SEVEN TOOLS OF QUALITY-

ISHIKAWAS BASIC TOOLS OF QUALITY

Kaoru Ishikawa developed seven basic visual tools of quality so that the average person could analyze and interpret data. These tools have been used worldwide by companies, managers of all levels and employees.

Are the fundamental methods for gathering& analyzing quality related data.

1) CHECK SHEET/ DEFECT CONCENTRATION DIAGRAM The check sheet is a simple document that is used for collecting data in real-time and at the location where the data is generated. Is a form used to collect information in such a way that it makes not only the collection of data easy, but also the analysis of that data automatic. The function is to present information in an efficient , graphical format.

In this the operator merely adds a mark to the tally on the prepared sheet.

The document is typically a blank form that is designed for the quick, easy, and efficient recording of the desired information, which can be either quantitative or qualitative. When the information is quantitative, the checksheet is sometimes called a tally sheet.

The frequency of a particular defect helps the operators to spot problems.

WHEN TO USE When data can be observed and collected repeatedly by the same person or at the same location. When collecting data on the frequency or patterns of events, problems, defects, defect location, defect causes, etc. When collecting data from a production process.

Check Sheet Procedure Decide what event or problem will be observed. Develop operational definitions. Decide when data will be collected and for how long. Design the form. Set it up so that data can be recorded simply by making check marks or Xs or similar symbols and so that data do not have to be recopied for analysis. Label all spaces on the form. Test the check sheet for a short trial period to be sure it collects the appropriate data and is easy to use. Each time the targeted event or problem occurs, record data on the check sheet.

CHECK LIST
Product Name XXXXXXX Defective Item Mold Cracked Fibers Pinholes 2/5 (M) 2/6 (T) 2/7 (W) 2/8 (T) Line Name ABC 2/9 (F) Total 15 7 12

////

/// // // ////

//

//// ////

// / / ////

Spots
Seam defects Other Total

//// / //

/// ///

// //
//
14

7
11 6 8 56

/
11 12

///
11

2) PARETO CHARTSNamed after Italian economist Vilfred Pareto. Is a graphical tool for ranking causes of problems from the most significant to the least significant. Its is a bar graph. The lengths of the bars represent frequency or cost (time or money), and are arranged with longest bars on the left and the shortest to the right. The number of occurrences of an events is arranged in the descending order. It puts the data in a hierarchical order which allows the significant problems to be corrected first.

Helps to identify those defects that cause most problems.

When to Use When analyzing data about the frequency of problems or causes in a process. When there are many problems or causes and you want to focus on the most significant. When analyzing broad causes by looking at their specific components. When communicating with others about your data.

To identify the VITAL FEW FROM TRIVIAL MANY and to concentrate on the vital few for improvement.
They are actually histograms aided by the 80/20 rule.

Remember the 80/20 rule states that approximately 80% of the problems are created by approximately 20% of the causes.
A Pareto diagram indicates which problem we should solve first in eliminating defects and improving the operation.

Pareto Chart Procedure Decide what categories you will use to group items. Decide what measurement is appropriate. Common measurements are frequency, quantity, cost and time. Decide what period of time the Pareto chart will cover: One work cycle? One full day? A week? Collect the data, recording the category each time. (Or assemble data that already exist.) Subtotal the measurements for each category. Determine the appropriate scale for the measurements you have collected. The maximum value will be the largest subtotal from step 5. Mark the scale on the left side of the chart. Construct and label bars for each category. Place the tallest at the far left, then the next tallest to its right and so on. If there are many categories with small measurements, they can be grouped as other.

Example #1 shows how many customer complaints were received in each of five categories.

3) Flowchart A flowchart is defined as a pictorial representation describing a process being studied. Flowcharts can be used for: (i) defining and analyzing processes; (ii) building a step by step picture of the process for analysis, discussion, or communication purposes; (iii) defining, standardizing, or finding areas for improvement in a process; (iv)comparing and contrasting the actual work flow of a process with an ideal flow; and (v)to help train employees Flow charting is the first step we take in understanding a process.

