The Basic Seven Qc Tools
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The Basic Seven (B7) Tools of Quality A PowerPoint Training Presentation By Keith H. Cooper "As much as 95% of quality related problems in the factory can be solved with seven fundamental quantitative tools." - Kaoru Ishikawa
What are the Basic Seven Tools of Quality? • • • • • • •
Fishbone Diagrams Histograms Pareto Analysis Flowcharts Scatter Plots Run Charts Control Charts
Where did the Basic Seven come from? Kaoru Ishikawa
• Known for “Democratizing Statistics” • The Basic Seven Tools made statistical analysis less complicated for the average person • Good Visual Aids make statistical and quality control more comprehendible.
The Basic Seven (B7) Tools of Quality Fishbone Diagrams • No statistics involved • Maps out a process/problem • Makes improvement easier • Looks like a “Fish Skeleton”
Constructing a Fishbone Diagram • Step 1 - Identify the Problem • Step 2 - Draw “spine” and “bones” Example: High Inventory Shrinkage at local Drug Store
Shrinkage
Co nst ructing a Fish bone Dia gram • Step 3 - Identify different areas where problems may arise from Ex. : High Inventory Shrinkage at local Drug Store
employees
Shrinkage
shoplifters
Co nst ructing a Fish bone Dia gram • Step 4 - Identify what these specific causes could be Ex. : High Inventory Shrinkage at local Drug Store
Shrinkage Expensive merchandise out in the open
Anti-theft tags poorly designed
No security/ surveillance
shoplifters
Constructing a Fishbone Diagram • Ex. : High Inventory Shrinkage at local Drug Store employees attitude training new trainee benefits
Shrinkage Expensive merchandise out in the open
Anti-theft tags poorly designed
No security/ surveillance
shoplifters
practices
Constructing a Fishbone Diagram • Step 5 – Use the finished diagram to brainstorm solutions to the main problems.
The Basic Seven (B7) Tools of Quality Histograms • Bar chart • Used to graphically represent groups of data
Constructing a Histogram From a set of data compute • sum • mean (x) • Max • Min • Range (max-min)
Constructing a Histogram • Use range to estimate beginning and end • Calculate the width of each column by dividing the range by the number of columns
Range # of Columns
= Width
Acme Pizza Example • Let’s say the owner wants a distribution of Acme’s Thursday Night Sales Data Set from last Thursday(slices)
02122413121224341432232122122142 21212212121212121222121211222314 22322212322422441222322122421242 1721223121121222122121222424
Acme Pizza Example Mean = 2.032258 Max = 7 Min = 0 Range = 7 Question For 7 columns what would the width be?
Range/Columns=7/7=1 slice
Acme Pizza Example Histogram 65
# times ordered
70 60 50 40
33
30 20 8
10
12
0 1
2
3
4
0
0
1
5
6
7
Slices of Pizza
Constructing a Histogram How is this helpful to Acme? • 2 slices of pizza most common order placed • Distribution of sales useful for forecasting next Thursday’s late night demand If you were an Acme manager how could you apply this information?
The Basic Seven (B7) Tools of Quality Pareto Analysis • Very similar to Histograms • Use of the 80/20 rule • Use of percentages to show importance
Acme Pizza (part 2) Slices 0 1 2 3 4 5 6 7
Frequency 1 33 65 8 12 0 0 1
% .3 13.09 25.79 3.17 4.76 0 0 .3
Acme Pizza (part 2)
# times ordered
• The completed Pareto Analysis results in the following graph: 70 60 50 40 30 20 10 0
21
1
2
43
34
75
56
Slices of Pizza
67
Acme Pizza (part 2) Critical Thinking • How does the Pareto Analysis differ from the Histogram? • How can this be a useful tool to the Acme boss?
The Basic Seven (B7) Tools of Quality Flowcharts • A graphical picture of a PROCESS
Process
Decision The process flow
Flowcharts Don’t Forget to: • Define symbols before beginning • Stay consistent • Check that process is accurate
Acme Pizza Example (Flowchart) Window (start)
Take Customer Order
no Lockup
Oven
Time to close?
no
yes Get Pizza
Put More in
yes
Money?
no
2 Pies Available?
yes Take to Customer
How can we use the flowchart to analyze improvement ideas from the Histogram? Window (start)
Take Customer Order
no Lockup
Oven
Time to close?
no
yes Get Pizza
Put More in
yes
Money?
no
2 Pies Available?
yes Take to Customer
Want some practice? Make a flowchart for: • • • • •
Taking a shower Cooking dinner Driving a car Having a party Creating a Flowchart
Any other processes you can think of?
