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1 +, 1 +
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! $ ' +-
Satyanarayan Gangaram Pitroda
! > 0 B
BharthariNtiatakam
IS 14978:2002
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Indian Standard
NEW SEVEN TOOLS FOR QUALITY MANAGEMENT
lCS 03.120.30
(3 BIS 2002
BUREAU
MANAK
April 2002
..
OF
BHAVAN,
INDIAN
STANDARDS
9 BAHADUR
SHAH
NEW DELHI 110002
ZAFAR
MARG
Price Group 7
FOREWORD
This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by the Statistical
Methods for Quality and Reliability Sectional Committee had been approved by the Management and Systems
Division Council.
In this era of globalization, the organizations are aiming for continuous quality improvement, for which they
need tools and techniques. The basic seven tools, namely, Check-sheet, Histogram, Scatter diagram, Stratification,
Pareto diagram, Cause-and-Effect diagram, and Control charts are useful for quality control. In addition the
following new seven tools are also very useful for quality improvement:
a)
b)
c)
d)
e)
f)
g)
Affinity Diagram,
Tree Diagram,
Arrow Diagram,
Process Decision Programme Chart,
Matrix Diagram,
Relations Diagram, and
Matrix Data Analysis.
These new tools are essentially systems and documentation methods, interrelated, used to achieve success in
design by identifying customers needs and translating them to technical requirements in the intermediate steps
in the finest detail as also for solving quality-related problems. Therefore, these tools are also used by the
Quality Function Deployment (QFD) team in any organization to achieve better design in less time. Quality
Function Deployment (QFD) refers to a system for designing a product or service by translating the customers
needs into appropriate technical requirements at each stage with the participation of members of all functions
of the supplier organization.
It may be mentioned that these new seven tools are complimentary to old seven tools and therefore do not
replace them.
The relations ip among these new seven tools has been shown in 4.
The Composition of the Committee responsible for the formulation of this standard is given in Annex A.
t+<
-
Is 14978:2002
Indian Standard
NEW SEVEN TOOLS FOR QUALITY MANAGEMENT
1 SCOPE
Procedure
3.1.3
a)
b)
a)
b)
c)
d)
e)
Affinity Diagram,
Tree Diagram,
Arrow Diagram,
Process Decision Program me Chart,
Matrix Diagram,
o Relations Diagram, and
@ Matrix Data AnaIysis.
c)
d)
2 REFERENCE
The following standard contains provision, which
through reference in this text constitutes provision of
this standard. At the time of publication, the edition
indicated was valid. All standards are subject to
revision and parties to agreements based on this
standard are encouraged to investigate the possibility
of applying the most recent edition of the standard
given below:
1S No.
12801:1989
o
!4)
3.1.4 Examples
3.1.4.1 Affinity diagram for Requirements for a
Telephone Answering Machine is shown in Fig. 1
and Table 1.
TitIe
Pareto diagram and cause and effect
diagram
3.2.1 Application
3.1.1 Application
3.2.2 Description
A tree diagram systematically breaks down a topic
into its component elements. Ideas generated by
brainstorming and graphed or clustered with an
affinity diagram can be converted into a tree diagram
to show logical and sequential links. This tool can be
used in planning and problem solving.
3.1.2 Description
When a large number of ideas, opinions or other
concerns about a particular topic are being collece d,
this tool organizes the information into groupin~~
based on the natural relationships that exist among
them. The process is designed to stimulate creativity
and full participation, It works best in groups of limited
size (a maximum of eight members is recommended)
in which members are accustomed to working together.
This tool is often used to organize ideas generated by
brainstorming.
