Scatter Diagrams

Stratification
Pareto Diagram
Control Charts

Traditional and New Tools

Cause and Effect Diagram
Check Sheet
Histograms

Begin Module 1

Summary

Module 4

Seven New Tools

Module 3

Session 9

Traditional and New Tools

Cause and Effect Diagram
Check Sheet
Histograms

Module 2

Module 1

Session Outline

Rajiv Gupta
BITS Pilani
August 2014
Lecture 9

MMZG 522 Total Quality

Management

1.
2.
3.
4.
5.
6.
7.

C-E (Cause-Effect) Diagram

Stratification Analysis
Check Sheet
Histogram
Scatter Diagram
Pareto Chart
Control Charts

Seven Traditional or Basic Quality

Tools

Used primarily in reactive mode to improve

quality
Mostly quantitative --They handle
Quantitative data
Their format allows visualization of quality
issues/problems
Used primarily on the shop floor
Any of the tools can be used with any
other tools.

Traditional Tools

1. Seven Traditional or Basic Quality Tools (e.g.

C-E diagrams, Stratification, Histogram, Pareto
Chart, Control Charts)
2. Seven New Quality Tools (e.g. Relations
Diagram, Affinity Diagram, Tree Diagram,
Matrix Diagram, Arrow Chart, Process Decision
Program Chart)
3. Other: Product/Process Development Tools
(e.g. Benchmarking, QFD, FMEA, Faulty Tree
Analysis, Reliability Analyses, Experiment
Design, CAD, FEA, Prototyping, CAM, etc.)

Tool Grouping

Cause and Effect Diagram

Relations Diagram
Affinity Diagram
Systematic Diagram
Matrix Diagram
Matrix Data Analysis
Process Decision Program Chart (PDPC)
Arrow Diagram

Also called Ishikawa or Fishbone Diagram

Drawn to investigate only one Bad or good
effect
Causes broken down into major and minor
causes
Excellent for brainstorming and in teams
Team members can vote to obtain most likely
causes for problem solving
Two types of C-E Diagrams: Traditional and
Process

1.
2.
3.
4.
5.
6.
7.

Seven New Quality Tools

Mainly used in proactive manner (to create

quality).
Used primarily for planning and by management
(for brainstorming)
Qualitative in nature
More effective when used by multi-functional
teams
Visual in nature help visualize problems,
issues, relationships, etc.
Any of the tools can be used with any other
tools.

New Quality Tools

Data should be collected accurately and

quickly to allow visualization and analysis
Tabular and Pictorial (Graphical) Formats
Creativity plays a major role in the design
of a check sheet.

Check Sheet

C-E Process Chart

C-E Diagram (Fish Diagram)

12

11

10

14

13

15

Quantitative data consisting of values of a

variable from a sample are plotted to obtain
distribution
It is a bar chart but each bar represents
frequency of occurrences within an interval
represented by the bar.
Not all bar charts are histograms (Note: Bar
charts of categorical data are not histograms).
Sufficient sample size or observations (>30) and
number of intervals (5-15) needed for useful
analysis/interpretation

Histogram

Check Sheet - Graphic

Check Sheet - Tabular

16

Session 9
End of module 1

Outputs from
three (1,2,3)
machines
combined

18

17

Histograms with Stratified Data

Histogram

Scatter Diagram Stratified Data

Scatter Diagram

Traditional Tools contd.

Scatter Diagrams
Stratification
Pareto Chart
Control Charts

Begin Module 2

Session 9

21

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Pareto Chart

24

23

Bar chart of categorical data arranged from

largest to smallest occurrence frequency
Cumulative percentage of occurrence provides
Vital few and useful many
Powerful quality improvement tool. (Great for
continuous improvement keep solving
problems that have largest impact to quality).

Pareto Chart

Can be used with other tools

Data separated (identified) by categories
for visualization and analyses
Stratification by source (machine,
operator/user, supplier, location, time of
the day, day, season, etc.)

Stratification

Control Chart-- R- Chart

Control Chart X-Bar Chart

27

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25

Visual plot of process output along with

control limits
Variables Charts (X-bar and R, X-bar and
S) and Attributes Charts (P, NP, U, C).
Variables based on successive values of
a parameter
Attribute based on defectives and defects

Control Charts

Seven New Tools

Relations Diagram
Affinity Diagram
Event Tree
Systematic Diagram
Matrix Diagram
Process Chart
Arrow Diagram

Begin Module 3

Session 9

End of module 2

Session 9

Control Chart P-Chart

30

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Affinity
Diagram

Affinity Diagram

Relations Diagram

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32

31

Matrix Diagram

Systematic Diagram

Event Tree

36

35

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Process Chart

Provides information on a process

- Description of Steps
- Sequence/Flow of steps
- Time Required to complete
- Distance Traveled
- Decisions Made
- People Involved
- Material, Information, Tools, etc.

Process Chart

39

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37

Level of or quantitative information about

relationships in terms of direction
(increase/decrease), strength/importance,
priority

Matrix Data

End of module 3

Session 9

Tools More effective when used

as a system for improvement

Arrow Diagram

42

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End of module 4

Session 9

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44

Quality and Management tools have been

developed over the years to help analyze and
solve problems on the shop floor and elsewhere
The traditional tools tend to be more quantitative
and are used in a reactive mode
The seven new tools are more qualitative and
can be used in a proactive mode
Ideally, the tools ought to be used in conjunction
with other tools so that their usefulness is
enhanced

Summary of Session 9

Summary

Begin Module 4

Session 9