Introduction to the Use of Classic Quality Tools Presented by Dr. Joan Burtner Certified Quality Engineer Associate Professor of Industrial Engineering and Industrial Management

ETM 591 ISE 427 Fall 2010Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 2 Seven Classic Problem- Solving Tools of Quality Flowchart Flowchart Check Sheet Check Sheet Cause-and-Effect Diagram Cause-and-Effect Diagram Pareto Chart Pareto Chart Control Chart Control Chart Histogram Histogram Scatter Diagram Scatter Diagram

ETM 591 ISE 427 Fall 2010Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 3 Classic Quality Tool 1: Flowchart Maps the sequence of steps and decision points in a process Maps the sequence of steps and decision points in a process Helps group to have common understanding of the process Helps group to have common understanding of the process

ETM 591 ISE 427 Fall 2010Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 4 Classic Quality Tool 2: Check Sheet Also known as a tally sheet Also known as a tally sheet Helps gather data on the frequency of occurrence of particular events or defects Helps gather data on the frequency of occurrence of particular events or defects Check sheet design often requires prior knowledge of the process Check sheet design often requires prior knowledge of the process Chips Scratches Dents Finish flaws Black spots Rough edges 

ETM 591 ISE 427 Fall 2010Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 5 Classic Quality Tool 3: Cause-and-Effect Diagram Other names Other names  Fishbone diagram  Ishikawa diagram  C-E diagram Used to show the many different causes that may contribute to a problem (effect) Used to show the many different causes that may contribute to a problem (effect) Causes are frequently generated through brainstorming sessions Causes are frequently generated through brainstorming sessions

ETM 591 ISE 427 Fall 2010Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 6 Classic Quality Tool 3: C-E Diagram (cont.) Manufacturing Environment 4M Chart Manufacturing Environment 4M Chart  Man  Machine  Methods  Materials Service Environment 4P Chart Service Environment 4P Chart  People  Policies  Procedures  Plant

ETM 591 ISE 427 Fall 2010Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 7 Classic Quality Tool 4: Pareto Chart Pareto (an 1800s Italian economist) noted that 80 percent of the wealth in Italy was held by 20 percent of the population Pareto (an 1800s Italian economist) noted that 80 percent of the wealth in Italy was held by 20 percent of the population Juran (20 th century) 80% of the variation in a process is caused by 20% of the variables Juran (20 th century) 80% of the variation in a process is caused by 20% of the variables  20% - vital few  80% - trivial many or useful many

ETM 591 ISE 427 Fall 2010Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 8 Classic Quality Tool 4: Pareto Chart (cont.) Causes are frequently documented in a check list which is used to generate a Pareto chart Causes are frequently documented in a check list which is used to generate a Pareto chart Managers use Pareto charts to help focus or prioritize process improvement efforts Managers use Pareto charts to help focus or prioritize process improvement efforts Compare to a histogram (X-axis) Compare to a histogram (X-axis)

ETM 591 ISE 427 Fall 2010Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 9 Classic Quality Tool 5: Control Chart Purpose 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 Chart consists of UCL, CL, LCL, and data points Examined for nonrandom patterns Examined for nonrandom patterns

ETM 591 ISE 427 Fall 2010Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 10 Classic Quality Tool 6: Histogram Bar graph that represents the frequency distribution of the data Bar graph that represents the frequency distribution of the data X-axis shows cell boundaries X-axis shows cell boundaries Y-axis shows cell frequency Y-axis shows cell frequency Shape of the bars is only a rough indication of the distribution Shape of the bars is only a rough indication of the distribution

ETM 591 ISE 427 Fall 2010Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 11 Classic Quality Tool 7: Scatter Diagram Also known as an X-Y graph Also known as an X-Y graph “Shows whether or not there is a correlation between two variables” “Shows whether or not there is a correlation between two variables” Caution: A statistical correlation does not guarantee a direct cause and effect Caution: A statistical correlation does not guarantee a direct cause and effect Linear/nonlinear Linear/nonlinear Positive/negative Positive/negative

ETM 591 ISE 427 Fall 2010Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 12 Contact Information US Mail: US Mail: Mercer University School of Engineering 1400 Coleman Avenue Macon, GA Phone: (478) Phone: (478)