Flow charts can be drawn in many styles.

They can be drawn by using pictures, engineering symbols, or just squares and rectangles.

Also, flow charts can be used to describe a single process, parts of a process, or a set of processes.
There is no right or wrong way to draw a flow chart.

By breaking the process down into its constituent steps, flowcharts can be useful in identifying where errors are.

Shirts arrive from laundry

Pull shirts From rack

Remove hangers

Inspect for damages Yes Damage

Note any repair req.

Steps: Dry-cleaned shirts arrive at laundry Arranged / kept on racks Put shirts from rack Remove hanger Inspect Note repair needs Discard if badly damaged Sort according to size Fold shirt Place on proper rack
Update Records Yes

Discard

Sort acc. To size

Place On Rack Check for Proper rack No OK Or Not

Fold Shirt

Dry-cleaning & Repair process

4) CAUSE & EFFECT DIAGRAM Also referred as Ishikawa Diagram after its inventor.

Also known as Fish bone because of its shape, similar to the side view of a fish skeleton.
The fishbone diagram identifies many possible causes for an effect or problem. It can be used to structure a brainstorming session. It immediately sorts ideas into useful categories

It is simply a diagram that shows the causes of a certain event.

The undesirable outcome is shown as effect & related causes are shown as leading to or potentially leading to said effect.

Steps: Identify & state the problem. Identify the causes Brainstorm the major categories of causes of the problem. If this is difficult use generic headings:
Methods Machines (equipment) People (manpower) Materials Measurement Environment

Now organize the causes & sub causes in diagram format. Helps the person to think systematically & logically.

It graphically illustrates the relationship between a

WHEN TO USEWhen identifying possible causes for a problem. Especially when a teams thinking tends to fall into ruts.

E.g- Possible causes for tackling pattern alignment errors.

Method
No Standard Operating procedure

Materials
Pattern Not proper

Incorrectly aligned pattern

Customers Direction unclear Template Place wrong Training Ignored instruction

Information

Machines CAUSES

People EFFECT

Poor Permanent Press cutting

Unskilled operator

Thread tension Too tight Seam Puckering

Structural jamming

Too many stitches Per inch CAUSES EFFECT

Diagram of the Incorrect Deliveries Example:

5) HISTOGRAMIs a bar chart or bar graph Plots data in a frequency distribution The most commonly used graph for showing frequency distributions, or how often each different value in a set of data occurs. Histograms provide the easiest way to evaluate the distribution of data. Different from check sheet as in this data is grouped into rows so identity of individual value is list. Graphical depiction of number of occurrences an event. Works best with small amounts of data that vary considerably.

WHEN TO USE
The data are numerical values.

To see the shape of the datas distribution, especially when determining whether the output of a process is distributed approximately normally. Analyzing whether a process can meet the customers requirements. Analyzing what the output from a suppliers process looks like. Whether a process change has occurred from one time period to another. To determine whether the outputs of two or more processes are different. To communicate the distribution of data quickly and easily to others.

HISTOGRAM SHAPES AND MEANING

Normal. A common pattern is the bell-shaped curve known as the normal distribution. In a normal distribution, points are as likely to occur on one side of the average as on the other. Skewed. The skewed distribution is asymmetrical because a natural limit prevents outcomes on one side. The distributions peak is off center toward the limit and a tail stretches away from it.

These distributions are called right- or left-skewed according to the direction of the tail. Double-peaked or bimodal. The bimodal distribution looks like the back of a two-humped camel. The outcomes of two processes with different distributions are combined in one set of data. A two-shift operation might be bimodal.

For example, if your data ranges from 1.1 to 1.8, you could have equal bins of 0.1 consisting of 1 to 1.1, 1.2 to 1.3, 1.3 to 1.4, and so on. The vertical axis of the histogram is labeled Frequency (the number of counts for each bin), and the horizontal axis of the histogram is labeled with the range of your response variable.

