3 G’ s

GENCHI : ACTUAL PLACE

GENBUTSU: ACTUAL THING
GENJITSU: ACTUALLY
& 7 QC Tools
Dr. D. P. Sahoo
 QC TOOLS

• QC Tools are based on statistical methods and are effective for

improving the production process and reducing its defects.
• The first step: Observe to find the true cause, which is the careful
observation of the phenomenon of the defect.
• After such careful observation, the true cause becomes apparent.
Analyzing Problems Using
Data
• Objective of Collecting Data
• Data is a guide for our actions. From data, we
learn pertinent facts that are useful for
problem-solving.
• Data is required for controlling and monitoring
the process
• Data is required for analysis of non-
conformance
 QC TOOLS
In case of a problem:
· Urgently proceed to the workplace where the fault has occurred.
· Ascertain the fault visually.
· Observe well the conditions leading to the fault.
Listen attentively to the opinion of the operator.
 QC TOOLS
QC tools lend objectivity and accuracy to observation.
The principles of the statistical way of thinking are:
· Give greater importance to facts.
· Do not express facts in terms of senses or ideas.
• Use figures derived from specific observed results.
· Go to the actual site where the problem is occurring, observe the
actual object, and make measurements on that object actually by
yourself.
 QC TOOLS
Observational results, accompanied as they are by error and
variation, are part of a hidden whole. Finding that hidden whole is
observation’s ultimate goal.
Accept regular tendency, which appears in a large number of
observational results as reliable information.
 QC TOOLS
Seven QC Tools are useful for analyzing problems using data. These
seven tools are:
• Check Sheet
• Histogram
• Scatter Diagram
• Graphs
• Pareto Diagram
• Cause and Effect Diagram
• Control Charts
 CHECK SHEETS
• A structured form is used to collect and analyze data
• In real time.
They are also known as defect concentration diagrams or tally sheets. It was made
popular by Dr. Kaoru Ishikawa.

A blank form that is designed for the quick, easy, and efficient recording of the desired
information, which can be either quantitative or qualitative.
 STARTING POINT FOR PROBLEM-SOLVING
 THE PROCESS IS SIMPLE METHOD OF DATA COLLECTION
 ESSENTIAL TO ENSURE THAT NO ITEMS ARE OMITTED WHEN INSPECTING
 USEFUL FOR PROCESS CONTROL
Is the practice of monitoring and adjusting a process to
achieve a desired outcome
Classification Check sheet: A classification check sheet is used to
collect data in a categorized form. It provides a visual overview of the
problem areas.
Defect location check sheet: The defect location check sheet reveals
the area of the product that tends to see most of the defects

Frequency check sheet: The number of occurrences of a

trait on a part can be indicated.
Measurement scale check sheet: A measurement scale is divided
into intervals and measurements are indicated by checking an
appropriate interval. This check sheet provides a visual description of
the probability distribution, which helps get a better idea of process
capability and performance.
What are the benefits of a Checksheet?
 Checksheets facilitate and document the Data Collection process.

 Facilitates data collection in a systematic and organized manner.

 Helps collect data in a processable form by processable I mean data from

which one or multiple inferences could be drawn.

 Checksheet is a simple and effective way to display data.

 Acts as input for multiple 7 QC tools such as Pareto, Histogram, etc.

 It helps identify the frequency of defect occurrence.

 Quantify defects by type location And cause.

Do not confuse between Checksheet & Checklist.

• A checklist is a tool to make sure all steps of a particular process are completed and not
missed.
• A checksheet is to collect data in a systematic and organized manner for inferences.
HISTOGRAMS

A histogram is a graphical tool used for representing data as frequency

distribution.

It groups data into continuous number ranges and each range corresponds to a vertical bar i.e.
the height of each bar shows how many cases fall into each range.
Uses of Histogram • Summarize large data sets graphically.
• Compare measurements to specifications.
• Communicate information to the team.
• Assist in decision-making.

A histogram is a two-axis chart.

 Its Y-Axis displays the frequency and
 the X-Axis displays the number range.
 One of the distinguishing features of Histogram is that there are no gaps between the range
bars.
Pros
• Helps visualize the data distribution pattern and conclusions can be
drawn by just looking at the shape of the histogram.

• Provides a clear idea about the frequency and hence predicts probabilistic
chances of any event occurring.

