A Course on

7 QC Tools

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COURSE OBJECTIVES

At the end of the seminar, participants will be able to..

Know the 7QC tools
Identify the tool to be used for gathered data
Define one’s role in achieving continuous
improvement

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COURSE CONTENT

1. INTRODUCTION
2. SEVEN QC TOOLS
3. APPLICATION
4. WORKSHOP

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 WHY FOCUS ON THE PROCESS?

What is the glue that ties all our task together?

What is the framework that we use to understand what task we
do now?
What allows us to tie together our inputs and outputs?

What allows us the thread to cross functional organizational

boundaries?
What gives us the structure to identify and eliminate most non-value
added tasks?
What makes it easy to measure our progress?

What allows us to focus on what is done versus who is doing it?

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WHEN DOES A PROCESS NEEDS TO BE IMPROVED ?

Chasing Around

Too many wastes

High rejection rates

Skills are difficult to learn Too many backlogs

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FIVE ACTIVITIES IN ANY KIND OF PROCESS

Operation

Transportation

Inspection

Temporary Storage or
Delay

Permanent Storage

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 VALUE ADDED ACTIVITY

Is an activity which we do in
our work that satisfies our
customer.

It is the activity that is paid by

the customer.

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 WAYS IN PROCESS IMPROVEMENT

1. Combine some of the activities.

2. Change the sequence of the activities.
3. Eliminate unnecessary activities.
4. Simplify the process.

Focus on WHAT needs to be done to

satisfy the customer.

In process improvement, the goal is to

eliminate any step that is not value added.

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2. 7 QC Tools

a) Checksheets
b) Pareto Diagram
c) Cause and Effect Diagram
d) Histogram
e) Scatter Diagram
f) Stratification
g) Graph

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I.CHECKSHEETS

A check sheet is a form used to

present collected data in an arranged
manner.
It is an easy to understand form used to
answer the question: “How often are
certain events happening ?”
TRANSLATE
OPINION FACTS

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Types of Checksheets
1. Recording Checksheets
A Check sheet where data entry are
coded in accordance with some
defined scheme.

DEFECTS MON TUES WED THURS FRI SAT TOTAL

OVERTRIM III IIII IIII-II III II I 21
UNDERTRIM I I IIII I IIII-I III 16

FIBERS II I II III II IIII 15

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2.Defect Location Checksheets

It is a drawing of the parts/ products

which needs to be checked for defects.
Mark is put on the drawing whenever a
defect is found. This way you can tell
what section of the part receives the
most.

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3. Checklist
- is a type of check sheet which is used in
situation when we have to monitor the
parameters or check the status of a certain
work area. Example:
Date Shift Time Temperature Check by
Sept 4,'05 A 7:00 AM 280 C Lyn
B 2:00 PM 279 C Abe
C 10:00 PM 281 C Ryan

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II. PARETO DIAGRAM

Is a special form of vertical bar graph, or column graph

where data classifications are arranged in descending
magnitude from left to right.
Shows the frequency of various categories of a problem
Accompanied by a cumulative percentage line, starting
from the most frequent until 100% is reached
Follows the “80-20” Rule
Require the collection of data using Check Sheets

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Important Points in Constructing a Pareto
Chart

The “80-20” Pareto Rule states that a few causes

are responsible for the most effect
Provides rank-ordered list of causes and their
relative contribution
A 50% reduction of the most common cause is
easier to accomplish than eliminating the least
common cause
Choosing the right category is critical

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Practical Usage of the Pareto Chart

 Display causes of problems in order of

importance

 Verify the root causes of problems after

cause-and-effect analysis

 Display “before” and “after” data for

process improvement projects

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Steps on How to Construct a Pareto Chart

1. Choose the problem to be studied.

2. Data collection:
Define each category
Subtotal the data
Rank in its descending order
Compute for its percentage
3. Make a Bar graph. Plot the most frequent category at
the left portion of the graph.
4. Draw the cumulative frequency. Use the percentages for
each successive category. (Note: The 100% point on the
right axis corresponds with the sum of all occurrences
on the left scale.)
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Sample

N = 94
• 100%
80 •
Number of Complaints

• 80%

Percentage
60
60%

40
40%

20
20%

0 0%
Delivery Quality Poor Document Others
Problems Related Service Related

Pareto Chart: XYZ Customer Complaints

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• Different Uses

1. To highlight major problems

25
20

# 15
COMPLAINTS 10
5
-
Poor Late Wrong Wrong Others
package Delivery Quantity Specs

CLASSIFICATION
BY COMPLAINTS

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2. To compare problems through the use of
different measuring scales

Customer Complaint
4 Thousands
25

20 3

15 $ 2
# LOSS
10
1
5

-
0
Wrong
Wrong
Specs
Spec

• The most frequent problems are not the most costly.

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3. Toaid in the root cause analysis
( Multi-level Pareto)

Cause
Effect
Cause of Injury
Types of Injury
25 20
20 15
15 10
# 10 # 5
5 -
- SOLDER STEAM DUST
EYE LEGS HAND SPLASH

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4.To evaluate before and after corrective
actions

• Before • After
20 20

15 15 EFFECTIVE

10 10

5
5
-
- EYE LEGS HAND
EYE LEGS HAND

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6. The tricks of Drawing Pareto

1.) Vertical Axis –results are variable

a. Quality – defect, claim , rework
b. cost – losses, cost of material,
expenditures
c. Safety – fire, accidents
d. Morale – attendance, absentees

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2. Horizontal axis- classification of causes or
results
A. Classification by cause
a. People - operator, section , etc.
b. Material - manufacturer, origin, type
c. Machine/ Equipment – by gage, by line
d. Methodology- method, condition
e. Time – by hour, by day, by week

B. Classification by Effect - by reject time, by

defect rate, by work content
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III.Cause and Effect Diagram
This is used to analyze the characteristic of
a process or a situation and the factors that
contribute to them. The diagram was
developed to represent the relationship by
all “ effects” and the possible “ causes”
influencing it.

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Diagram
Causes Effect

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Steps in Constructing Cause and Effect Diagram

1. Begin the process by agreeing on one statement

that describes the selected problem
2.Write the problem on the box on the right
3.Brainstorm to arrive the possible causes of the
problem. Write the main cause inside the smaller
boxes
4.Analyze well to arrive at the sub-causes of the
problem
5.Once diagram is completed, go to each cause/ sub
causes and decide if it is vital to the solution.
6.Propose solutions. Eliminate others

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HISTOGRAM

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IV.HISTOGRAM
It is also known as the frequency distribution
chart.It is a type of bar graph where data
exist in a range and is divided in intervals.
In its interval, the data occurrence is tallied
into a frequency chart and is drawn into a
graph form. A histogram reveals the
amount of variation that any process has on
it.

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HISTOGRAM

A chart that displays the frequency

distribution of one measure or
characteristic of data from a process.
Used to display the patterns of variation of
either discrete or continuous interval data.
The Control Charts are constructed, in
essence, from a series of Histogram.
 Since it provides information about a
process, they are used as a corollary tool
for process analysis.
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Points to Remember in
Constructing a Histogram
Provides an easy-to-understand means of
displaying the variability of data
Does not show change in data over time, but
represents a snapshot at a certain point in time;
use Run or Control Charts for trend analysis
Histogram shape often provides information that
is not evident from Control Charts
Visual interpretations of Histograms include the
spread (i.e., variability), skew and uniformity of
shape.

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Practical Usage of Histogram

Display and compare process variability with expected

variability
Verify whether process is normally distributed or
skewed
Determine whether two machines, processes, etc. are
producing with the same median, mean, and variability
Provide visual information that helps to interpret the
output of a process and to understand both common and
special causes of variation when used with Control
Charts

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Example of a Histogram
9.00 9
9.00 1

9.20 9
9.20 9
40
9.40 16
9.40 16
30
9.60 27
F 9.60 27
R
20 9.80 31
E 9.80 31
Q
10.00 23
10 10.00 23

10.20 12
10.20 12
-
9.00 9.20 9.40 9.60 9.80 10.00 10.20 10.40 10.60 10.80 10.40 2
10.40 2
THICKNESS
10.60 4
10.60 4

10.80 -
10.80 0

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Example
9.9 9.3 10.2 9.4 10.1 9.6 9.9 10.1 9.8

9.8 9.8 10.1 9.9 9.7 9.8 9.9 10.0 9.6

9.7 9.4 9.6 10.0 9.8 9.9 10.1 10.4 10.0

10.2 10.1 9.8 10.1 10.3 10.0 10.2 9.8 10.7

9.9 10.7 9.3 10.3 9.9 9.8 10.3 9.5 9.9

9.3 10.2 9.2 9.9 9.7 9.9 9.8 9.5 9.4

9.0 9.5 9.7 9.7 9.8 9.8 9.3 9.6 9.7

10.0 9.7 9.4 9.8 9.4 9.6 10.0 10.3 9.8

9.5 9.7 10.6 9.5 10.1 10.0 9.8 10.1 9.6

9.6 9.4 10.1 9.5 10.1 10.2 9.8 9.5 9.3

10.3 9.6 9.7 9.7 10.1 9.8 9.7 10.0 10.0

9.5 9.5 9.8 9.9 9.2 10.0 10.0 9.7 9.7

9.9 10.4 9.3 9.6 10.2 9.7 9.7 9.7 10.7

9.9 10.2 9.8 9.3 9.6 9.5 9.6 10.7

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Steps in Constructing the chart
1.Count the number of data ( n=125)
2.Determine R. ( R= largest- smallest no. ) =
10.7-9.0 = 1.7
3.Determine K ( No. of classes )

Number of Data Points Number of Classes (K)

Under 50 5~7
50 ~ 100 6 ~ 10
100 ~ 250 7 ~ 12
Over 250 10 ~ 20

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4. Determine H = R/K = 1.7/10 =.17
( rounded –off to 0.2 )
5. Determine the class boundary and
complete the chart.

