1. The Seven Tools Of Quality Management
1 Flow charts
2 Check sheets
3 Scatter diagrams
4 Histograms
5 Pareto charts
6 Cause and effect diagrams (Fishbone/Ishikawa diagrams)
7 Control charts
Note: There are seven new tools, to aid in senior management planning, in addition to the seven tools covered here.

2. Flow charts Uses: To document flow of a new or current process
To create common understanding of how a process works.
To allow checking of sequence of activities
To indicate problems
To allow improvement of a process.
To increase understanding of processes
To identify linkages between processes.
To assess compliance between actual and intended processes
To identify gaps between procedures

3. Flow charts A flowchart is: How to use a flowchart:
A diagrammatic tool to show the sequential relationship between activities, or the path or paths a process follows. It can be used as an overview, with broad detail, or as a fine detail tool with precise and small steps in processes.
How to use a flowchart:
Read the chart from start to finish following all paths to their end.
Read all notes and labels on the chart.
Question each step in the process as required.

4. Flow charts Steps in Creating a flowchart
1 Determine who should be involved in drawing up the flowchart.
2. Involve all team members.
3 Allow time to create and check the chart.
4. Before drawing the chart, decide on the detail required
5. Have questions prepared to help draw the chart.
6 Identify the start and end-points, each decision point, each process, then join points together.
You may wish to tape interviews with participants for future reference.

5. Flow charts Symbols used in a flowchart
Start End Decision point. Process Flow, the
Question must direction of
have a Yes or movement
no answer.

7. Check sheets Uses To gather data
To provide clear record of data gathered
To ensure that everyone will gather comparable data
To provide data in a suitable form for further analysis
To highlight if a problem exists
A check sheet is:
A form used to record how many times something has occurred. It is usually used by those involved in collecting raw data.

8. Check sheets How to use a check sheet:
Obtain the correct sheet for the purpose.
Position yourself to clearly see what is going on.
Conduct the observation at the required intervals.
Place lines or strokes of a pen into appropriate box, groups of five make it easy to count the strokes
Analyse the count of categories.

9. Check sheets Steps in creating a check sheet
1. Decide what data you need
2. Design a form to suit the people using it and the type of data to be collected
3. Test the check sheet, using someone not involved with designing the sheet
4. Revise the sheet as necessary
5. Design a tally check sheet to summarise the data from individual forms (if necessary)

10. Check sheets Tenant Times Late Jones 2 Smith 3 Malcolm 5 Henare
Hashimoto
Peterson 3
Mene
Gerbic 8

11. Check sheets 35 30 25 20 Number of 10.00 cm bars 15 10 5
Machine setting (cm)
Number of cm bars

12. Check sheets Defects in a laminated printed circuit board
DDDDD
DDD S S
DDDDD
DDD S S WW
SSS S WW
LLLLL LL
Defects in a laminated printed circuit board
Key: L = lamination problem, W = wrong component,
D = defective component, S = soldering problem

14. Scatter diagrams Uses To show relationships
To show strength of relationship

16. Scatter diagrams
Is a graph which shows relationship between two variables. A graph without lines joining the dots.
A graph that shows possible cause and effect relationships (regression)

17. Scatter diagrams How to use scatter diagrams: View the diagram for
shape
trends (positive upwards, negative downwards)
closeness of points to a line

18. Scatter diagrams Steps in creating a scatter diagram
Identify possible related variables
Collect data
Create scales for axes
Plot the points
Interpret the graph

19. Scatter diagrams

20. Histograms Uses To display statistical information.
To show frequency of occurrence,
To see concentrations of values
To sort data sets
To see gaps or outliers in the data set.
To see the shape of the data set, symmetry or skewing etc.
To allow problem identification

21. Histograms
A member of the Bar graph family. In quality management, histograms are used to plot discrete and continuous data.
These graphs show frequency of occurrence of the group of data by the height or length of a rectangle, which represents a group or category of data. Created by people collecting and analysing data, and read by people who require to understand the relationships between data groups.

