CQE Handbook 3rd edition Ch. 27 Quality Control Tools Presented by Dr. Joan Burtner Certified Quality Engineer Associate Professor of Industrial Engineering and Industrial Management

Seven Basic Tools as defined by the American Society for Quality (ASQ) Check Sheet Pareto Chart Scatter Diagram Histogram Cause-and-Effect Diagram Flowchart Control Chart ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Check Sheet Also known as a tally sheet Helps gather data on the frequency of occurrence of particular events or defects Check sheet design often requires prior knowledge of the process Poor Performance on Statistics Exam Check Sheet SS MS JB RR GB didn't eat breakfast √   not enough sleep didn't study too many exams that day didn't understand topic poor math skills unfair test forgot to bring calculator ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Check Sheet Mechanics Design the check sheet for a given application. sheet Record the data. Use the data for analysis or input to additional graphical tools such as Pareto charts or histograms. Poor Performance on Statistics Exam Check Sheet SS MS JB RR GB didn't eat breakfast √   not enough sleep didn't study too many exams that day didn't understand topic poor math skills unfair test forgot to bring calculator ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Pareto Chart Pareto (an 1800s Italian economist) noted that 80 percent of the wealth in Italy was held by 20 percent of the population. This is called the Pareto Principle. Juran (20th century) applied the Pareto Principle to quality improvement vital few useful many (sometimes called trivial many) Mechanics Minitab offers a built-in function for the Pareto chart Manual method: Count items in each category. Plot on graph in order of descending frequency. ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Pareto Chart Causes are frequently documented in a check sheet which is used to generate a Pareto chart Managers use Pareto charts to help focus or prioritize process improvement efforts The chart to the right was generated in Minitab ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Scatter Diagram Also known as an X-Y graph Purpose is to graphically display indications of a relationship between two variables Caution: A statistical correlation does not guarantee a direct cause and effect. Caution: Excel will yield the equation for a straight line “best fit” ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Scatter Diagram Mechanics Select two variables of interest. Set a scale for the axes. Collect and chart the data. Evaluate the results. Linear/nonlinear Positive/negative ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Histogram Purpose is to graphically depict the frequency of occurrence , where occurrences are sorted into categories of a defined range along a continuous scale X-axis shows cell boundaries Y-axis shows cell frequency Shape of the bars is only a rough indication of the distribution ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Histogram Mechanics Determine the amount of data to be collected Determine number of columns or bins to be used Collect and record data Prepare the graphic and graph the data (Minitab and Excel have built-in functions for histograms) X-axis shows bin boundaries Y-axis shows bin frequency ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Cause-and-Effect Diagram Used to show the many different causes that may contribute to a problem (effect) Causes are frequently generated through brainstorming sessions Other names Fishbone diagram Ishikawa diagram C-E diagram 4 M diagram 4 P diagram 6 M diagram Methods Machine Flat Tire Man Materials ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Cause-and-Effect Diagram Mechanics Select a single problem or opportunity (effect) Identify major causes Identify the minor causes associated with each major cause. (Add structure.) Identify additional cause structure. (Add detail.) Note: Ideas are frequently generated through brainstorming sessions conducted BEFORE major/minor causes are identified. People Policy Difficulty finding billing office Plant Procedure ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Popular C-E Diagram Categories 4M Chart Man Machine Methods Materials 4P Chart People Policies Procedures Plant 6M Chart Man Machine Methods Materials Mother Nature Measurement ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Flowchart Purpose is to provide a graphic representation of the elements, components, or tasks associated with a process Maps the sequence of steps and decision points in a process Helps group to have common understanding of the process Load Wash Dry Paint Cure Distribute Scrap ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Flowchart Mechanics Select a start and stop point. List major steps/tasks and decision points. (Show in sequential order.) Use standardized graphical symbols to document the process. Review results. (Verify and refine as necessary.) Note: It is standard protocol to have more than one person independently verify results. Start Basic processing Flow Decision ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Basic Quality Tool : Control Chart Purpose Indicates how a process behaves over time Shows when a process is being influenced by special causes Chart consists of UCL, CL, LCL, and data points Examined for nonrandom patterns See Chapter 37 for mechanics of construction ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering

Contact Information Email: Burtner_J@Mercer.edu US Mail: Dr. Joan Burtner, Chair Department of Industrial Engineering and Industrial Management Mercer University School of Engineering 1501 Mercer University Drive Macon, GA 31207 Phone: (478) 301- 4127 ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering