What is an error

Errors are inadvertent, unintentional, accidental mistakes

made by people because of human sensitivity designed into our products and process Errors result in those Once in a while defects that we always find difficult to control Examples
Running out of Petrol Locking keys in your card Forgetting to stop Forgetting to turn the gas knob off Forgetting to unplug iron box

Error Examples
Missing Parts
Forgetting to assemble a part, screws, labels etc Misassembled Parts Incorrect Processing Using a mixed up rejected part Incorrect parts

Why are we bothered?

Cost us Money
Cost us Time Cause us danger/possible injury Could cost a human life If errors are so easily committed! How do we give our

customers 100% correct part or service? When this thought cameit was the beginning of Error Proofing or Poke Yoke

Poka Yoke
You cannot put a floppy in the wrong direction in to

the computer A pen drive cannot be connected wrongly Some filing cabinets, one drawer locks all the rest Or one open will not allow locking An overflow hole near the top of the sink helps to prevent overflow Poka Yoke is a concept of preventing people from doing mistakes in work

Poka Yoke
How do we achieve Poka Yoke?
First and foremost task is to educated workforce on

the concept Management should empower employees to make a bunch of small improvements to their processes continuously

KANBAN
Kan Visual
Ban - Card or a board Japanese word Visual Board signal board or bill

board It is system of notification from one process to the other in a manufacturing system It is a pull system of manufacturing as against conventional push system

KANBAN
When a customer places an order
A work order is sent to the assembly line This in turn orders parts from the process line The process line orders the material needed for

procurement Like this the system continues Whenever there is a need, then only all manufacturing activity is resorted to

Table of Contents
Quality techniques
7 Basic Quality techniques

Histograms Pareto Charts Run Charts Scatter Diagrams Control Charts Flow Charts Cause and Effect Diagrams

New techniques

Other Tools

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Introduction
In the following we will Examine the Techniques and

Tools that Support Quality Management within a company. There are for the 7 Basic Tools which we are going to define. Generally they can be subdivided into:

mathematical statistical Tools logical tools

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Histograms
What is it?

LSL

USL

A Histogram is a bar graph usually used to present frequency data Define Categories for Data Collect Data, sort them into the categories Count the Data for each category Draw the Diagram. each category finds its place on the x-Axis. The bars will be as high as the value for the category Histograms provide an easy way to evaluate the distribution of Data over different categories

How does it Work?

What is its use?

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Histograms
Example: take the failure rate of a machine over a period of x weeks. Now Assign every week the number of failures that occurred. Draw the Histogram. Let the bar represent the weeks. The height of the Bar on the y-axis is the number of failures that occurred during that week.
LSL

USL

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Pareto Charts
What is it?

A Pareto Chart is a Histogram + a cumulative line

Type

How does it Work?

Similar like a Histogram First define categories, collect Data and sort them into the Categories. Count the occurrences for each category. Now rank the categories starting with highest value. Draw cumulative points above all the bars and connect them into a line. Pareto Charts are used to apply the 80/20 rule of Joseph Juran which states
that 80% of the problems are the result of 20% of the problems. A Pareto Chart can be used to identify that 20% route causes of problem.

What is its use?

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Pareto Charts
Example:

A certain machine has different kinds of failures that occur. The Maintenance department identifies these types of failures and counts their occurrence over a period of 3 month. The Data is then added up. The Failures are ranked by their occurrence values starting with the most frequently occurring failure. A histogram is drawn with bars representing the types of failures. Furthermore are cumulative values assigned to the failure types and drawn into the diagram. Now determine the point were the cumulative line crosses the 80% mark. Concentrate of the failure types that lie left of this mark.

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Pareto Charts
100% Percentages of defects found

50%

Types of defects
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What is it?

Measurement

Run Charts
Run Charts are representing change in measurement over a sequence or time

Time

How does it Work?

Gather Data Organize Data Measurements (y) must be confronted with time or sequence of the events. Chart Data Interpreting Data Determining Cyclic Events and there average character

What is its use?

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Run Charts
Example

Oil consumption of a specific machine over a period of time.

Measurement

Time
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Scatter Diagrams
What is it?

Statistical tool showing a trend in a series of values.

Y

How does it Work?

Gain values series Draw graph with value points Draw trend line: m*x+a Calculate m value Calculate a value Calculate points for trend line.

What is its use?

Demonstrating correlations between values and showing trends for value changes.
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Scatter Diagrams
Y

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Control Charts
What is it?
Statistical tool, showing whether A process is in control or not

Upper limit Average/Spec Lower limit

How does it Work?

Define Upper limit, lower limit and medium value
Draw Chart. Gather values and draw them into chart

What is its use?

Taking samples of a process and detect possibility of process being out of control

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Control Charts
Y Upper limit Average/Spec

Lower limit

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Flow Charts
What is it?
Input Process

Within Spec?

Yes

Output

Way of representing a Procedure using simple symbols and arrows adjust A Flowcharts shows the activities in a process and the relationships between

No

them. Operations and Decisions can be represented

How does it Work?

Determine what Process or Procedure you want to represent. Start at a certain point and go then step by step using circles or rectangles for operations or other elements, diamonds for decisions, arrows show the flow and the direction. Document the elements with titles. Let it close with an ending point. A Flow chart lets a process or procedure be understood easily it also demonstrate the relationships between the elements.

What is its use?

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Flow Charts
Example:

start Repair machine Check machine OK?
Yes

You intend to repair a certain machine. First you perform the repair thought to be necessary No Then You check it If it does not work you continue with repairs If it works you finish

end

Input

Process

Within Spec?

Yes

Output

No

adjust
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ISHIKAWA DIAGRAM
Cause & Effect diagram or

Fishbone diagram
Used for analysis of industrial process He was a Japanese University Professor He pioneered quality management processes in the

Kawasaki shipyards

Cause and Effect Diagrams

What is it?

Cause a Cause b

Its a diagram that demonstrates effect the relationship between Effects and the categories of their causes The Arrangement of the Diagram lets it look like a fishbone it is therefore also called fish-bone diagram
Cause c Cause d

How does it Work?

Determine the Effect or Problem you would like to examine Categorize the possible causes find subcategories Describe the possible causes

What is its use?

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Cause and Effect Diagrams

Machine Man

effect

Milieu

Measurement

Method

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Ishikawa Diagram Example

Problem
Too many defects

Ishikawa Diagram Example

Method Manpower Main Cause Too many defects

Material

Machinery
Main Cause

Ishikawa Diagram Example

Method Manpower Drill Overtime Too many defects Wood Steel Material Lathe

Machinery
Sub-Cause

Ishikawa Diagram Example

Method Manpower Drill Slow Tired Overtime Too many defects

Wood Steel Material

Old
Lathe

Machinery