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Distribution chart

CLASS # CLASS BOUNDARIES MID- POINT

9.00 ~ 9.19 9.1

TOTAL
1
9.20 ~ 9.39 9.3
2 1
9.40 ~ 9.59 9.5
9
3
9.60 ~ 9.79 9.7 16
4
9.80 ~ 9.99 9.9 27
5
10.00 ~ 10.19 31
10.1
6
23
7 10.20 ~ 10.39 10.3
12
8 10.40 ~ 10.59 10.5
2
9 10.60 ~ 10.79 10.7
4
10 10.80 ~ 10.99 10.9 0

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6. Construct the chart

40

30

F
R
20
E
Q

10

-
9.00 9.20 9.40 9.60 9.80 10.00 10.20 10.40 10.60 10.80
THICKNESS

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 35

30

25
Frequency

20

15

10

2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0

Check Out Time (Minutes)

Histogram: Video One Check-Out Time

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V.SCATTER DIAGRAM

It is used to study the possible

relationship between one variable
to another. It is used to test for
possible cause and effect
relationships.

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Constructing a Scatter Diagram
1. Collect the corresponding group of data
2. Draw the vertical and the horizontal axis of the
diagram
3. Determine which is the cause( factor) and the
effect (characteristics ).
Cause – X axis
Effect - Y axis
4. Plot the points. If you found repeated data,
encircle the data as many times as appropriate.

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PATTERNS AND MEANINGS

1. An increase in y depends
Y
POSITIVE on an increase in x. If x is controlled,
y will be naturally controlled.
X
Example :
* height vs. weight
* training vs. performance

Y
2. Possible 2. If x is increased, y will increase
positive somewhat, but y seems to have
correlation cause other than x.
X

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Y 3. No
3. There is "no" correlation
correlation
X

4. An increase in x will cause

a tendency for a decrease in
4. Possible y.
Y
negative Examples:
correlation * quality vs. customer
X complaints
* training vs. rejects

Y
5. Negative 5. An increase in x will cause a
correlation decrease in y. Therefore, as
X
with item 1 above, x may be
controlled instead of y.

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VI.STRATIFICATION

It the process of classifying information into

groups based on categories and
characteristics. Several other words
partially describes it.

•Splitting •Grouping

•Dividing •Categorizing

•Organizing •Pigeon Holing

•Sorting •Characterizing

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For Example:
1. Data on injuries in a certain plant may be
considered as rising or falling, but that
number is actually the summary of all
injuries. That is :
a. By types – cut, burns, etc
b. by location – eyes, hands, foot
c. by department – maintenance, production,
etc.

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Stratification breaks down single numbers into
meaningful categories or classification to
focus on corrective actions
40

30
# Per Month

20

10

-
J F M A M J

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VII. GRAPHS
What is a Graph ?
A graph is used to transmit the most useful
information as summarized form. While
utilizing the human being’s sensitive vision.
In other words, not only the numerical data
displayed on a paper, but are transformed
into graphs which are aimed to have great
impact on the following

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1. Understand the information more quickly
2. Acquire more information by interpreting
one data
3. Take necessary actions without
negligence

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How to prepare and use graphs

1. Bar Graph
This graph is used to compare the length
of a bar with a specific width, and then to
interpret the quantified number of the
intended unit. A bar graph has strong
merit as it is easy to prepare and interpret.
In preparing the Bar graph, the following is
recommended :

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Preparation:
1.Sequence of the disposition( for
comparison, from large to small, or from
small to large sequence is better)
2. Distance between bars is not so narrow
or wide( ½ of bars breadth is
recommended)
3. Baseline and scale are clearly shown
( Scale should start from the cross point and
scale should be rounded to the nearest
exact number)
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Baseline

The basic scale ( zero) should be indicated

clearly. If this is not possible, in this example,
this would prevent the wrong impressions
caused by illusions

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2. Broken Line Graph
The Broken line graph is usually used to
present the trend values which are time-
bound. Preparation concept for the base
line and graduation lines are the same
as the Bar Graph.

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Guidelines in Preparation
1. The ordinate (Y) represents the varying value
while the abscissa (x) for time-scale ( year, day,
hour )
2. Both scales should be equally positioned
3. When explaining more than 2 varying
characteristics
a. The ordinate scale must be specific for the
interpretation of the benefits
b. If the lines are crossed, the interpretation he
interpretation generally confused. However,
these lines are needed in doing the graph.

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Examples

2,000

P
R
O
1,500 D
U
C
T
I
1,000 O
N
Q
U
A
L
500 I
T
Y
(
T
- o
n
JUL AUG SEP OCT NOV DEC
)

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Process stability is seldom a natural state. It is an
achievement, the result of eliminating special causes
one by one on statistical, leaving only the random
variation of a stable process.
W. Edwards Deming

Improvement of the process can be pushed effectively,

once statistical control is achieved and maintained.
Joseph M. Juran

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