Examples of How Histograms Can Be Used

Histograms can be used to determine distribution of sales. Say for instance a company wanted to measure the revenues of other companies and wanted to compare numbers.

6) SCATTER DIAGRAM or XY graph or Scatter plot

It is a graphical technique that is used to analyze the relationship between two a performance measure and factors that might be driving it. The scatter diagram graphs pairs of numerical data, with one variable on each axis, to look for a relationship between them. If the variables are correlated, the points will fall along a line or curve. The better the correlation, the tighter the points will hug the line. It cannot prove that one variable causes the change in the other. This graphical approach is quick, easy to communicate to others, and generally easy to interpret. It depicts that relationship exists & how strong it is.

In this horizontal (x) axis represents the measurement values of one variable & the vertical (y) axis represents the measurement of second variable.
E.g.- The strength of the yarn is dependent on twists per inch, moisture absorbency in the fabric, fabric thickness & so on. When to Use a Scatter Diagram When you have paired numerical data.

When trying to determine whether the two variables are related, such as When trying to identify potential root causes of problems.
After brainstorming causes and effects using a fishbone diagram, to determine objectively whether a particular cause and effect are related. When determining whether two effects that appear to be related both occur with the same cause.

Positive Correlation
As the item on the X axis increases, the item on the Y axis also increases, and vice versa

Negative Correlation As the item on the X axis increases, the item on the Y axis decreases

No relationship; Changing the values of item X does not have any effect on the value of item Y,

7) CONTROL CHART or Statistical process control Displays statistically determined upper & lower limits drawn on either side of the process average. If the chart indicates that the process is currently under control then it can be used with confidence to predict the future performance of the process. If the chart indicates that the process being monitored is not in control, the pattern it reveals can help determine the source of variation to be eliminated to bring the process back into control. This chart shows if the collected data are within upper or lower limits previously determined through statistical calculations of raw data from earlier traits.

Simple chart with time on x axis & characteristic measured on y axis, with control limits for the quality characteristics measured.

Variations or Fluctuations can be Normal or Abnormal: Normal- small differences causes the data to fluctuate like small differences in material, atmospheric conditions, equipments etc.

Abnormal- large differences causes changes in a process resulting in variation in the characteristics measured like material taken from different lot, inexperienced operator, new setting in machines etc.
The process is in control, all points will plot within the control limits. Any observations outside the limits, or systematic patterns within, suggest the introduction of a new (and likely unanticipated) source of variation, known as a special cause variation. Since increased variation means increased quality cost.

The two broadest groupings are for variable data and attribute data.
Variable data are measured on a continuous scale. For example: time, weight, distance or temperature can be measured in fractions or decimals. The possibility of measuring to greater precision defines variable data.

Attribute data are counted and cannot have fractions or decimals. Attribute data arise when you are determining only the presence or absence of something: success or failure, accept or reject, correct or not correct. For example, a report can have four errors or five errors, but it cannot have four and a half errors.

QC in Garment Manufacturing unit Export houses earn foreign exchange for the country, so it becomes mandatory to have good quality control of their products. In the garment industry quality control is practiced right from the initial stage of sourcing raw materials to the stage of final finished garment. For textile and apparel industry product quality is calculated in terms of quality and standard of fibres, yarns, fabric construction, colour fastness, surface designs and the final finished garment products. quality expectations for export are related to the type of customer segments and the retail outlets.

There are a number of factors on which quality fitness of garment industry is based such as - performance, reliability, durability, visual and perceived quality of the garment. Quality needs to be defined in terms of a particular framework of cost.

