Quality Tools

• Process Flow Chart • Histogram

• Cause-and-Effect • Scatter Diagram
Diagram • Statistical Process
• Check Sheet Control Chart
• Pareto Analysis
 Flow Chart

• A diagram of the steps in a process

• Helps focus on location of problem in a process
 The Basic Seven (B7) Tools of Quality

Fishbone Diagrams

• No statistics involved

• Maps out a process/problem

• Makes improvement easier

• Looks like a “Fish Skeleton”

 Cause-and-Effect Diagram
• Cause-and-effect diagram (“fishbone” diagram)
– chart showing different categories of problem
causes
 Check Sheets and Histograms

• Tally number of defects

from a list of causes

• Frequency diagram of
data for quality problem
Pareto Analysis
What it is
Pareto Analysis is used to record and analyse data relating to a problem in such a way as to
highlight the most significant areas, inputs or issues. Pareto Analysis often reveals that a small
number of failures are responsible for the bulk of quality costs, a phenomenon called the ‘Pareto
Principle.’

This pattern is also called the ‘80/20 rule’ and shows itself in many ways. For example:

• 80% of sales are generated by 20% of customers.

• 80% of Quality costs are caused by 20% of the problems.
A Pareto diagram allows data to be displayed as a bar chart and enables the main contributors
to a problem to be highlighted.
Purpose:
Prioritize problems. Pareto Charts
How is it done?
• Create a preliminary list of
problem classifications.
• Tally the occurrences in
each problem classification.
• Use of the 80/20 rule
•
• Arrange each classification
in order from highest to
lowest
• Construct the bar chart
 Pareto Analysis

• Pareto analysis
– most quality problems result from a few causes
 Pareto Chart

. 2-9
 Pareto Chart
Pareto of D3 Small Engine Card Faults

600 100

500 80

400

Percent
60
Count

300
40
200
20
100 .
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Cm Co CW DeJo Th SoF Co Oth
Defect
Count 141 139 69 52 22 20 20 17 17 17 16 13 10 10 10 8 6 5 29
Percent 23 22 11 8 4 3 3 3 3 3 3 2 2 2 2 1 1 1 5
Cum % 23 45 56 65 68 71 75 77 80 83 85 87 89 91 92 94 95 95 100
 Scatter Diagram

• Graph showing relationship between 2 variables

in a process
• Identifies pattern that may cause a quality
problem
 Control Chart
• A chart with statistical upper and lower limits
• If sample statistics remain between these limits we
assume the process is in control
 Process Control Chart
Out of control
Upper
control
limit

Process
average

Lower
control
limit

1 2 3 4 5 6 7 8 9 10
Sample number

Copyright 2011 John Wiley & Sons,

Inc.
 Control Charts
• A graph that monitors process quality
• Control limits
• upper and lower bands of a control chart
• Attributes chart
• p-chart
• c-chart
• Variables chart
• mean (x bar – chart)
• range (R-chart)
 A Process Is in Control
If …

1. … no sample points outside limits

2. … most points near process average
3. … about equal number of points above
and below centerline
4. … points appear randomly distributed