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Quality_Tools2.ppt

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The document discusses the Basic Seven tools of quality analysis which were developed by Kaoru Ishikawa to make statistical analysis more accessible. The seven tools are fishbone diagrams, histograms, Pareto analysis, flowcharts, scatter plots, run charts, and control charts. Each tool is used for a different type of quality analysis, such as identifying causes of problems, displaying the distribution of data, determining priorities, mapping processes, and monitoring variations. Examples using data from a pizza shop called Acme are provided to demonstrate how each tool can be constructed and applied to quality improvement efforts.

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The Basic Seven (B7) Tools of Quality A PowerPoint Training Presentation By Keith H. Cooper "As much as 95% of quality related problems in the factory can be solved with seven fundamental quantitative tools." - Kaoru Ishikawa
What are the Basic Seven Tools of Quality? Fishbone Diagrams Histograms Pareto Analysis Flowcharts Scatter Plots Run Charts Control Charts
Where did the Basic Seven come from? Kaoru Ishikawa Known for Democratizing Statistics The Basic Seven Tools made statistical analysis less complicated for the average person Good Visual Aids make statistical and quality control more comprehendible.
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
Constructing a Fishbone Diagram Step 1 - Identify the Problem Step 2 - Draw spine and bones Example: High Inventory Shrinkage at local Drug Store Shrinkage
Constructing a Fishbone Diagram Step 3 - Identify different areas where problems may arise from Ex. : High Inventory Shrinkage at local Drug Store Shrinkage employees shoplifters
Constructing a Fishbone Diagram Step 4 - Identify what these specific causes could be Ex. : High Inventory Shrinkage at local Drug Store Shrinkage shoplifters Anti-theft tags poorly designed Expensive merchandise out in the open No security/ surveillance
Constructing a Fishbone Diagram Ex. : High Inventory Shrinkage at local Drug Store Shrinkage shoplifters Anti-theft tags poorly designed Expensive merchandise out in the open No security/ surveillance employees attitude new trainee training benefits practices
Constructing a Fishbone Diagram Step 5 Use the finished diagram to brainstorm solutions to the main problems.
The Basic Seven (B7) Tools of Quality Histograms Bar chart Used to graphically represent groups of data
Constructing a Histogram From a set of data compute sum mean (x) Max Min Range (max-min)
Constructing a Histogram Use range to estimate beginning and end Calculate the width of each column by dividing the range by the number of columns Range # of Columns = Width
Acme Pizza Example Lets say the owner wants a distribution of Acmes Thursday Night Sales Data Set from last Thursday(slices) 0 2 1 2 2 4 1 3 1 2 1 2 2 4 3 4 1 4 3 2 2 3 2 1 2 2 1 2 2 1 4 2 2 1 2 1 2 2 1 2 1 2 1 2 1 2 1 2 1 2 2 2 1 2 1 2 1 1 2 2 2 3 1 4 2 2 3 2 2 2 1 2 3 2 2 4 2 2 4 4 1 2 2 2 3 2 2 1 2 2 4 2 1 2 4 2 1 7 2 1 2 2 3 1 2 1 1 2 1 2 2 2 1 2 2 1 2 1 2 2 2 4 2 4
Acme Pizza Example Mean = 2.032258 Max = 7 Min = 0 Range = 7 Question For 7 columns what would the width be? Range/Columns=7/7=1 slice
Acme Pizza Example 33 65 8 12 0 0 1 0 10 20 30 40 50 60 70 1 2 3 4 5 6 7 Slices of Pizza Histogram
Constructing a Histogram How is this helpful to Acme? 2 slices of pizza most common order placed Distribution of sales useful for forecasting next Thursdays late night demand If you were an Acme manager how could you apply this information?
The Basic Seven (B7) Tools of Quality Pareto Analysis Very similar to Histograms Use of the 80/20 rule Use of percentages to show importance
Acme Pizza (part 2) Slices Frequency % 0 1 .3 1 33 13.09 2 65 25.79 3 8 3.17 4 12 4.76 5 0 0 6 0 0 7 1 .3
Acme Pizza (part 2) The completed Pareto Analysis results in the following graph: 0 10 20 30 40 50 60 70 1 2 3 4 5 6 7 Slices of Pizza 2 1 4 3 7 5 6
Acme Pizza (part 2) Critical Thinking How does the Pareto Analysis differ from the Histogram? How can this be a useful tool to the Acme boss?
The Basic Seven (B7) Tools of Quality Flowcharts A graphical picture of a PROCESS Process Decision The process flow
Flowcharts Dont Forget to: Define symbols before beginning Stay consistent Check that process is accurate
Acme Pizza Example (Flowchart) Window Take Customer Money? (start) Order Get Pizza Lockup Put More in Oven 2 Pies Available? Time to close? Take to Customer no yes no yes no yes
How can we use the flowchart to analyze improvement ideas from the Histogram? Window Take Customer Money? (start) Order Get Pizza Lockup Put More in Oven 2 Pies Available? Time to close? Take to Customer no yes no yes no yes
Want some practice? Make a flowchart for: Taking a shower Cooking dinner Driving a car Having a party Creating a Flowchart Any other processes you can think of?
