Tools for Continuous Quality Improvement

For solving the problems and involves data collection, analysis, hypothesis and validation Called as 7 QC tools
Check sheets Histogram Flow chart Pareto chart Cause and effect diagram Control chart Scatter diagram

7 QC Tools contd.
Check sheets A systematic record
keeping or data collection Observations are recorded as they happen and reveals pattern or trends

7 QC Tools Contd..
Histograms
Displays large amount of data that are difficult to interpret in raw form Provides summary of data and also reveals whether the process is centered, the degree of variation etc. Used to identify process capability relative to customer requirements
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7 QC Tools Contd..
Flow charts
Shows the sequence of events Mostly used in manufacturing and service operations to describe working procedures Valuable process information can be obtained in addition to identifying problematic areas

7 QC Tools contd.
Pareto Diagram helps to prioritize the
problem by arranging them in decreasing order of importance helps management quickly identify the critical areas (those causing most of the problems) that deserve immediate attention. It supports 80/20 rule.
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7 QC Tools Contd.. Cause and Effect diagram

Called as Ishikawa diagram or fish bone diagram Explores possible causes of problem due to men, machine, material and method To identify root cause, each cause may be further broken down

7 QC Tools contd.

7 QC Tools Contd..
Control charts
Distinguishes special (assignable) causes of variation from common causes Used to monitor and control a process on a ongoing basis Plots a selected quality characteristic, found from subgroups of observations, as a function of sample number Central line on the control chart is the average value of the characteristic Two limits, UCL and LCL are used to detect whether the process goes out of control
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7 QC Tools contd.

7 QC Tools Contd..
Scatter Plots
Shows the relationship between two variables Used as a follow up to cause and effect analysis to find whether a stated cause has impact on quality
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What are the

New Seven Q.C. Tools

1. Affinity Diagrams
2. Relations Diagrams

3. Tree Diagrams
4. Matrix Diagrams

5. Matrix Data Analysis 6. Arrow Diagrams 7. Process Decision Program Charts

New Seven Q.C. Tools

1. Affinity Diagrams

For Pinpointing the Problem in a Chaotic Situation and Generating Solution Strategies

Gathers large amounts of verbal data (ideas,

opinions, issues)

Organizes the data into groups based on natural relationship Makes it feasible for further analysis and to find a solution to the problem.

New Seven Q.C. Tools

Affinity Diagrams

Constructing an Affinity Diagram

Group Method Approach

1. Select a topic 2. Collect verbal data by brainstorming 3. Discuss info collected until everyone understands it thoroughly 4. Write each item on separate data card 5. Spread out all cards on table

New Seven Q.C. Tools

Affinity Diagrams

Constructing an Affinity Diagram

Group Method Approach (cont.)

6. Move data cards into groups of similar themes

(natural affinity for each other)

7. Combine statements on data cards to new Affinity statement 8. Make new card with Affinity statement 9. Continue to combine until less than 5 groups

New Seven Q.C. Tools

Affinity Diagrams

Constructing an Affinity Diagram

Group Method Approach (cont.)

10. Lay the groups outs, keeping the affinity clusters together Next, complete the diagram

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New Seven Q.C. Tools

2. Relations Diagrams

For Finding Solutions Strategies by Clarifying Relationships with Complex Interrelated Causes

Resolves tangled Allows

issues by unraveling the logical connection for Multi-directional thinking rather than as Interrelationship diagrams

linear
Also known

New Seven Q.C. Tools

Relations Diagrams

Constructing a Relations Diagram

Group Method Approach

1. Express the problem in form of Why isnt something happening? 2. Each member lists 5 causes affecting problem

3. Write each item on a card 4. Discuss info collected until everyone understands it thoroughly

New Seven Q.C. Tools

Relations Diagrams

Constructing a Relations Diagram

Group Method Approach (cont.)

5. Move cards into similar groups 6. Asking why, explore the cause-effect relationships, and divide the cards into primary, secondary and tertiary causes 7. Connect all cards by these relationships 8. Further discuss until all possible causes have been identified

New Seven Q.C. Tools

Relations Diagrams

Constructing a Relations Diagram

Group Method Approach (cont.)

9. Review whole diagram looking for relationships among causes 10. Connect all related groups

Next, complete the diagram

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New Seven Q.C. Tools

3. Tree Diagrams

For Systematically Pursuing the Best Strategies for Attaining an Objective

Develops a succession of strategies for achieving objectives Reveals methods to achieve the results.

Also known as Systematic diagrams or hierarchy diagram

Completing a Tree Diagram

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New Seven Q.C. Tools

4. Matrix Diagrams

For Clarifying Problems by Thinking Multidimensionally

The matrix

diagram shows the relationship between two, three or four groups of information. It also can give information about the relationship, such as its strength, the roles played by various individuals or measurements. Six differently shaped matrices are possible: L, T, Y, X, C and roof-shaped, depending on how many groups must be compared.

L-Shaped Matrix Diagram

This L-shaped matrix summarizes customers requirements.

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T-Shaped Matrix Diagram

This T-shaped matrix relates product models (group A) to their manufacturing locations (group B) and to their customers (group C).

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New Seven Q.C. Tools

5. Matrix Data Analysis

A complex mathematical technique for analyzing matrices.
Can

be used in various fields (market surveys, new be used when Matrix diagram does not give Prioritization Grid
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product planning, process analysis)

Can

sufficient information
Useful as

New Seven Q.C. Tools

6. Arrow Diagrams

For Working Out Optimal Schedules and Controlling Them Effectively

The arrow diagram shows the required order of tasks in a project or process, the best schedule for the entire project, and resource problems and their solutions. Network technique using nodes for events and arrows for activities Used in PERT (Program Evaluation and Review Technique) and CPM (Critical Path Method)

Completing an Arrow Diagram

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New Seven Q.C. Tools

7. Process Decisions Program Charts

For Producing the Desired Result from Many Possible Outcomes The process decision program chart systematically identifies what might go wrong in a plan under development.

Countermeasures are developed to prevent or offset those problems.

By using PDPC, you can either revise the plan to avoid the problems or be ready with the best response when a problem occurs.

PDPC Example
A medical group is planning to improve the care of patients with chronic illnesses such as diabetes and asthma through a new chronic illness management program (CIMP). They have defined four main elements and, for each of these elements, key components. The information is laid out in the process decision program chart below. Dotted lines represent sections of the chart that have been omitted. Only some of the potential problems and countermeasures identified by the planning team are shown on this chart. 31

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