PDCA CYCLE

7 Basic Tools
Flow Chart Check Sheet Histogram Pareto Chart Scatter Diagram Cause & Effect Diagram Run Chart/Statistical Process Control

Flow Charts are used to...

document a process improve understanding reveal differences in methods uncover non-value added activities

Flow Chart Example: Self-Serve Gas Before Improvement

Drive in check price self serve? to pump yes no shut off engine walk to pay station

check card transmit

approved? yes no

turn on pump

back to car

pump gas

walk to booth

wait

copy to file employee totals charges check accuracy prepare receipt sign copy

return to car
on the road again

copy to wallet

Flow Chart Example: Self-Serve Gas After Improvement

Drive in check price self-serve? yes no go to pump shut off engine insert card in pump store in system on the road again copy to wallet

approved?
yes check credit card wait no

wait for receipt

pump gas

CHECK SHEETS
Data collection & analysis

Contents mixed Poor taste Low temperature Utensils dirty Price issue Other

Histograms
Graphical descriptive statistics (mean and standard deviation)
Uniform

Bell-Shaped Bimodal

Pareto Charts
Similar to a histogram, used to find most popular category Based upon the Pareto principle...

Basic Pareto Diagram

6 5

Slow down

More examples Level too high Too much work

Remember prerequisites

Sequence Wrong

Complaints courtesy of my Spring OPC class

Alternate Pareto Diagram

6 5 4 3 2 1 0
100%
90% 80% 70% 60% 50% 40% 30%

20%
10%
Slow down More examples Level too high Too much Remember Sequence work prerequisites Wrong

0%

Count

Cumulative %

Complaints courtesy of my Spring OPC class

Scatter Diagram
Graphical descriptive statistics (correlation)
Exam Score

Class 1 Class 2 Homework Problems

Cause & Effect Diagrams

Also known as fishbone diagrams or Ishikawa diagrams, after their creator Kaoru Ishikawa In general, used to find and cure causes (NOT symptoms) of problems

Cause & Effect Example

METHODS MANPOWER Drivers lost Poor dispatching Chef late

Large order snafus Bad cars

Small ovens

Lack of ingredients

LATE PIZZA DELIVERY FRIDAY & SATURDAY

MACHINES

MATERIALS

Run Chart
Graphical descriptive statistics (trend)
Defectives/Sample
10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10

Statistical Process Control

Finds special variation Average 3 Variation * General form of limits Center line = Average
Control Chart
0.12 0.1 0.08 0.06 0.04 0.02 0 1 2 3 4 5 6 7 8 9 10

p pbar UCLp LCLp

* Not the variance