Agen

da Week 6

 Review Homework 
Week 7 assignment
• Problems Ch 3: 2, 4 • Read chapter 4
 Chapter 3: Problem Solving • Homework
• Desksides: 7 QC Tools
problems: Ch 3
• Flow chart
- 11, 12, 23, 28(c)
• Run Chart

• Pareto Diagram
• Case Study: "How
• Histogram We Slashed
• Cause and Effect Diagram Response Time"
• Check sheet

• Scatter diagram

• Control chart

Quality Improvement: Problem Solving

Seven Quality
Tools
Chapter 3: Problem
Solving

Quality Improvement: Problem Solving

Seven Quality
Control Tools
• Pareto Chart
• Histogram
• Process flow diagram
• Check sheet
• Scatter diagram
• Control chart
• Run Chart
• Cause and Effect Diagram

Quality Improvement: Problem Solving

Pareto Principle
 Vilfredo Pareto (1848-1923) Italian
economist
• 20% of the population has 80% of the
wealth
 Juran used the term “vital few, trivial
many”. He noted that 20% of the quality
problems caused 80% of the dollar loss.

7QualityTools

Quality Improvement: Problem Solving

Pareto chart
30 28
25
% Complaints

20
16
15
12 12
10
6
5 4 3
0
Loose Stitching Button Material
Threads flaws problems flaws

7QualityTools

Quality Improvement: Problem Solving

 Chart
Pareto

Percent from each cause

10
20
30
40
50
60
70

0
Po
o
W rD
ro es
ng ig
di n
(64)

m
D e ens
fe io
ct n
(13)

ive s
M pa
ac r ts
hi
ne
(10)

ca
O l
pe ibra
ra tio
to
(6)

r e ns
De rro
Quality Improvement: Problem Solving fe rs
ct
(3)

ive
m
Causes of poor quality

Su at
r fa er
ce ia
ls
(2)

ab
ra
sio
ns
(2)
Histogram
25

20

15
Frequency

10

.9
9
9
9
9
9
9
9
9
9
.9
.9

.9
.9
.9

e
1.

3.
4.
5.
6.
7.
8.
9.
2.

or
10
11
12
13
14
15
M
Cate gory

7QualityTools

Quality Improvement: Problem Solving

Histogram

40
35
30
25
20
15
10
5
0 1 2 6 13 10 16 19 17 12 16 20 17 13 5 6 2 1

Quality Improvement: Problem Solving

Flowcharts
 Flowcharts
• Graphical description of how work is done.
• Used to describe processes that are to be
improved.

7QualityTools

Quality Improvement: Problem Solving

Flow Diagrams
" Draw a flowchart for whatever you do.
Until you do, you do not know what you
are doing,
you just have a job.”

-- Dr. W. Edwards Deming.

Quality Improvement: Problem Solving

Flowchart
Flowchart
Activity

Yes
Decision

No

7QualityTools

Quality Improvement: Problem Solving

Flowchart

Quality Improvement: Problem Solving

Flow Diagrams

Quality Improvement: Problem Solving

Flow Diagrams

Quality Improvement: Problem Solving

Process Chart
Symbols
Operations
Inspection

Transportation

Delay

Storage

Quality Improvement: Problem Solving

Process Chart
Date: 9-30-00 Location: Graves Mountain
Analyst: TLR Process: Apple Sauce

Distance
Operation
Transport Description

Storage
Inspect

(min)

(feet)
Time
Delay
Step

of
process

1 Unload apples from truck 20

2 Move to inspection station 100 ft
3 Weigh, inspect, sort 30
4 Move to storage 50 ft
5 Wait until needed 360
6 Move to peeler 20 ft
7 Apples peeled and cored 15
8 Soak in water until needed 20
9 Place in conveyor 5
10 Move to mixing area 20 ft
11 Weigh, inspect, sort 30
Page 1 0f 3 Total 480 190 ft

Quality Improvement: Problem Solving

Quality Improvement: Problem Solving
Check
Check Sheet
Sheet

Shifts

√√√ √√√√ √ √√√

Defect Type

√√ √√√

√√√√ √√√

√√ √

7QualityTools

Quality Improvement: Problem Solving

Check Sheet
COMPONENTS REPLACED BY LAB
TIME PERIOD: 22 Feb to 27 Feb 1998
REPAIR TECHNICIAN: Bob

TV SET MODEL 1013

Integrated Circuits ||||
Capacitors |||| |||| |||| |||| |||| ||
Resistors ||
Transformers ||||
Commands
CRT |

Quality Improvement: Problem Solving

Cause-and-Effect
Cause-and-Effect
Diagrams
Diagrams
 Show the relationships between a
problem and its possible causes.
 Developed by Kaoru Ishikawa (1953)


Also known as …
• Fishbone diagrams
• Ishikawa diagrams

7QualityTools

Quality Improvement: Problem Solving

Cause
Cause and
and Effect
Effect
“Skeleton”
“Skeleton”
Materials Procedures

Quality
Problem

People Equipment
7QualityTools

Quality Improvement: Problem Solving

Fishbone Diagram
Measurement Human Machines

Faulty testing equipment Poor supervision Out of adjustment

Incorrect specifications Lack of concentration Tooling problems

Improper methods Inadequate training Old / worn

Quality
Inaccurate Problem
temperature Poor process
control Defective from vendor
design
Ineffective quality
Not to specifications management
Dust and
Dirt Material- Deficiencies
handling problems in product
design
Environment Materials Process

Quality Improvement: Problem Solving

Cause and effect
diagrams
 Advantages
• making the diagram is educational in itself
• diagram demonstrates knowledge of
problem solving team
• diagram results in active searches for
causes
• diagram is a guide for data collection

Quality Improvement: Problem Solving

Cause and effect
diagrams
To construct the skeleton, remember:

For manufacturing - the 4 M’s
 man, method, machine, material

For service applications
 equipment, policies, procedures, people

Quality Improvement: Problem Solving

Scatter Diagram

Quality Improvement: Problem Solving

Run Charts
 Run Charts (time series plot)
• Examine the behavior of a variable over
time.
• Basis for Control Charts

Quality Improvement: Problem Solving

Control Chart 27

24
UCL = 23.35
21
Number of defects

18 c = 12.67

15

12

6
LCL = 1.99
3

2 4 6 8 10 12 14 16
Sample number
Quality Improvement: Problem Solving
Control Charts

Quality Improvement: Problem Solving

“Stem and leaf”
displays
Data
Integrated Circuit Response Time (ps)

4 .6 4 .0 3 .7 4 .1 4 .1 5 .6 4 .5 6 .0 6 .0 3 .4
3 .4 4 .6 3 .7 4 .2 4 .6 4 .7 4 .1 3 .7 3 .4 3 .3
3 .7 4 .1 4 .5 4 .6 4 .4 4 .8 4 .3 4 .4 5 .1 3 .9

Quality Improvement: Problem Solving

“Stem and leaf”
displays
Integrated Circuit Response Time (ps)

3 7 4 4 7 7 4 3 7 9

4 6 0 1 5 6 2 6 7 1 1 5 6 4 8 3 4

5 6 1

6 0 0

Quality Improvement: Problem Solving

Dot diagrams

Integrated Circuit Response Time (ps)

3 4 5 6
Plant A

Plant B

Quality Improvement: Problem Solving