The national regulatory quality certification and international quality programmes like ISO 9000 series lay down the broad quality parameters based on which companies maintain the export quality in the garment and apparel industry.
Some of main fabric properties that are taken into consideration for garment manufacturing for export basis:

Overall look of the garment. Right formation of the garment. Feel and fall of the garment. Physical properties. Colour fastness of the garment. Finishing properties Presentation of the final produced garment. Basic Thumb Rules for Garment Exporters

For a garment exporter there are many strategies and rules that are required to be followed to achieve good business.
The fabric quality, product quality, delivery, price, packaging and presentation are some of the many aspects that need to be taken care of in garment export business.

Some rules that are advisable for garment exporters are listed below:
Quality has to be taken care by the exporter, excuses are not entertained in international market for negligence for low quality garments, new or existing exporters for both it is mandatory to use design, technology and quality as major up gradation tools.

Apart from superior quality of the garment, its pricing, packaging, delivery, etc has to be also taken care of.
The garment shown in the catalogue should match with the final garment delivered. It is important to perform according to the promises given to the buyer, or else it creates very bad impression and results in loss of business and reputation.

In international market, quality reassurance is required at every point.

Proper documentation and high standard labels on the garment are also important aspects as these things also create good impression. Timely delivery of garments is as important as its quality. If your competitor has the better quality of garment in same pricing, it is better to also enhance your garment quality. Before entering into international market, garment exporters have to carefully frame out the quality standards, or else if anything goes wrong it could harm the organization. And after that strictly follow it. The garment quality should match the samples shown during taking the orders.

The garment exporters should know to negotiate a premium price after quality assurance is done. Quality is ultimately a question of customer satisfaction. Good Quality increases the value of a product or service, establishes brand name, and builds up good reputation for the garment exporter, which in turn results into consumer satisfaction, high sales and foreign exchange for the country.

The perceived quality of a garment is the result of a number of aspects, which together help achieve the desired level of satisfaction for the customer.
Therefore quality control in terms of garment, pre-sales service, posts -sales service, delivery, pricing, etc are essentials for any garment exporter.

Quality is a multi-dimensional aspect. There are many aspects of quality based on which the garment exporters are supposed to work.
Quality of the production. Quality of the design of the garment. Purchasing functions' quality should also be maintained Quality of final inspection should be superior. Quality of the sales has to be also maintained. Quality of marketing of the final product is also important as the quality of the garment itself.

The following standards are commonly found in garments of quality construction.

Appearance, Overall - Notions compatible in color, fiber, weight, and design. - Fabric used correctly-plaids, stripes, checks, or other designs attractively planned for matching. - Fabric nap correctly used. - Pressed to give smooth look to finished garment. - Loose ravellings, and thread ends removed. Belts - Style of belt suitable to garment design, uniform width. - Ends well finished. - Closure appropriate. - Durable and attractive.

Buttons - Neatly and securely fastened. - Appropriate in size and design. - Placement accurate and attractive, uniform distance from edge and in spacing between. - Appropriate shank provided. - Stitching started and ended under button. Buttonholes - Flat and securely stitched. - Even in width and length. - Placed at points of strain. - Attractive and accurate in distance from edge and in spacing between. - Cut on grain. - Appropriate in size. - Appropriate interfacing used.

Collars - Free from bulk-seams ,clipped, or notched. - Under stitching holds under collar in place so it does not show. - Appropriate interfacing used. - Shape symmetrical on right and left. - Curved edges smooth, points sharp and flat. - Rolls smoothly or lays flat according to design. Cuffs - Flat, smooth, free from bulk-seams and under stitched where applicable. - Even in width. - Under cuff does not show. - Appropriately interfaced.

Darts - Tapered and smooth-free from pucker or bubble at point. - Securely fastened at ends. - Symmetrical in shape, length, and spacing. - Attractive placement. - Pressed correctly-vertical darts pressed toward center, horizontal darts pressed down. Facings - Flat, smooth, free from bulk. - Securely tacked in place at seams, darts, and openings. - Facing edges free from raveling. - Any edge finish flat, smooth, and free from bulk.