• Helps display a large set of data in a compressed manner.

Cons

• The histogram doesn’t show information about what is happening within

each bin of the graph.

• It shows the number of values within an interval but not the actual values
i.e. we cannot read exact values because data is grouped into categories.

• With Histogram it’s difficult to compare two data sets.

• Histogram use only with continuous data.

SCATTER DIAGRAMS

 Scatter Diagrams are used to study possible relationships

between two variables.

 These diagrams cannot prove that one variable causes the

other, they do indicate the existence of a relationship, as well
as the strength of that relationship.

 The purpose of the Scatter Diagram is to display what happens

to one variable when another variable is changed.

 The diagram tests a theory that the two variables

are related. The type of relationship that exists is indicated
by the slope of the diagram.
Samples & Reading method

(a) There is a trend that

if x increases and y increases also (plus
relation)
(b) There is the trend that if x increases y in-
creases also.
( It seems to be a plus relation.)
(c) In case of no relation
(d) If x increases and y decreases mostly. (It
seems to be a minus relation.)
(e) The trend is that If x increases, y de-
creases. (We say that it’s a minus
relation.)
 PARETO CHART
A Pareto chart is a graphical tool used to display the relative proportions of
occurrence of different values. It is named after economist Vilfredo Pareto’ The
Pareto principle, also known as the 80/20 rule

popularized in business and quality management as a way to focus on those activities

that will yield the most results.

The theory behind the principle is that a relatively small number of causes (the vital few)
produce the majority of effects (the trivial many).

The Pareto chart is used for:

1. To find and illustrate the significant causes of a problem.

It is used as part of the problem-solving process to help identify

2.
which problems need to be solved first.

3.The underlined norms are 80/20 rule, which states that 80%
of the effects come from 20% of the causes.
When to use a Pareto Chart?

Ask yourself two questions.

• Can the data be arranged into categories?

• Is the rank of each category important?

If the answer is “yes” to both these questions, you can use Pareto charts.

Practical Application of Pareto Chart

A Pareto chart to help you prioritize the projects. The chart can identify the
most common causes of a problem, and then you can focus your efforts
on those areas. This will help you get the biggest results in the shortest amount
of time.

A Pareto chart is a powerful tool that can be used in Six Sigma,

“define” phase of DMAIC [Define, Measure, Analyze, Improve, and Control], Root
cause analysis and Quality Control.
Advantages

• The Pareto chart helps to identify the main cause of defects or problems.
Defects are ranked in order of their severity.

• The Pareto chart helps to determine the cumulative impact of the defect.

• It is simple and easy to use. It helps to prioritize the defects and to determine
the corrective action for the highest-priority defects.
Disadvantages

• One of the main disadvantages of the Pareto chart is that it can be difficult to
use for small data sets.

• A Pareto chart can be time-consuming to create and may not be accurate when
used with small data sets.

• The Pareto chart is not always the best tool to use when trying to identify the
root cause of a problem.
How to Create a Pareto Chart in Excel?

Step #1 : Create Data Table

Step #2 : Populate Basic data

Step #3 : Sort the Quantity Column from
Largest to Smallest

Step #4 : Add Formula for Cumulative

Quantity
Step #5 : Calculate Percentage Contribution
to Cumulative Quantity

Step #6 : Insert Pareto Chart

PARETO CHART ANALYSIS

No.
Of Cumulative
Problem Percentage
Items

Problem Type
Cause-and-Effect Diagram
What is it?
• A Cause-and-Effect Diagram (also known as a “Fishbone
Diagram”) is a graphical technique for grouping people’s ideas
about the causes of a problem
Why use it?
• Using a Cause-and-Effect Diagram forces the team to consider
the complexity of the problem and to take an objective look at
all the contributing factors.
• It helps the team to determine both the primary and the
secondary causes of a problem and is helpful for organizing the
ideas generated from a brainstorming session.

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Cause-and-Effect Diagram
When to use it?
• It is used after the causes have been grouped by relationships
(e.g., by using a Causal Table or “Why-Because” Technique). It
is a useful diagram for problem analysis. Therefore, a Cause-
and-Effect Diagram should be used before deciding how to
deal with the problem
How to use it?
• Before constructing the Cause-and-Effect Diagram, one need to
analyze the causes. The steps are as follows:
1. Re-examine the problem by asking:
• What is the problem?
• Who is affected?
• When does it occur?
• Where does it occur?

