to the

7QC TOOLS TRAINING & WORKSHOP

TAIYO PLASTIC CORP. OF THE PHILS

Objectives of the workshop

To develop people in solving work

related problems
To raise the level of quality and productivity To learn the basic tools in problem solving

TAIYO PLASTIC CORP. OF THE PHILS

Benefits of Team Members

Enhance leadership and teamwork among member. Improve working environment.

Develop their capabilities in identifying and solving problems.

Develop the members self-confidence.

TAIYO PLASTIC CORP. OF THE PHILS

Benefits for the Company

Improve the quality standards and quality consciousness of the team members. Lower the cost through the reduction of waste, losses and defects.

Improve level of awareness of team members in solving problem. Improve workers efficiency.

TAIYO PLASTIC CORP. OF THE PHILS

7 QC TOOLS BACKGROUND
In the 1950s the Japanese began to learn and apply the statistical quality control tools and thinking that WALTER SHEWHART and WILLIAM EDWARD DEMING developed in the 1930s and 1940s. Their progress in continuous improvement led to the expansion of the use of these tools. KAORU ISHIKAWA, head of the Japanese Union of Scientist and Engineers (J.U.S.E) expanded the use of these approaches in Japanese manufacturing in 1960s with the introduction of the 7 Quality Control tools.
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7 QC TOOLS
1. Cause and Effect Diagrams

2. Pareto Diagrams
3. Graphs 4. Histograms 5. Check Sheets 6. Scatter Diagrams 7. Controls Charts

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7 QC TOOLS 1. Cause and Effect Diagrams

It is also called the Fishbone Diagram because of its appearance or Ishikawa Diagram named after the man who popularized its use in Japan. Its most frequent use is to list the cause of particular problems.

TAIYO PLASTIC CORP. OF THE PHILS

7 QC TOOLS
Material

Cause and Effect Diagrams

Method

Problem

Machine

Man

TAIYO PLASTIC CORP. OF THE PHILS

7 QC TOOLS
Material

Cause and Effect Diagrams

Machine
Watering a tress takes a long time

Dont understand the characteristic of trees Being tired Wasteful watering

Needs two women Hose is long Work done on hot days Hose is heavy

No watering standard
Dont understand the watering conditions

Faucets are far from trees Method Man TAIYO PLASTIC CORP. OF THE PHILS 9

7 QC TOOLS
1. Cause and Effect Diagrams

2. Pareto Diagrams
3. Graphs 4. Histograms 5. Check Sheets 6. Scatter Diagrams 7. Controls Charts

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7 QC TOOLS

2. Pareto Diagrams
Shows the distribution of items and arrange them from the most frequent to the least frequent with the final bar being miscellaneous. The tool is named after Wilfredo Pareto, the Italian economist who determined that wealth is not evenly distributed. Some of the people have most of the money. This tools is graphical picture of the most frequent causes of a particular problem. It shows where to put your initial effort to get maximum gain
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7 QC TOOLS
40

Pareto Diagrams
120%

100% 30 80%

20

60%

Column 1 Line 2

40% 10 20%

0%

short shot

weldline

sinkmark

gas burn

others

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7 QC TOOLS
40

Pareto Diagrams
120%

100% 30
No. of defects
Scale mark

80%
Percentage

20

60%

40% 10 20%

0%

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7 QC TOOLS

Pareto Diagrams
Draw the graph format
40 120% 100%
No. of defects

30

Scale mark

20

60% 40%

10 20% 0 short shot weldline sink mark gas burn others 0%

TAIYO PLASTIC CORP. OF THE PHILS

Percentage

80%

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7 QC TOOLS
40

Pareto Diagrams
Draw the bar graph
120%

100% 30 80%

20

60%

40% 10 20%

0%

short shot

weldline

sinkmark

gas burn

others

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7 QC TOOLS
40

Pareto Diagrams
Draw the line graph
120% 100% 100% 30 74% 83% 80%

20

58%

60%

32% 10

40%

20%

0%

short shot

weldline

sinkmark

gas burn

others

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7 QC TOOLS
1. Cause and Effect Diagrams

2. Pareto Diagrams
3. Graphs 4. Histograms 5. Check Sheets 6. Scatter Diagrams 7. Controls Charts

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7QC TOOLS
(Pcs)