Fit - Adequate ease for comfort. - Fitting details (neckline, armhole, waistline) properly located on body. - Silhouette lines follow silhouette of body. - Lengthwise grain line perpendicular to floor; crosswise grain line parallel to floor. - Darts point to and stop short of the fullest part of the area they fit. - Free from strain and/or excess fullness. Gathers - Uniform, evenly distributed. Stitched so pleats are not formed. - Adequately full-do not look skimpy or bulky.

Hems - Flat and inconspicuous, unless meant to be decorative. - Seams pressed as required and graded to reduce bulk. - Hem fold pressed so hem hangs smoothly at lower edge. - Hem edge smooth, flat, and free from raveling. - Excess fullness evenly eased, free from pleats. - Seams aligned. - Hem edge finish should not create ridge or add bulk. - Hem even in width. - Width appropriate for garment style and fabric type. - Topstitching attractive in size and placement, straight. - Hand stitches uniform, secure, and inconspicuous. - Fused hems securely fused and flat. - Hem hangs parallel to floor. - Length attractive for wearer and appropriate for garment.

Interfacing - Enhances body and wear of garment. - Color and care requirements compatible to outer fabric. - Free from bulk and ravellings. - Not visible on inside or outside of garment.

Lining - Conceals inner construction of garment without adding excess bulk. - Color and care requirements compatible with outer fabric. - Fits smoothly inside garment with seams aligned. - If attached at hems, has pleat for ease. - If free hanging-attached at seams - Hemmed shorter than garment-1/2 inch shorter than sleeves and 1 inch shorter than skirt or pants.

Neckline - Free from bulk. - Facings flat , clipped, and under stitched. - Design symmetrical.
Needlework (hand stitching) - Uniform stitches, secure. - Correct technique used-stitch with single thread. - No bulky knots at thread ends. - Correct stitch used for purpose. Placket - Flat, free from excess bulk. - Inconspicuous unless meant to be decorative. - Correct technique used for purpose-faced, bound, hemmed.

Pleats, tucks - Uniform in width (unless design varies). - On straight grain of fabric when design allows. - Neatly pressed as required. - Stitching straight. - Spacing attractive and accurate.

Pockets - Flat, smooth, free from bulk. - Stitching straight. - Pressed neatly. For Patch pockets - Upper corners reinforced. - Square corners mitered; round corners symmetrical. - Hem appropriate width and neatly finished. - Attractive placement. - If in pairs, coordinated in size, shape, and fabric design (if applicable).

In-seam pockets - Interfaced, under stitched, lay flat when worn. - Inconspicuous unless meant to be decorative Pressing - Garment smooth and free from wrinkles. - Free from sheen and scorch. - No ridges from seams or facings. - Seams pressed flat and inconspicuous. - Darts presses to shape garment. - Pleats, tucks, creases pressed as design requires.

Seams - Securely stitched, straight, flat, free from bulk. - Stitches appropriate in size and tension. - Fullness eased as required. - Crossed seams intersect correctly. - Pressed in correct direction. - Fabric design matched as possible. - If finish used, no added bulk or tension. - Free from ravelling.
Sleeves Set-in sleeves - Fullness evenly distributed. - Seam smooth and even in width around cap. - Underarm section of seam trimmed and double stitched. - Seam pressed toward sleeve cap.

Stitching - Stitch length and tension appropriate for fabric. - Straight, knots, and skipped stitches. - Beginning and ending of stitching locked in appropriate way. - Loose threads cut off.
Waistband - Smooth, even width. - Free from bulk. - On grain. - Interfaced. - Stitching straight. - Corners square. - Skirt or pants eased to fit band. - Sets exactly at top of zipper.

Zipper - Placket smooth, flat, and free from puckering. - Stitching straight and even. - Placket appropriate length and width. - Seams and neckline edges match. - Zipper completely covered. - Zipper slides easily. - Inconspicuous unless meant to be a design feature. - Skirt and zippers end at band. - Neckline zippers end 1/2 inch from neckline so fastener (hook and eye or snap) can be attached above zipper.