3.2.3 Procedure
a)
b)
IS 14978:2002
Qtsiclcreference carcl
bEi@z
I
~
Clear
instructions
I
I
Secret access code
~
II
By Grouping
As Per
3.1.3
Incoming messages
3.3.1 Application
------j
Clear instructions
Quick reference card
Instructions
Easy to erase
Erase selected messages
3.3.2 Description
Construct the diagram by placing the topic
in a box on the left-hand side;
Branch the major categories laterally to the
right;
For each major category, define the component elements and sub-elements, if any;
Laterally branch to the right the component
elements and sub-elements for each major
category; and
Review the diagram to ensure that there are
no gaps in either sequence or logic.
3.2.4 Example
The Tree diagram for Telep?tone Answering Machine
2
EzEcl
Identify training needs
of
.
Organization
Supplier
Customer
Identifi customer
Management
Commitment
Controls
Define processes
Determine process
capability
Identi& faculty
J
Make project by
project improvement
Create a steering
committee with real
authority
measurement
I Establish
system
Interpret customer
requirements correctly
Grant access to
information
I
Establish consistent
reward system
Update profile of
trainees
Implement corrective
action
,., ..,..
..>.
&.
Z.,
I>
1S 14978:2002
(Topic)
(Major Categories)
(Sub-elements)
(Component Elements)
Variable length
message
Incoming message
Memory counters
Indicates number of
messages
=
Clear instructions
Instructions
I
FIG.
messages
3 TREE DIAGRAMFORTELEPHONEANSWERINGMACHINE
-.
Award certificate
--l
Management support
-1
Awareness of impofiance
--i
Poor attendance
1-1
1-
Priority
Individual appreciation
-4
t
I
Advertisement
1
Separate newspaper for training
function
-i
,.
FIG. 4 TREE DIAGRAMFORPOORATTENDANCEAT QUALITYCIRCLEMEETING
....
.
,
IS 14978:2002
F:::::::Anelementthat
W+@
~
~
I
mim
o
2
Node number
W@
A2
@-@
t+
1B4
Parallel job
C3
Job type
a
A
B4
c.
?7
2
A
I
Job card
~lco
..-
3.3.3 Procedure
a)
b)
c)
d)
e)
List the necessary jobs for project completion and then write them on the paper.
Prepare job card by writing the type of the
work.
Arrange the job cards on a large piece of paper according to whether they are preceding,
succeeding or parallel jobs.
Remove all job cards for unnecessary jobs and
add the job cards of necessary jobs that have
been omitted.
Determine the location of the cards as per
following criteria:
find the pr~cess where the maximum job
cards can be placed in series. Position
the job cards that have a preceding
succeeding relationship along this process with an interval enough for a node
to be placed between them.
3.3.4 Example
Arrow diagram for Quality assurance during
production preparation stage is shown in Fig. 6.
3.4 Process, Decision Program Chart (PDPC)
3.4.1 Application
G
.:
u
W!5
--)+...(-)+..(-)
3:
Zk
...............------.................................................................................
23
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k
3
.%
3
A.n.n-
.. .-
IS 14978:2002
3.4.3 Procedure
3.4.2 Description
3.4.2.1 The process decision program chart (PDPC)
method is used to define the solution process when
dealing with problems that have more than one
possible outcome. [t anticipates the unexpected
outcomes at each stage and plans for it.
3.4.2.2 PDPC has two following patterns:
Pattern I In this pattern process starts with initial
condition A and proceeds to the desired final
condition Z in an organized manner (see Fig. 7).
Pattern 11- In this pattern, first the final condition
Z is set. Then the process from Z to the initial
point A is developed with the inclusion of various
alternatives from many points of view (see Fig. 7).
-/7
B2
B,
Pattern
Bq
I
Preferable
Condition
Beginning
Condition
Pattern
- II
When Z is an undesired condition, we must find a solution that cuts the chain Z + Al -+ A
FIG.
$!_
IS 14978:2002
h)
j)
k)
3.4.4 Examples
3.4.4.1 Process decision program chart for decrease
main drive kW variability by Pattern 1 is shown in
Fig. 8.
b)
c)
e)
A
Likely Relationship
Complete the matrix
Homogenizer variability
Main feeder
Pressure balance
Motor problem
Decrease NJ flow
FIG.