22. Histograms How to use Histogram:
View the diagram for uniformity of shape, asking these questions:
are there one or more peaks?
is the graph “normal’ in shape?
is the data clumped together?
is there a positive, negative or no skew?
are there any unusual features?
Calculate the spread,
Note any outliers (values distant from the main group of values)

23. Histograms Steps in creating a Histogram Collect your data
Determine the range of the data
Determine how many groups you need
Group the data
Construct the axes
Draw the bars
Label the graph

24. Histograms

26. Pareto charts
Uses:
Identifying the one or two situation categories in which most of a problem occurs.
To focus attention on the major contributing factors.
To show progress in quality improvement projects.

27. Pareto charts A Pareto diagram is:
A method of classifying importance or order of magnitude. It is a technique used to indicate the relative importance of occurrences. It can be regarded as an ordered or sorted Histogram.
Managers at any level would read the diagram; people collecting data and performing the data analysis would prepare it.

28. Pareto charts How to use a Pareto diagram:
A Pareto diagram is a guide to action. It prioritises tasks or problems for you.
View the diagram for shape, asking these questions:
is there one dominant category?
is the diagram the expected shape?
Check the action to take,
Instigate action on chosen activity.

29. Pareto charts Steps in creating a Pareto Diagram Create a Histogram
Sort the categories
Read off the categories in order.

30. Pareto charts 40 35 30 25 20 15 10 5 B A D C G
Other
Defects Count

32. Cause and effect / fish bone / Ishikawa diagrams
Uses:
To solve problems.
To educate.
To guide discussion.
To actively seek causes.
To collect data.
To show relationships.

33. Cause and effect diagrams
A diagram showing the links between a problem and its possible causes.
Has a problem stated in the box on the right side of the diagram and possible causes (under classification) on the left of the diagram.
Common classifications are:
Workers Materials,
Methods Machines
Environment

34. Cause and effect diagrams
How to use a cause and effect diagram
scan the diagram for an overview
Read the diagram, problem, possible causes
Read detail
Seek more causes under the classifications
Rank causes for likelihood of being the cause and degree of difficulty to rectify.

35. Cause and effect diagrams
Steps in creating a C&E diagram
Gather team to create diagram
Select the scene, ensure all understand the situation
Identify the real problem
Develop possible causes
Classify causes into headings
Agree probable causes
Redraw diagram
Repeat until satisfied

36. Cause and effect diagrams
Techniques used
Brainstorming for ideas, problem identification and probable causes.
Crawford slip method
codes
N, for not difficult to fix, V very difficult
n, for not expensive, v very expensive
Select items coded Nn to rectify and gain some quick improvement.

38. Cause and effect diagrams
Workers
Materials
Lack of training
Lack of care
Faulty roll steel
Dents in end panel of control box
Poor procedures
Poor maintenance
Parts dropped off conveyor
Methods
Machinery
Poor set up

39. Run chart
Uses:
To indicate changes or differences in patterns over time.
To compare data from the same process at different time-periods.
To compare different sources of the same process during the same time-period.

40. Run chart A Run chart is:
A record of measurements presented in the order or sequence in which the data was taken.
It can take the form of a scatter graph or a line graph.
It has a time axis (the x-axis ) and a measurement axis (the y-axis).

41. Run chart How to use a Run chart:
A Run Chart is a guide to action, an aid to making decisions. It displays the data in time order and so indicates trends.
View the diagram for shape, asking these questions:
is there a trend up or down?
is the data showing a wide spread?
is the data showing ‘normal’ variation?
Investigate reason for shape, if necessary
Make a choice based on data presented.

42. Run chart Steps in creating a run chart Decide process to be measured
Choose time period, x-axis
Choose scale, y-axis
Record data
Analyse data
Make decision of next action

43. Run chart run chart of number of defects in a batch from supplier 1
104
106
108
110
112
114
116 5 10 15 20 25 30 35 40 45
Batch number
Number of defects in a batch

44. Run chart run chart of number of defects in a batch from supplier 2
104
106
108
110
112
114
116 5 10 15 20 25 30 35 40 45
Batch number
Number of defects in a batch

45. Control charts
Are similar to run charts but have control limits attached to gauge suitability to a process.
See Powerpoint file
control charts.ppt

47. Errors associated with Sampling and SPC
DECISION
Search for defect Leave process as it is
CONDITION in process and try
to correct it
Process is Type I error Correct decision
working properly
Process is defective Correct decision Type II error