked
Two normal distributions with two peaks in middle indicating more than one distribution at work
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Types of Histograms
Plateau
More than one distribution at work
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Types of Histograms
Comb
Alternative peaks showing possible errors in data collection and analysis
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Types of Histograms
Skewed
An asymmetrical shape - positively or negatively skewed - usually reflecting limits in the specification on one side
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Types of Histograms
Truncated
Usually being a part of a normal distribution with part of it having been removed.
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Types of Histograms
Isolated peak
Two normal distributions suggesting two processes taking place at the same time.
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Types of Histograms
Edged peaked
A normal distribution curve with a large peak at one end indicating errors in data recording.
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SCATTER DIAGRAM
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If two variables x and y, are related such that as x increases / decreases with another variable y, a correlation is said to exist between them.
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A scatter diagram is a chart that pictorially depicts the relationship between two such data types.
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Mileage (km/Lit)
Speed (km/h)
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A scatter diagram depicts the relationship as a pattern that can be directly read.
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If y decreases as x increases, then the two types of data are negatively correlated.
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If no significant relationship is apparent between x and y, then the two data types are not correlated.
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Graphs and charts are pictorial representation of the data, making it easy to spot trends, ratios and comparisons among different groups of data.
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The more common types of graphs and charts are Line graphs, Bar charts and Pie charts.
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Purpose of Graphs and Charts Pie charts are used to show percentages or proportions of different components of a specific item.
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% Defectives
. . .
Week Number
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Personnel Performance
Average
Very Good
Excellent
Percentage
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B %
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