:;
j
3.5.4 Example
3.5.2 Description
Gear box
,:*
8 PROCESSDECISIONPROGRAMMECHART
9
.-
...
E
Establish production techniques for extrusion models
,,
+A
o
0
&
I
I
+~~
4.
v
Improve C type
mold
Appearance is OK
Solution
FIG.
.
I
al
a2
a3
ij--
b2
b3
b4#
....................
IS 14978:2002
c ;3
C2
c1
...........
bl
b2
b3
B:
.
T-Type Matrix
L-Type Matrix
FIG.
3.6.1 Application
3.6.4 Procedure
3.6.2 Description
3.6.3 Format
A special feature of relation diagram is its unrestricted
format. However general formats are as given below.
3.6.3.1 Centrally converging relations diagram
The mnjor item or problem to be solved is located in
the center, and the related factors are arranged around
the item or problem in such a way as to indicate close
relationships.
3.6.3.2 Directionally intensive relations diagram
The major item or problem to be solved is located on
one side of the diagram, and the various factors
arranged in accordance with the flow of their major
cause-and-effect relationships on the other side.
11
$%
Is 14978:2002
Table 2 Matrix Diagram for Quality Functions
and Responsibilities
(Clause 3.5.4)
Disciplines Involved
Quality Function
,-5
8
[1)
(2)
w
.:
(4)
(6)
(8)
35!?==
(9)
0
0
(13)
(14)
4.
Preparation of inspection
plan
5.
Selection of instruments
6.
7.
Reeeive inspection
8.
9.
0
A
0
0
3=
12.
In-process eorrtrol
13.
14.
15.
@0
-@_
o
A
.
17.
Maintenance
-6-
--z-
0
0
T-
Q_
0
0
0
0
0
0
@
0
J%_
IS 14978:2002
Lack of clear job expectations
by subcontractors
.,
-/
in management
Lack of knowledge of matching
people to job requirements
+
Lack of information on job
+
Wrong person sent
+
Ezzpzz3
Unreasonable customer
*
Unclear customer expectations
Advertising promises
No, buy-in
from boss
Resource priorities
We only work on crises
4
Resource
Boss does not
understand the issue
constraints
,Oobusydoing
paper-work
FIG.
12 RELATIONSDIAGRAMFORRESOURCEPRIORITIES
c)
3.7.4 Example
Matrix data analysis for product uses and their desired
qualities is shown in Table 3.
3.7.3 Procedure
a)
b)
4 INTER-RELATIONSHIP
AMONG
NEW
SEVEN TOOLS
The inter-relationship
among seven new tools
described in 3.1 to 3.7 is shown in Fig. 13.
13
. &
IS 14978:2002
Table 3 Matrix Data Analysis
(Clause 3.7,4)
Product uses and Desired Qualities
S1No.
Washable
Products
1.
+
Mens summer suits
xl 1
X12
2.
x 2.1
3.
X31
Resists
Perspiration
.-
Flame
Retardanl
23
X13
=-t=-
X22
X23
--t--=-
X32
x] 3
Non-
Chemical
Resistant
irritating
to Skin
24
-=t--=-
25
x,24
x, ?5
I
4.
X41
X4.2
5.
Skirts
X51
X5.2
6.
Trousers
X61
X62
7.
Overcoats
X71
8.
Raincoats
X81
9.
OffIce wear
X91
X92
x I(1I
X,(,2
10.
11.
12.
Work clothes
1
I Sportswear
I
I Student wear
X111
13.
X111
X112
I
X,2,
X131
X132
x723
x724
X723
23
X924
-+-l-+
X,223
X15.24
x1525
Dress shkts
X151
X15.2
X151
=-t==-
..
x 401
..