The Basic Seven (B7) Tools of Quality Scatter Plots • 2 Dimensional X/Y plots • Used to show relationship between independent(x) and dependent(y) variables
Acme Pizza (Scatter Diagram) Minutes Cooking 10 45 30 75 60 20 25
Defective Pies 1 8 5 20 14 4 6
In this simple example, you can find the existing relationship without much difficulty but…
Scatter Diagrams Defective Pizzas
•Easier to see direct relationship
25 20 15 10 5 0 0
20
40
60
Time Cooking (minutes)
80
Scatter Diagrams As a quality tool • What does this tell Acme management about their processes? • Improvements? Defective Pizzas
25 20 15 10 5 0
0
20
40
60
Time Cooking (minutes)
80
The Basic Seven (B7) Tools of Quality Run charts
• Time-based (x-axis) • Cyclical • Look for patterns
Slices/hour
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Run Charts
8 9 10 11 12 1 2 3 4
8 9 10 11 12 1 2 3 4 8 9 10 11 12 1 2 3 4
PM- AM
PM- AM
PM- AM
Thursday
Thursday
Thursday
Time
The Basic Seven (B7) Tools of Quality Control Charts
• Deviation from Mean
• Upper and Lower Spec’s • Range
Control Charts Upper Limit
X
Lower Limit
Unacceptable deviation
Control Charts Acme Pizza Management wants to get in on the control chart action •Average Diameter = 16 inches •Upper Limit = 17 inches •Lower Limit = 15 inches
Acme example Control Charts Upper Limit
17 inches
16 inches=
X
Lower Limit 15 Inches Small Pie
Acme example #50 Control Charts •Pies within specifications were acceptable •One abnormally small pie is “uncommon” •Should be examined for quality control
Summary • Basic Seven Tools of Quality • Measuring data • Quality Analysis • “Democratized statistics”
Bibliography •
Foster, Thomas. Managing Quality. An Integrative Approach. Upper Saddle River : Prentice Hall, 2001.
•
Stevenson, William. “Supercharging Your Pareto Analysis.” Quality Progress October 2000: 51-55.
•
“Dr Ka oru Is hik aw a.” In terne t “http://www.dti.gov.uk/mbp/bpgt/m9ja00001/m9j a0000110.html.” 16 February 2001.
•
“Chemical and Process Engineering.” Internet. “http://lorien.ncl.ac.uk/ming/spc/spc8.htm.” 17 February 2001.
What are the Basic Seven Tools of Quality? • • • • • • •
Fishbone Diagrams Histograms Pareto Analysis Flowcharts Scatter Plots Run Charts Control Charts
Where did the Basic Seven come from? Kaoru Ishikawa
• Known for “Democratizing Statistics” • The Basic Seven Tools made statistical analysis less complicated for the average person • Good Visual Aids make statistical and quality control more comprehendible.
The Basic Seven (B7) Tools of Quality Fishbone Diagrams • No statistics involved • Maps out a process/problem • Makes improvement easier • Looks like a “Fish Skeleton”
Constructing a Fishbone Diagram • Step 1 - Identify the Problem • Step 2 - Draw “spine” and “bones” Example: High Inventory Shrinkage at local Drug Store
Shrinkage
Co nst ructing a Fish bone Dia gram • Step 3 - Identify different areas where problems may arise from Ex. : High Inventory Shrinkage at local Drug Store
employees
Shrinkage
shoplifters
Co nst ructing a Fish bone Dia gram • Step 4 - Identify what these specific causes could be Ex. : High Inventory Shrinkage at local Drug Store
Shrinkage Expensive merchandise out in the open
Anti-theft tags poorly designed
No security/ surveillance
shoplifters
Constructing a Fishbone Diagram • Ex. : High Inventory Shrinkage at local Drug Store employees attitude training new trainee benefits
Shrinkage Expensive merchandise out in the open
Anti-theft tags poorly designed
No security/ surveillance
shoplifters
practices
Constructing a Fishbone Diagram • Step 5 – Use the finished diagram to brainstorm solutions to the main problems.
The Basic Seven (B7) Tools of Quality Histograms • Bar chart • Used to graphically represent groups of data
Constructing a Histogram From a set of data compute • sum • mean (x) • Max • Min • Range (max-min)
Constructing a Histogram • Use range to estimate beginning and end • Calculate the width of each column by dividing the range by the number of columns
Range # of Columns
= Width
Acme Pizza Example • Let’s say the owner wants a distribution of Acme’s Thursday Night Sales Data Set from last Thursday(slices)
02122413121224341432232122122142 21212212121212121222121211222314 22322212322422441222322122421242 1721223121121222122121222424
Acme Pizza Example Mean = 2.032258 Max = 7 Min = 0 Range = 7 Question For 7 columns what would the width be?
