Quality Control Training

Seven QC Tools

KAIZEN unit of Ethiopia

1. Seven QC Tools

1) Pareto Chart
2) Histogram
3) Control Chart
4) Scatter Plot
5) Cause and Effect Diagram
6) Check Sheet
7) Graph

2. New Seven QC Tools

1) Affinity Diagram Method

2) Association Diagram Method
3) Tree Diagram Method
4) Matrix Diagram Method
5) Arrow Diagram Method
6) PDPC
7) Matrix Data Analysis Method
1) Pareto Chart
In the Pareto chart, individual values are stratified according to
the items and arranged in the descending order of the frequency
of occurrence. In addition, the cumulative total is represented.
Pareto Chart

Logical bus
configuration Connector Insulation
Switch error failure Congestion failure

Terminal Line Incident DF IP Failure to

device failure during jumper Software assignment turn the
construction error error error power on

Cumulative frequency
Factor

Thus, the Pareto chart is a QC technique with which to analyze

the most important items among a set of events (factors).
This technique is useful in deciding priority goals regarding
management and improvement.
[How to create a Pareto chart]
(1) Gather data for each investigation theme item.
(2) Arrange items in a descending order with respect to the quantity of data.
(3) Calculate the cumulative total and cumulative percentage.
(4) Create a bar graph for each item.
(5) Create a cumulative line graph.
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 2) Histogram
A histogram is a graphical display of the frequency distribution of
metrological characteristics. In this diagram, adjacent rectangles are shown.
The range of values measured is divided into several intervals. Each
interval is represented by the base of each rectangle. The areas of
rectangles are proportional to the frequency of the value measured
corresponding to each interval.

Histogram

Number of
data

Values measured

500 data are divided into intervals between 28 and 72 in increments of 2.

The number of data is represented as a graph. This graph indicates that the
number of class values above 48 and below 50 are the highest.
Thus, the data range is divided into several intervals (classes) and the
frequency of data that belong to each interval is represented as a bar graph.
[How to create a histogram]
(1) Gather data.
(2) Examine the maximum and minimum values of data to obtain a difference (range)
between the maximum value and the minimum value.
(3) Define the number of intervals based on the range.
(4) Create a frequency distribution table and bar graph.
(5) Change intervals and choose the type of interval that will make it easier to
understand the characteristics of the data set. P.4
3) Control Chart
In the control chart, generally, consecutive values observed or
groups of statistic values are represented as points between the
upper and lower control limits in chronological order or in the
order of sample numbers. To facilitate the detection of a trend of
plotted values toward one control limit, a center line is displayed.

A control chart is used to check the stability of quality in

chronological order. This chart is used to examine if quality data is
within the upper and lower control limits and determine if process
or facility adjustment is needed.
[How to create a control chart]
(1) Extract samples from products that have been finished for each
predefined timeframe and plot measured values (mean value) on the graph.
(2) Once measured points are outside of the control limits, immediately
stop the manufacturing process to investigate the cause and take action to
eliminate the cause.

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4) Scatter Plot
Two characteristics are represented as horizontal and vertical
axes. Observed points are plotted on the diagram.
Weight (kg)

Height (cm)

Whether or not there is any relationship between the two items is

identified by looking at the distribution of points.
This plot indicates that the taller a person is the heavier the
person is.
This relationship is referred to as a “positive correlation.”
If points are plotted from the bottom left to the top right, there is
a “negative correlation.” If points are dispersed indicating no
relationship, there is “no correlation.”
[How to create a scatter plot]
(1) Gather data regarding two items.
(2) Determine vertical and horizontal axes and plot data points on the chart.

P.6
 5) Cause and Effect Diagram
A cause and effect diagram systematically indicates a relationship
between a specific result and its cause.
This diagram organizes a characteristic (result) according to the
factors (causes) and simplifies a relationship between the
characteristic and factors.

Customer Department
Complicated order Highest priority Not Actually not observed
computerized Manual
Fill out the order form Urgent order Hand Due date
delivery
Handwriting Handwriting Work concentrates in the morning.
Bulk shipment Test
Fax-based order placement Fill out the invoice Creation of and request Envelop stuffing
Search for the shop code Investigation request search for Packing list delivery
documents and

department take time.

