7 QC TOOLS

TAIYO PLASTIC CORP. OF THE PHILS

1

to the

7QC TOOLS TRAINING & WORKSHOP


2

Objectives of the workshopObjectives of the workshop

To raise the level of quality and productivity

To develop people in solving work –

related problems

To learn the basic tools in problem solving


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Benefits of Team MembersBenefits of Team Members

Enhance leadership and teamwork among member.

Improve working environment.

Develop the member’s self-confidence.

Develop their capabilities in identifying and solving problems.


4

Benefits for the CompanyBenefits for the Company

Improve the quality standards and quality consciousness of the team members.

Improve level of awareness of team members in solving problem.

Improve worker’s efficiency.

Lower the cost through the reduction of waste, losses and defects.


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7 QC TOOLS BACKGROUND7 QC TOOLS BACKGROUND

In the 1950’s the Japanese began to learn and apply the statistical quality control tools and thinking that WALTER SHEWHART and WILLIAM EDWARD DEMING developed in the 1930’s and 1940’s. Their progress in continuous improvement led to the expansion of the use of these tools. KAORU ISHIKAWA, head of the Japanese Union of Scientist and Engineers (J.U.S.E) expanded the use of these approaches in Japanese manufacturing in 1960’s with the introduction of the 7 Quality Control tools.


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7 QC TOOLS7 QC TOOLS

1. Cause and Effect Diagrams

2. Pareto Diagrams

3. Graphs

4. Histograms

7. Controls Charts

5. Check Sheets

6. Scatter Diagrams


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7 QC TOOLS7 QC TOOLS1. 1. Cause and Effect DiagramsCause and Effect Diagrams

It is also called the Fishbone Diagram because of its appearance or Ishikawa Diagram named after the man who popularized its use in Japan.

Its’ most frequent use is to list the cause of particular problems.


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7 QC TOOLS7 QC TOOLSCause and Effect DiagramsCause and Effect Diagrams

Problem

ManMachine

MethodMaterial


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7 QC TOOLS7 QC TOOLSCause and Effect DiagramsCause and Effect Diagrams

Wate

ring

a tre

ss ta

kes a

lon

g tim

e

Man

Machine

Material

Needs two women

Hose is heavy

Hose is long

Faucets are far from

treesMethod

Wasteful watering

Don’t understand the characteristic of

trees

Don’t understand

the watering

conditions

No watering standard

Being tired

Work done on hot days


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2. Pareto Diagrams

3. Graphs

4. Histograms

7. Controls Charts

5. Check Sheets

6. Scatter Diagrams


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7 QC TOOLS7 QC TOOLS2. Pareto Diagrams2. Pareto Diagrams

Shows the distribution of items and arrange them from the most frequent to the least frequent with the final bar being

miscellaneous. The tool is named after Wilfredo Pareto, the Italian economist who determined that wealth is not evenly

distributed. Some of the people have most of the money.

This tools is graphical picture of the most frequent causes of a particular problem. It shows where to put your initial effort to get

maximum gain


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7 QC TOOLS7 QC TOOLSPareto DiagramsPareto Diagrams

0

10

20

30

40

short shot weldline sinkmark gas burn others

0%

20%

40%

60%

80%

100%

120%

Column 1

Line 2


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• Scale mark

0

10

20

30

40

0%

20%

40%

60%

80%

100%

120%

No.

of

defe

cts

Perc

enta

ge


14


0

10

20

30

40

short shot weldline sink mark gas burn others

0%

20%

40%

60%

80%

100%

120%

• Scale mark

No.

of

defe

cts

Perc

enta

ge

Draw the graph format


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0

10

20

30

40


0%

20%

40%

60%

80%

100%

120%

Draw the bar graph


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100%

83%

74%

58%

32%

0

10

20

30

40


0%

20%

40%

60%

80%

100%

120%

Draw the line graph


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2. Pareto Diagrams

3. Graphs

4. Histograms

7. Controls Charts

5. Check Sheets

6. Scatter Diagrams


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7QC TOOLS7QC TOOLS3. Graphs (Line Graph)3. Graphs (Line Graph)

0

2

4

6

8

10

12

14

16

jan feb mar apr ma jun jul aug sep

Sh

ort

sh

ot

months

(Pcs)

• target• Adjust mold temp

• Adjust injection speed


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7 QC TOOLS7 QC TOOLSGraphs (Bar Graph)Graphs (Bar Graph)

0123456789

10111213141516

Num

ber

of

defe

ct (

per

item

)

(Pcs)


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2. Pareto Diagrams

3. Graphs

4. Histograms

7. Controls Charts

5. Check Sheets

6. Scatter Diagrams


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7 QC TOOLS7 QC TOOLS4. Histograms4. Histograms

Is a bar graph showing a distribution of variables. This will helps identify the cause of problems in a process by the shape of the distribution as well as the width of the distributionA histogram divides the range of data into

categories and shows the amount of data collected in each. This makes it easier to determine at a glance median values and distribution.


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7 QC TOOLS7 QC TOOLSHistogramsHistograms

Width of distribution

Width of range

median


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7 QC TOOLS7 QC TOOLSHistogramsHistograms

Width of distribution

Width of range

median


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2. Pareto Diagrams

3. Graphs

4. Histograms

7. Controls Charts

5. Check Sheets

6. Scatter Diagrams


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7 QC TOOLS7 QC TOOLS5. Check sheet5. Check sheet

Check sheet is used to decide in advance the details of forms, categories, and timing so that checks can be made without fail on inspection and verification items for various and wide-ranging data. The check sheet makes it easier to arrange necessary data into order and to discover problems early on.


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2. Pareto Diagrams

3. Graphs

4. Histograms

7. Controls Charts

5. Check Sheets

6. Scatter Diagrams


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7 QC TOOLS7 QC TOOLS6. Scatter Diagram6. Scatter Diagram

This diagram is helpful when dealing with two types of data. It expresses with dots, one type of data on its horizontal axis and the second type on its vertical axis.

This diagram helps to verify if there is a correlation between the two types of data.


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7QC TOOLS7QC TOOLSScatter diagramsScatter diagrams

0

0.5

1

1.5

2

2.5

3

3.5

4

0 10 20 30 40 50 60 70 80 90 100 110

Gas

con

sum

pti

on

speed

(liters)


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2. Pareto Diagrams

3. Graphs

4. Histograms

7. Controls Charts

5. Check Sheets

6. Scatter Diagrams


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7 QC TOOLS7 QC TOOLS7. Control Chart7. Control Chart

A control chart is a line graph of a process drawn in relation to limit lines. Its purpose is to indicate whether each of the points in the process is normal or abnormal, to show where the center of the process is and to show how consistently the process is being maintained.It is very useful for the early detection of malfunctions. In a control chart the upper and

lower control limit lines are drawn and data is expressed using a broken line.


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USL

LSL

LCL

UCL

CL

DATA


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Calculating control limit for x – R chart:

UCL = X + ( A2 x R )

LCL = X - ( A2 x R )

* A2 is a constant from the table.


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1. OUT OF CONTROL - DATA IS OUTSIDE THE UPPER OR LOWER CONTROL LIMIT

USL

LSL

LCL

UCL

CL

DATA

DATA


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2. OUT OF CONTROL - RUN OF 7 CONSECUTIVE POINTS ON ONE SIDE OF THE CENTER LINE

USL

LSL

LCL

UCL

CL


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3. OUT OF CONTROL - TREND OF 7 CONSECUTIVE POINTS INCREASING OR DECREASING

USL

LSL

LCL

UCL

CL


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Date post:	06-Sep-2014
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