Material A
b 24
F===+-+
x23
eationdiagram
Logical
Creative
Tree diagram
+
Matrix diagram
data analysis
PDPC
Arrow diagram
FIG. 13 INTER-RELATIONSHIP
AMONGNEW SEVEN TOOLS
14
xw 25
x]
X2
..
=-l--=
-=-4==
-+-t-=-
=-t--=-
I_=_
Matrix
x12,25
XIJ ?.5
-=-t-==
X1224
X1424
X143
1:
II X11.25
x13.25
X142
X10.25
X1324
X141
1.
xl 1.24
II
XC)
25
-=--t==
Baby wear
1.
x 10.24
X173
40
%25
..
X123
X122
15.
Xc,24
Home wear
14.
X62,
X103
-=t-=s193
X425
=-t=-
X63
X53
I
I
X42,
X43
X24
x25
.+
IS 14978:2002
ANNEX A
(Foreword)
COMMITTEE
COMPOSITION
Organization
PROPS. P. MurwzrasE(Chmrtnan)
SHRSB.
N.JW
StatR.S. BHAROAVA
(Alrernae)
SsrruA.K. SRNASTAVA
SriruS.N.JHA
StrarG. V. SOBRAMANMN
(Alternate)
StrarNAWN
KAFVR
SHSU
S.K. SSUVASTAVA
Da AS.HOKKuma
EscortsLimited, Faridabad
SHRtC.S. V.N~KA
(Alternate)
SkrruA.V. KSUSHNAN
LT-COL P. VLIAYAN(Alternate)
Ms N. V.NWK
DRS. D. SHARMA
(Alternate)
DRA.K. SRtVASTAVA
DRB. DAS
DRDSBABRATA
RAY(Alternate)
Indkminstitute of Management,Lucknow
PROFS. C. &.MOWKJRTV
%0 U. hA
PROFS. R. MOWAN
PROFARVrNO
SsrH (Alternate)
Lucas-TVSLimited, Chennai
SmuN. S. SRSENNASAN
SHRIG. VUAYA KUMAR(A(terrrate)
SwruY. K.BHAT
SHRIG. W. DATEY(Alternate)
0s S. K. AGARWAL
SRF Limited,Chennai
A.SANSEEVA
RAO
SHSU
Srau*M
SUBWNIAN (Alfernate)
%su .%K.KIMOTM
SHRIS. N. DAS
SmuSHAWtT
SARUP
(Alternate)
Universityofllclhi, Delhi
PROF.M. C. AGRAWAL
DRS. N. PAL(Alternate)
SmuSURESH
KW
(Alternate)
SHRIP.N. SRUL4wrrr
(Alternate)
PROFA. N. NANKANA
Smu D. R. %N
BIS DirectorateGeneral
SW P. K. GAMBHSR,
Directorand Head (MSD)
and Member-Secretary
[RepresentingDirectorGeneral LEx-oflcio)]
15
IS 14978:2002
(Confirmedjirarn page I 5)
O?garization
Calcutta University, Kolkata
WauA,K. SWASTAVA
DR ASHOKKw.m
DRB. DAS
PROFS. R. MOHAN
SW Y. K. BHAT
SmuG. W. DATEY(Afernare)
DRA. LAHUU
(Aherrrate)
DRS. K.AGARWAL
SsmrS. K. KlhlOTM
hOF M. C. Amwm
PROFA. N. NANKANA
Smu D. R. Sm
SmuA.K. SRIVASTAVA
SrnuY. K. BHAT
Sr-awS. K. ~01111
SmusHANrt
SAROP
In
W-auD. R. Sm
16
..=
BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of goods
and attending to connected matters in the country.
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implementing the standard, of necessary details, such as symbols and sizes, type or grade designations.
Enquiries relating to copyright be addressed to the Director (Publications), BIS.
Review of Indian Standards
Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of
BIS Catalogue and Standards: Monthly Additions.
This Indian Standard has been developed from Doc : No. MSD 3 (123)
Amendments
Amend No.
Date of Issue
Text Affected
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