Operations of the logistics
Fill in the shop code Phone call forms Everyday
B y two Difficult to
Separate form for each item for each customer Wrong shipment problem people communicate
EDI-based order placement
Web investigation Order entry Each worker’s desk
Re-edit with Excel check is far away.
Passive work awareness Positioning as
issue handling
No one could personnel Credit ticket
If we could do it, we do it even if I
would have done it. requested. Personnel are not
effectively utilized. Business transfer
The improvement No one has not been
request process is not does it. Clerical workers are available. achieved.
in place.
There is a gap of Freight charge calculation
There is no dedicated director. awareness between us
and subsidiaries. Accounts payable
The logistics department is in a vulnerable position. processing
Delivery date adjustment
Business
complexity is not No stock
understood.
Sales Subsidiary Sales management

From its shape, this diagram is also referred to as “fishbone

diagram.”
[How to create a cause and effect diagram]
(1) Identify a characteristic (problem).
(2) List factors that cause the characteristic and draw a main bone.
Refer to 5M1E (Man, Machine, Material, Method, Measurement,
Environment).
(3) While considering the factors of the characteristic and repeatedly trying
to identify the reasons, draw middle bones, small bones, and very small
bones.
(4) Highlight highly influential items in different colors or with circles.
P.7
6) Check Sheet
This table is used to check each item.
There are two types of sheets: for one for recording and one for checking.
For recording: To perform the check when data is collected.
For checking: To prevent checked items from being missed.

Item Check Total

Item A

Item B
Item C
Item D

Item E
Item F

Item G
Total

[How to create a check sheet]

(1) Clarify the purpose of data collection.
(2) Determine items to be checked.
(3) Fill in the items checked on the table.

P.8
7) Graph
The term “graph” refers to regular graphs such as bar charts, line charts, pie charts,
and radar charts.
All graphs other than the Pareto chart, histogram, control chart, and scatter plot are
generally referred to as a “graph.”
A graph is a useful tool that makes it easy to grasp data characteristics in all scenarios.
(1) A graph allows for the prompt interpretation and profound understanding of
information..
(2) A graph helps us identify problems. When the detection of the problem is difficult
using numbers only, it becomes easier to identify these issues through the plotting of
the data on a graph.
(3) The contents of a graph is highly appealing and persuasive.
(4) It is possible to generate the interest of third parties.
(5) The use of software makes it easy to create a graph.
(6) A graph can also be utilized as a record.

Characteristics of each type of graph

(1) Line chart: A line chart is used to organize data in chronological order to
comprehend the characteristics of data. Data items include those that change over the
course of time such as quantity and amounts of money.
(Example) To display changes in data such as commodity price, production volume, sales,
and number of defects.

(2) Bar chart: A bar chart is used to observe chronological changes and trends as well
as the size of data. It is also used to compare multiple items.
(Example) To compare the production volume, sales, shipments among companies or
divisions.

(3) Component bar chart: A component bar chart is used to visually display the
breakdown of each item (percentage) and the percentage to other samples.
(Example) To simultaneously compare the numeric values, breakdown, and gross totals
that represent changes in production volume, sales, and shipments for each company or
office.

P.9
Characteristics of each graph
(4) Pie chart: A pie chart is used to visually display the breakdown
(percentage) of each item.
(Example) To simultaneously compare the numeric values, breakdown, and
gross totals that represent changes in production volume ratio, sales ratio,
and shipments for each office.

(5) Radar chart: A radar chart is used to compare data values and
the balance among variables for each sample.
(Example) To plot each indicator data item regarding the 7 Wastes and 3S
that have been obtained through corporate diagnosis on a radar chart in
order to discuss the necessary educational plan.

(6) Weibull probability paper: A Weibull probability paper is used to

statistically analyze the service life of a system or component.
(Example) Plotting data such as downtime makes it easy to obtain shape
parameters, downtime parameters, and the average life.

(7) XY line chart: On an XY line chart, multiple Y-axis data is

plotted for X-axis data. An XY line chart is used to observe the
trend of a group of points within a standard or between standards
regarding a specific value on the X axis.

P.10
 1) Affinity Diagram Method
This method is used to gather a variety of similar opinions and
ideas in order to group, organize, and analyze them.