3. Graphs (Line Graph)

16 14 12 10 8 6 4 2 0 jan feb mar apr ma jun jul aug sep
Adjust injection speed Adjust mold temp

target

Short shot

months
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(Pcs)

Number of defect (per item)

16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

sh or ts el dl in e si nk m ar k de nt un cu tg at e br ok en bu bb la le ck s in g pr in t flo w m ar k
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7 QC TOOLS

Graphs (Bar Graph)

ho t

TAIYO PLASTIC CORP. OF THE PHILS

7 QC TOOLS
1. Cause and Effect Diagrams

2. Pareto Diagrams
3. Graphs 4. Histograms 5. Check Sheets 6. Scatter Diagrams 7. Controls Charts

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7 QC TOOLS
4. Histograms
Is a bar graph showing a distribution of variables. This will helps identify the cause of problems in a process by the shape of the distribution as well as the width of the distribution A histogram divides the range of data into categories and shows the amount of data collected in each. This makes it easier to determine at a glance median values and distribution.

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7 QC TOOLS
Histograms
median

Width of distribution Width of range

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7 QC TOOLS
Histograms
median

Width of distribution Width of range

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7 QC TOOLS
1. Cause and Effect Diagrams

2. Pareto Diagrams
3. Graphs 4. Histograms 5. Check Sheets 6. Scatter Diagrams 7. Controls Charts

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7 QC TOOLS
5. Check sheet
Check sheet is used to decide in advance the details of forms, categories, and timing so that checks can be made without fail on inspection and verification items for various and wide-ranging data. The check sheet makes it easier to arrange necessary data into order and to discover problems early on.

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7 QC TOOLS
1. Cause and Effect Diagrams

2. Pareto Diagrams
3. Graphs 4. Histograms 5. Check Sheets 6. Scatter Diagrams 7. Controls Charts

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7 QC TOOLS

6. Scatter Diagram
This diagram is helpful when dealing with two types of data. It expresses with dots, one type of data on its horizontal axis and the second type on its vertical axis. This diagram helps to verify if there is a correlation between the two types of data.

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7QC TOOLS
(liters)

Scatter diagrams
4

Gas consumption

3.5 3 2.5 2 1.5 1 0.5 0 0 10 20 30 40 50 60 70 80 90 100 110

speed
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7 QC TOOLS
1. Cause and Effect Diagrams

2. Pareto Diagrams
3. Graphs 4. Histograms 5. Check Sheets 6. Scatter Diagrams 7. Controls Charts

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7 QC TOOLS 7. Control Chart

A control chart is a line graph of a process drawn in relation to limit lines. Its purpose is to indicate whether each of the points in the process is normal or abnormal, to show where the center of the process is and to show how consistently the process is being maintained. It is very useful for the early detection of malfunctions. In a control chart the upper and lower control limit lines are drawn and data is expressed using a broken line.
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7 QC TOOLS 7. Control Chart

USL

UCL DATA

CL

LCL

LSL TAIYO PLASTIC CORP. OF THE PHILS 31

7 QC TOOLS 7. Control Chart

Calculating control limit for x R chart:
UCL = X + ( A2 x R )

LCL = X - ( A2 x R )
* A2 is a constant from the table.

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7 QC TOOLS 7. Control Chart

1. OUT OF CONTROL
DATA IS OUTSIDE THE UPPER OR LOWER CONTROL LIMIT
USL

DATA

UCL
DATA

CL

LCL LSL TAIYO PLASTIC CORP. OF THE PHILS 33

7 QC TOOLS 7. Control Chart

2. OUT OF CONTROL
RUN OF 7 CONSECUTIVE POINTS ON ONE SIDE OF THE CENTER LINE
USL

UCL

CL

LCL

LSL TAIYO PLASTIC CORP. OF THE PHILS 34

7 QC TOOLS 7. Control Chart

3. OUT OF CONTROL
TREND OF 7 CONSECUTIVE POINTS INCREASING OR DECREASING
USL

UCL

CL

LCL

LSL TAIYO PLASTIC CORP. OF THE PHILS 35

TAIYO PLASTIC CORP. OF THE PHILS

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