Range/Columns=7/7=1 slice
Acme Pizza Example Histogram 65
# times ordered
70 60 50 40
33
30 20 8
10
12
0 1
2
3
4
0
0
1
5
6
7
Slices of Pizza
Constructing a Histogram How is this helpful to Acme? • 2 slices of pizza most common order placed • Distribution of sales useful for forecasting next Thursday’s late night demand If you were an Acme manager how could you apply this information?
The Basic Seven (B7) Tools of Quality Pareto Analysis • Very similar to Histograms • Use of the 80/20 rule • Use of percentages to show importance
Acme Pizza (part 2) Slices 0 1 2 3 4 5 6 7
Frequency 1 33 65 8 12 0 0 1
% .3 13.09 25.79 3.17 4.76 0 0 .3
Acme Pizza (part 2)
# times ordered
• The completed Pareto Analysis results in the following graph: 70 60 50 40 30 20 10 0
21
1
2
43
34
75
56
Slices of Pizza
67
Acme Pizza (part 2) Critical Thinking • How does the Pareto Analysis differ from the Histogram? • How can this be a useful tool to the Acme boss?
The Basic Seven (B7) Tools of Quality Flowcharts • A graphical picture of a PROCESS
Process
Decision The process flow
Flowcharts Don’t Forget to: • Define symbols before beginning • Stay consistent • Check that process is accurate
Acme Pizza Example (Flowchart) Window (start)
Take Customer Order
no Lockup
Oven
Time to close?
no
yes Get Pizza
Put More in
yes
Money?
no
2 Pies Available?
yes Take to Customer
How can we use the flowchart to analyze improvement ideas from the Histogram? Window (start)
Take Customer Order
no Lockup
Oven
Time to close?
no
yes Get Pizza
Put More in
yes
Money?
no
2 Pies Available?
yes Take to Customer
Want some practice? Make a flowchart for: • • • • •
Taking a shower Cooking dinner Driving a car Having a party Creating a Flowchart
Any other processes you can think of?
The Basic Seven (B7) Tools of Quality Scatter Plots • 2 Dimensional X/Y plots • Used to show relationship between independent(x) and dependent(y) variables
Acme Pizza (Scatter Diagram) Minutes Cooking 10 45 30 75 60 20 25
Defective Pies 1 8 5 20 14 4 6
In this simple example, you can find the existing relationship without much difficulty but…
Scatter Diagrams Defective Pizzas
•Easier to see direct relationship
25 20 15 10 5 0 0
20
40
60
Time Cooking (minutes)
80
Scatter Diagrams As a quality tool • What does this tell Acme management about their processes? • Improvements? Defective Pizzas
25 20 15 10 5 0
0
20
40
60
Time Cooking (minutes)
80
The Basic Seven (B7) Tools of Quality Run charts
• Time-based (x-axis) • Cyclical • Look for patterns
Slices/hour
5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Run Charts
8 9 10 11 12 1 2 3 4
8 9 10 11 12 1 2 3 4 8 9 10 11 12 1 2 3 4
PM- AM
PM- AM
PM- AM
Thursday
Thursday
Thursday
Time
The Basic Seven (B7) Tools of Quality Control Charts
• Deviation from Mean
• Upper and Lower Spec’s • Range
Control Charts Upper Limit
X
Lower Limit
Unacceptable deviation
Control Charts Acme Pizza Management wants to get in on the control chart action •Average Diameter = 16 inches •Upper Limit = 17 inches •Lower Limit = 15 inches
Acme example Control Charts Upper Limit
17 inches
16 inches=
X
Lower Limit 15 Inches Small Pie
Acme example #50 Control Charts •Pies within specifications were acceptable •One abnormally small pie is “uncommon” •Should be examined for quality control
Summary • Basic Seven Tools of Quality • Measuring data • Quality Analysis • “Democratized statistics”
Bibliography •
Foster, Thomas. Managing Quality. An Integrative Approach. Upper Saddle River : Prentice Hall, 2001.
•
Stevenson, William. “Supercharging Your Pareto Analysis.” Quality Progress October 2000: 51-55.
•
“Dr Ka oru Is hik aw a.” In terne t “http://www.dti.gov.uk/mbp/bpgt/m9ja00001/m9j a0000110.html.” 16 February 2001.
•
“Chemical and Process Engineering.” Internet. “http://lorien.ncl.ac.uk/ming/spc/spc8.htm.” 17 February 2001.
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