This method is considered to be effective when a number of items

and elements related to the issue are intricately involved or when
solutions to the issue are confusing.
Dissatisfactory points regarding a
refrigerator (questionnaire survey results)

Structure Cooling
performance
Organization Ease of use
It takes time to
It is difficult to organize the inside of the freezer. It is impossible to see the deep area of the
make ice cubes.
It is difficult to organize the inside of the vegetable top shelf.
drawer. It is difficult to use the egg shelf.
It is difficult to organize the inside of the refrigeration It is difficult to use the door pocket.
compartment. It is difficult to store medium-sized bottles.
It is difficult to organize small items.
Noise
Capacity
There is an operating noise.
The capacity of the vegetable drawer There is a noise when making
is small. ice cubes.
The capacity of the freezer is small.
It is impossible to store pet bottles.
The refrigeration compartment is too
small.

Regarding the refrigerator, users need an optimal

capacity balance as well as an easy-to-use structure that
pays attention to details.

[How to create an affinity diagram]

(1) Fill in various ideas regarding a specific theme on cards, post-it notes,
or other sheets.
(2) Line up cards that you feel that are connected or related based on your
intuition and label the cards.
(3) Repeat the same task within each label and represent information as a
diagram by drawing frame borders or other lines.
(4) Finally, create a sentence while referring to the diagram.
P.11
2) Association Diagram Method
This method is used to clarify an issue that has a cause-and-
effect relationship or a goal and means. It is also used to identify
specific means to achieve a goal. In this method, causes and
results or a goal and means are connected using arrows.

Several members rewrite an association diagram several times. In

this process, this method helps consensus building among
members and allows for perceptional change. Thus, this method is
effective in identifying the point of an issue to open the path to
issue resolution.

There are The price set by

Special There too many the supplier is
materials are too dedicated higher than
are used many parts other
parts companies
There
are too
many Processing
workers and
assembling
times are Material
too long costs are
Acceptance There are too high
standard is too many
too high developers

Salary is
too high Labor Manufacturing
(Average costs are costs are too
age is too high high
high)

[How to create an association diagram]

(1) Fill in as many keywords related to an issue as possible on post-it notes or other
sheets (10 keywords or more).
(2) Group keywords that seem to be related and connect each keyword with lines.
Eliminate unnecessary keywords. P.12
(3) Repeat these procedures until you are fully satisfied.
3) Tree Diagram Method
This method is used to gradually develop a goal and the means to
achieve the goal with the ultimate objective of identifying the
means to achieve the goal.
Create a document that
matches the purpose of the
participation of the audience Appeal to listeners’ benefits

Arrange an easy-to-
Develop a title and table of contents
understand overall structure
and then create a main body
and flow
Create an
Use appropriate diagrams,
appealing
pictures, illustrations, graphs,
document
Adopt graphical and easy-to- charts, and videos, etc.
understand expressions
Produce movement through
appropriate animations and
In order to links
deliver a
successful
presentation Seize listeners’ attention first

Have a dialog with listeners

Ask simple questions
(do not talk unilaterally)

Talk in an Do not always read texts

appealing
manner Talk enthusiastically
Straighten up and talk with
(talking down to listeners is
confidence
strictly prohibited)

Talk in an appropriate voice

and articulate the end of
words

[How to create a tree diagram]

(1) Represent a goal by using the expression “in order to.”
(2) Clarify constraints on the achievement of the goal.
(3) Discuss means for achieving the goal with all members and extract important ideas.
(4) Place the goal in the center left. Then, place means to upper and lower right of the
goal and connect the goal and means with tentative lines.
(5) Consider that the means are goals and describe means for achieving these goals.
(6) Repeat (2)-(5) and extract means through discussion among all members.
(7) All members will review the flow from the goal to means and from means to the goal.
Innovate new means as well as organize and add labels if necessary.

P.13
4) Matrix Diagram Method
This method is used to clarify whether or not there is a
relationship between items or how strong the relationship is using
a two-dimensional table.

For example, this method is used to weigh means that have been
developed through the tree diagram method. It is also used to
determine priority.
Priority
for
Means Effects Feasibility adoption How to level up the priority

Clarification of benefits according to

Appeal to listeners’ benefits
the level or class of listeners

Develop a title and table of contents

and then create a main body

Use appropriate diagrams,

pictures, illustrations, graphs,
charts, and videos, etc.