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Structure

Cause-and-Effect Diagram
How to use it?
2. Brainstorm the team’s ideas about the causes of a
problem
3. The list of causes should be grouped by relationships
or common factors
4. Illustrate graphically the causes grouped by
relationships by using a Cause-and-Effect Diagram

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 Categ. Categ.
1 Cause 2
Cause 1
2 Problem

Categ. Categ.
3 4

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Checklist: What is it?
• A checklist is a tool you can use to systematically observe a
process, using a list of closed-ended questions
Why use it?
• To ensure that different types of service providers / processes in
your organization are complying with the stated standards of
treatment
When to use it?
• When you are trying to analyze a problem, or when you are
trying to find out if a solution to a problem has been
implemented successfully
• A checklist can be used also to check for the consistency of a
process on the basis of a flowchart
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Checklist: How to use it?
1. Review the steps of the process that you want to
observe
2. Select the critical steps of the process
3. Make a list of questions to check if the steps are
performed. These questions should be “closed”, that is,
able to be answered only by “Yes” or “No”
4. Perform the observations and collect the data

30
Example of a Checklist
Date:
Hour:
Place:
Name of Provider:
Profession:
Patient’s Clinical File #
Did you take the patient’s temperature? Yes No
Did you weigh the patient? Yes No
Did you take the patient’s blood pressure? Yes No
Did you take the patient’s blood pulse? Yes No
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Flowchart: What is it?
• A Flowchart is a tool that graphically represents the steps of a
process or the steps that users have to take to use the service
(user Flowchart)
Why use it?
• The Flowchart helps you analyze the number of steps and the
time required for each step, to detect bottlenecks,
unnecessary steps, repetitions, and other obstacles
When to use it?
• When you want to describe activities, identify problems,
identify the causes of problems, detect “bottlenecks”, and
define indicators
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Flowchart:
Process
Different symbols are used in a Starting Point
Flowchart to indicate the different
types of actions in the process:
•a circle for the beginning or end of the Steps in
process the Process
•a rectangle for a step in the process
(activities)
•a diamond for the decision points Decision

End
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Flowchart: How to create a Flowchart?
1. Observe for a few repetitions the process you will be charting.
Write down all the steps taken and decisions made in the
process.
2. Mark the path of the Flowchart from the beginning to the end by
connecting all the rectangles (activities) and diamonds (decision
points)
3. Return to the beginning of the path and repeat Step 2 for any
paths that branch off from the main path (at the decision points)
4. Record the last step at the bottom of the page, draw a circle
around it, and connect the primary path and any branching paths
to the last step
5. Review for accuracy

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CONTROL CHARTS
AND GRAPHS The control chart was invented by Dr. Walter A
Shewhart in the early 1920s.

CONTROL CHARTS
CHECKING WHETHER OR NOT A PROCESS IS IN CONTROL.
FACILITATING PROACTIVE ACTIONS FOR QUALITY
IMPROVEMENT.
GRAPHS
MAKING DATA VISUAL
EASY FOR UNDERSTANDING AT THE WORK PLACE.
Basics concepts for understanding Control charts

Understanding types of Variation

Control charts help us understand the type of variation in the process.

There are two types of variations.

Common cause variation

Common cause variation is the variation that is inherent in the process and cannot be
eliminated.

It occurs when there is a change in the process, but the cause of the change is not
known.

For example, common cause variation can occur when the temperature or humidity changes,
when different operators work on the process, or when the machine is not in good working
condition.
Special cause variation

Special cause variation is the variation that is not due to the common causes and can be
eliminated.

For example, special cause variation can occur when an operator makes a mistake, when
a machine breaks down, or when there is a change in the raw material.

Understanding type of Data

It is important to understand the types of data since the type of data is one of the
important considerations for control chart selection.

Attribute data is data that is measured on a nominal or ordinal scale.

Variable data is data that is measured on a numerical scale. Variable data can be either
continuous or discrete.
Graphs
• Line Graph
• Bar graph

Defect %
Production

Mon Tue Wed Thu

Graphs
• Pie Chart

Scratch

Blowholes

Size error

hardness
Control Chart
• Control chart

UCL

CL

LCL
THANKS