The Basic Seven (B7) Tools of Quality Scatter Plots 2 Dimensional X/Y plots Used to show relationship between independent(x) and dependent(y) variables
Acme Pizza (Scatter Diagram) Minutes Cooking Defective Pies 10 1 45 8 30 5 75 20 60 14 20 4 25 6 In this simple example, you can find the existing relationship without much difficulty but
Scatter Diagrams 0 5 10 15 20 25 0 20 40 60 80 Easier to see direct relationship Time Cooking (minutes)
Scatter Diagrams As a quality tool What does this tell Acme management about their processes? Improvements? 0 5 10 15 20 25 0 20 40 60 80 Time Cooking (minutes)
The Basic Seven (B7) Tools of Quality Run charts Time-based (x-axis) Cyclical Look for patterns
Run Charts 8 9 10 11 12 1 2 3 4 8 9 10 11 12 1 2 3 4 8 9 10 11 12 1 2 3 4 PM- AM PM- AM PM- AM Thursday Week 1 Thursday Week 2 Thursday Week 3 Slices/hour Time
The Basic Seven (B7) Tools of Quality Control Charts Deviation from Mean Upper and Lower Specs Range
Control Charts Upper Limit Lower Limit Unacceptable deviation X
Control Charts Acme Pizza Management wants to get in on the control chart action Average Diameter = 16 inches Upper Limit = 17 inches Lower Limit = 15 inches
Acme example Control Charts Upper Limit 17 inches Lower Limit 15 Inches Small Pie X 16 inches=
Acme example #50 Control Charts Pies within specifications were acceptable One abnormally small pie is uncommon Should be examined for quality control
Summary Basic Seven Tools of Quality Measuring data Quality Analysis Democratized statistics
Bibliography Foster, Thomas. Managing Quality. An Integrative Approach. Upper Saddle River : Prentice Hall, 2001. Stevenson, William. Supercharging Your Pareto Analysis. Quality Progress October 2000: 51-55. Dr Kaoru Ishikawa. Internet http://www.dti.gov.uk/mbp/bpgt/m9ja00001/m9j a0000110.html. 16 February 2001. Chemical and Process Engineering. Internet. http://lorien.ncl.ac.uk/ming/spc/spc8.htm. 17 February 2001.

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Quality_Tools2.ppt

  • 1. The Basic Seven (B7) Tools of Quality A PowerPoint Training Presentation By Keith H. Cooper "As much as 95% of quality related problems in the factory can be solved with seven fundamental quantitative tools." - Kaoru Ishikawa
  • 2. What are the Basic Seven Tools of Quality? Fishbone Diagrams Histograms Pareto Analysis Flowcharts Scatter Plots Run Charts Control Charts
  • 3. Where did the Basic Seven come from? Kaoru Ishikawa Known for Democratizing Statistics The Basic Seven Tools made statistical analysis less complicated for the average person Good Visual Aids make statistical and quality control more comprehendible.
  • 4. 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
  • 5. Constructing a Fishbone Diagram Step 1 - Identify the Problem Step 2 - Draw spine and bones Example: High Inventory Shrinkage at local Drug Store Shrinkage
  • 6. Constructing a Fishbone Diagram Step 3 - Identify different areas where problems may arise from Ex. : High Inventory Shrinkage at local Drug Store Shrinkage employees shoplifters
  • 7. Constructing a Fishbone Diagram Step 4 - Identify what these specific causes could be Ex. : High Inventory Shrinkage at local Drug Store Shrinkage shoplifters Anti-theft tags poorly designed Expensive merchandise out in the open No security/ surveillance
  • 8. Constructing a Fishbone Diagram Ex. : High Inventory Shrinkage at local Drug Store Shrinkage shoplifters Anti-theft tags poorly designed Expensive merchandise out in the open No security/ surveillance employees attitude new trainee training benefits practices
  • 9. Constructing a Fishbone Diagram Step 5 Use the finished diagram to brainstorm solutions to the main problems.