Produce movement through

appropriate animations and links
Establishment and practice of contents
Seize listeners’ attention first that can successfully seize listeners’
attention and get applause

Ask simple questions

Record and repeatedly practice

Do not always read texts

Straighten up and talk with Video-record and repeatedly practice

confidence

Talk in an appropriate voice

and articulate the end of words

[How to create a matrix diagram]

(1) Place means that have been developed through the tree diagram method on the
vertical axis.
(2) Fill in evaluation items (effects, feasibility, and rank, etc.) on the horizontal axis.
(3) Use evaluation symbols such as ◎,○,△, and× and specify evaluation standards for
each symbol.
(4) Fill in evaluation symbols in the fields at the intersection of the x axis and y axis.
(5) Rate the combinations of each means and evaluation. P.14
5) Arrow Diagram Method
This method is used to understand the project progress or clarify
work schedule problems through the illustration of the sequence
of tasks.

Tasks and the nodes of tasks are represented as circles.

Tasks Days of work Preceding task
Specification formulation
Programming Specification formulation
Manual draft creation Programming
Programming
Pre-test
Manual creation Pre-test
ROM creation Pre-test
Practical test plan creation Pre-test
Practical test Manual creation, ROM creation, practical test plan creation

7 days

2 days 5 days 5 days 1 day 10 days

2 days 2 days

Dummy task
This is used to adjust the progress of tasks.
For example, in this case, even if Task C is completed, the next task cannot be initiated unless Task D is
completed.

[How to create an arrow diagram]

(1) List all task names.
(2) Fill in times required, initiation conditions, and due dates for each task in the list.
(3) Looking at the aforementioned list, describe nodes between tasks as circles. This
circle is referred to as a node or event. Assign an order to each node.
(4) Connect nodes using arrows. This arrow is referred to as a task or activity. Put times
required (days required) in the areas adjacent to arrows.
(5) Clarify the critical path, the timing for initiating a series of tasks, and a key to
maintaining the schedule. The critical path refers to a path which indicates the minimum
time required to complete all tasks. A delay in the progress of tasks on the critical path
will cause a delay in the overall schedule. Therefore, the intensive management of the
critical path is essential.
P.15
6） PDPC Method
This method is used to graphically present all processes for
achieving a goal to identify the best process. In addition, this
method is used to identify problem preventative measures or
appropriate actions after a problem has occurred.
Publish a book

Request book publishing

from a publishing company

Publishing cost is
There is another Cannot maintain Cannot find
too high
similar book motivation a publisher

Review the concept Embody and Consider self- Review the specifications Advertise
of the book confirm every publishing of the book
day the changes
that will happen
Cannot find a concept to myself or The book is not Advertisement
No effect
rewards that will outstanding cost is too high
be given when
the book is
Use an idea published Innovate an Target the customer layer
generation method attractive cover and focus advertisement on
page or title the customer layer

The book is selling well

[How to create a PDPC]

(1) Clarify the initial condition at the start point and the current level.
(2) Determine constraints on the theme.
(3) Set up the start point and goal.
(4) Pick up necessary means and expected situations, place them in the
diagram, and connect them to the final result using arrows.
(5) Discuss the process again, complete a process that can lead to the
most ideal situation, and highlight the process in heavy lines.
(6) If the goal cannot be achieved, discuss the process sequentially from
the start point and add other paths.
(7) Confirm contradictions and actions to contingency situations, and P.16
complete the process diagram.
7) Matrix Data Analysis Method
This method is used to comprehensively grasp the relationship
between 3 or more variables or to clarify the characteristics of
the target using a small number of synthetic values.
Principal component 1 Principal component 2
Principal component 1 Principal component 2
Eigen vector (Horizontal axis) (Vertical axis)
Eigen value
Brightness
Contribution ratio
Contrast ratio
Cumulative contribution
View angle
Response speed
Current market price

19-inch liquid crystal display

Overall performance

Spreadsheet and word processor

Movie

[How to create a matrix]

Due to the complexity of calculation, generally, commercial statistic
software is often used.
(1) Arrange a matrix so that higher values indicate higher levels. For
example, if a shorter time is favorable, convert the value to speed, convert
it to an inverse, or add a minus sign.
(2) Ensure that values do not largely deviate from normal distribution or
there is no outlier.

P.17