  • 10. The Basic Seven (B7) Tools of Quality Histograms Bar chart Used to graphically represent groups of data
  • 11. Constructing a Histogram From a set of data compute sum mean (x) Max Min Range (max-min)
  • 12. Constructing a Histogram Use range to estimate beginning and end Calculate the width of each column by dividing the range by the number of columns Range # of Columns = Width
  • 13. Acme Pizza Example Lets say the owner wants a distribution of Acmes Thursday Night Sales Data Set from last Thursday(slices) 0 2 1 2 2 4 1 3 1 2 1 2 2 4 3 4 1 4 3 2 2 3 2 1 2 2 1 2 2 1 4 2 2 1 2 1 2 2 1 2 1 2 1 2 1 2 1 2 1 2 2 2 1 2 1 2 1 1 2 2 2 3 1 4 2 2 3 2 2 2 1 2 3 2 2 4 2 2 4 4 1 2 2 2 3 2 2 1 2 2 4 2 1 2 4 2 1 7 2 1 2 2 3 1 2 1 1 2 1 2 2 2 1 2 2 1 2 1 2 2 2 4 2 4
  • 14. Acme Pizza Example Mean = 2.032258 Max = 7 Min = 0 Range = 7 Question For 7 columns what would the width be? Range/Columns=7/7=1 slice
  • 15. Acme Pizza Example 33 65 8 12 0 0 1 0 10 20 30 40 50 60 70 1 2 3 4 5 6 7 Slices of Pizza Histogram
  • 16. Constructing a Histogram How is this helpful to Acme? 2 slices of pizza most common order placed Distribution of sales useful for forecasting next Thursdays late night demand If you were an Acme manager how could you apply this information?
  • 17. The Basic Seven (B7) Tools of Quality Pareto Analysis Very similar to Histograms Use of the 80/20 rule Use of percentages to show importance
  • 18. Acme Pizza (part 2) Slices Frequency % 0 1 .3 1 33 13.09 2 65 25.79 3 8 3.17 4 12 4.76 5 0 0 6 0 0 7 1 .3
  • 19. Acme Pizza (part 2) The completed Pareto Analysis results in the following graph: 0 10 20 30 40 50 60 70 1 2 3 4 5 6 7 Slices of Pizza 2 1 4 3 7 5 6
  • 20. Acme Pizza (part 2) Critical Thinking How does the Pareto Analysis differ from the Histogram? How can this be a useful tool to the Acme boss?
  • 21. The Basic Seven (B7) Tools of Quality Flowcharts A graphical picture of a PROCESS Process Decision The process flow
  • 22. Flowcharts Dont Forget to: Define symbols before beginning Stay consistent Check that process is accurate
  • 23. Acme Pizza Example (Flowchart) Window Take Customer Money? (start) Order Get Pizza Lockup Put More in Oven 2 Pies Available? Time to close? Take to Customer no yes no yes no yes
  • 24. How can we use the flowchart to analyze improvement ideas from the Histogram? Window Take Customer Money? (start) Order Get Pizza Lockup Put More in Oven 2 Pies Available? Time to close? Take to Customer no yes no yes no yes
  • 25. Want some practice? Make a flowchart for: Taking a shower Cooking dinner Driving a car Having a party Creating a Flowchart Any other processes you can think of?
  • 26. The Basic Seven (B7) Tools of Quality Scatter Plots 2 Dimensional X/Y plots Used to show relationship between independent(x) and dependent(y) variables
  • 27. Acme Pizza (Scatter Diagram) Minutes Cooking Defective Pies 10 1 45 8 30 5 75 20 60 14 20 4 25 6 In this simple example, you can find the existing relationship without much difficulty but
  • 28. Scatter Diagrams 0 5 10 15 20 25 0 20 40 60 80 Easier to see direct relationship Time Cooking (minutes)
  • 29. Scatter Diagrams As a quality tool What does this tell Acme management about their processes? Improvements? 0 5 10 15 20 25 0 20 40 60 80 Time Cooking (minutes)
  • 30. The Basic Seven (B7) Tools of Quality Run charts Time-based (x-axis) Cyclical Look for patterns
  • 31. Run Charts 8 9 10 11 12 1 2 3 4 8 9 10 11 12 1 2 3 4 8 9 10 11 12 1 2 3 4 PM- AM PM- AM PM- AM Thursday Week 1 Thursday Week 2 Thursday Week 3 Slices/hour Time
  • 32. The Basic Seven (B7) Tools of Quality Control Charts Deviation from Mean Upper and Lower Specs Range
  • 33. Control Charts Upper Limit Lower Limit Unacceptable deviation X
  • 34. Control Charts Acme Pizza Management wants to get in on the control chart action Average Diameter = 16 inches Upper Limit = 17 inches Lower Limit = 15 inches
  • 35. Acme example Control Charts Upper Limit 17 inches Lower Limit 15 Inches Small Pie X 16 inches=
  • 36. Acme example #50 Control Charts Pies within specifications were acceptable One abnormally small pie is uncommon Should be examined for quality control
  • 37. Summary Basic Seven Tools of Quality Measuring data Quality Analysis Democratized statistics
  • 38. Bibliography Foster, Thomas. Managing Quality. An Integrative Approach. Upper Saddle River : Prentice Hall, 2001. Stevenson, William. Supercharging Your Pareto Analysis. Quality Progress October 2000: 51-55. Dr Kaoru Ishikawa. Internet http://www.dti.gov.uk/mbp/bpgt/m9ja00001/m9j a0000110.html. 16 February 2001. Chemical and Process Engineering. Internet. http://lorien.ncl.ac.uk/ming/spc/spc8.htm. 17 February 2001.