The document discusses the seven traditional tools of quality: flow chart, check sheet, histogram, Pareto diagram, cause and effect diagram, scatter diagram, and control chart. It provides details on the purpose, construction, and use of each tool. The flow chart is used to depict process steps, the check sheet is used for systematic data gathering, the histogram displays frequency distributions, and the Pareto diagram identifies vital causes of quality loss. The cause and effect diagram analyzes potential problems, the scatter diagram depicts relationships between variables, and the control chart identifies process variations.

1. GE 6757 TOTAL QUALITY
MANAGEMENT
FACULTY
F.JUSTIN DHIRAVIAM
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
1

2. UNIT3
7 TRADITIONAL TOOLS OF QUALITY

3. 7 TRADITIONAL TOOLS OF QUALITY
• THESE TOOLS ARE CALLED AS “BASIC TOOLS” BECAUSE THEY
CAN BE USED BY PEOPLE WITH LITTLE FORMAL TRAINING.
• FLOW CHART ARE ALSO KNOWN AS STRATIFICATION OR RUN
CHART.
• STRATIFICATION IS A TECHNIQUE THAT SEPARATES DATA
GATHERED FROM A VARIETY OF SOURCES SO THAT PATTERNS CAN
BE SEEN.
• STRATIFICATION IS ONE OF THE ORIGINAL 7 TOOLS OF QUALITY.
• A RUN GRAPH IS A GRAPH THAT DISPLAYS OBSERVED DATA IN A
TIME SEQUENCE.

4. 7 TRADITIONAL TOOLS OF QUALITY
Statistical Tools Purpose
1 Flow Chart For depicting the essential steps of a
process by using standard symbols.
2 Check Sheet For a systematic data gathering by
tabulating the frequency of occurrence.
3 Histogram For graphically displaying the frequency
distribution of the numerical data.
4 Pareto Diagram For identifying the vital few causes that
account for a dominant share of quality
loss.
5 Cause & Effect
Diagram
For identifying and analyzing the
potential cause of a given problem.
6 Scatter Diagram For depicting the relationship between
two variables.
7 Control Chart For identifying process variations and
signaling corrective action to be taken.

5. RELATIONSHIP B/W 7 TOOLS & PDCA
S.N Q-7 Tools Plan Do Check Act
1 Flow Chart yes yes yes yes
2 Check Sheet yes yes
3 Histogram yes yes yes
4 Pareto Diagram yes yes yes
5 Cause & Effect
Diagram
yes yes yes
6 Scatter Diagram yes yes
7 Control Chart yes yes

6. FLOW CHART
• ALSO KNOWN AS PROCESS FLOW CHART, FLOW DIAGRAM
AND PROCESS DEPLOYMENT FLOW.
• IS A DIAGRAMMATIC VIEW OF THE VARIOUS STEPS IN
SEQUENTIAL ORDER THAT FORM AN OVERALL PROCESS IN
AN ORGANIZATION.
• USED IN THE QUALITY MANAGEMENT FOR DEPICTING THE
STEPS OF A PROCESS IS AN EASILY UNDERSTANDABLE FORM
BY USING STANDARD SYMBOLS.
• FLOW CHART IS A SIMPLE MAPPING TOOL.
• IS USED TO DOCUMENT AND ANALYZE THE CONNECTION
AND SEQUENCE OF EVENTS IN A PROCESS.
• USED TO CREATE AN INTEGRATED UNDERSTANDING OF
THE ACTIVITIES AND ITS RELATIONSHIP.

7. STANDARD SYMBOLS FOR CONSTRUCTING FLOW
CHART
S.No Symbol Name Meaning
1 Terminator For indicating the start
or end of the flow
process chart
2 Action (Rectangle) For indicating a
process or activity or
task or operation
3 Decision (Diamond) For indicating a
decision
4 Arrows For indicating the
direction of flow of the
process
5 Link For indicating a link to
another page or
another flow chart

8. STEPS INVOLVED IN CONSTRUCTION
1. DECIDE ON THE PROCESS TO BE INVESTIGATED
2. DEFINE THE START, END AND THE BORDERS OF THE
PROCESS.
3. LIST THE STEPS IN THE PROCESS BY DETERMINING
THE ACTIVITIES DECISIONS INPUTS AND OUTPUTS
OF THE PROCESS.
4. DRAW THE CHART PLACING THE PROCESS STEPS IN
THE ORDER OF THEIR SEQUENCING USING THE
STANDARD SYMBOLS.
5. COMPARE THE FLOW CHART WITH THE ACTUAL
PROCESS.

11. CHECK SHEET (DATA COLLECTION SHEET)
 A CHECK SHEET ALSO KNOWN AS TALLY SHEET
 IS A FORM FOR SYSTEMATIC DATA GATHERING AND
REGISTERING TO GET CLEAR VIEW OF THE FACTS.
 USED TO KEEP TRACK OF HOW OFTEN SOMETHING
OCCURS.
 FORM OF CHECK SHEET IS TAILORED FOR EACH
SITUATION/APPLICATION.
 USED TO INDICATE THE FREQUENCY OF A CERTAIN
OCCURRENCES.

12. CONSTRUCTION
1. FORMULATE THE OBJECTIVE FOR COLLECTING
DATA.
2. DECIDE WHICH DATA IS NECESSARY.
3. DETERMINE WHO AND HOW DATA WILL BE
ANALYSED.
4. DRAW A FORMAT TO RECORD DATA
5. COLLECT AND RECORD DATA PROBLEM WISE BY
PUTTING TALLY LINES
6. START COUNTING
7. MARK ON THE LIST THE TOTAL NUMBER OF FACTS
WHICH WERE NOTICED.

13. CHECK SHEET

15. TYPES OF CHECK SHEETS
1. PROCESS DISTRIBUTION CHECK SHEET – USED TO
COLLECT PROCESS VARIABILITY.
2. DEFECTIVE ITEM CHECK SHEET – USED TO SPECIFY THE
VARIETY OF DEFECTS OCCURRING WITH THEIR
FREQUENCY OF OCCURANCE
3. DEFECT LOCATION CHECK SHEET – USED TO IDENTIFY
WHERE DEFECTS OCCUR ON THE PRODUCT
4. DEFECT FACTOR CHECK SHEET – USED TO MONITOR THE
INPUT PARAMETER IN A PROCESS THAT MIGHT AFFECT
THE INCIDENTS OF DEFECTS

16. HISTOGRAM
• HISTOGRAM IS BAR CHART/DIAGRAM SHOWING A
DISTRIBUTION OF VARIABLE QUANTITIES OR
CHARACTERISTICS.
• GRAPHICAL DISPLAY OF THE FREQUENCY
DISTRIBUTION OF THE NUMERICAL DATA.
• DATAARE DISPLAYED AS A SERIES OF RECTANGLES
OF EQUAL WIDTH AND VARYING HEIGHTS.

19. USE
• USED TO SHOW CLEARLY WHERE THE MOST
FREQUENTLY OCCURRING VALUES ARE LOCATED AND
THE DATA IS DISTRIBUTED.
• ALSO A TOOL FOR DETERMINING THE MAXIMUM
PROCESS RESULTS
• ENABLES THE ANALYST TO QUICKLY VISUALIZE THE
FEATURES OF A COMPLETE SET OF DATA.

20. CONSTRUCTION
1. AFTER DATA COLLECTION COUNT THE NUMBER OF DATA
VALUES COLLECTED.
2. DETERMINE THE RANGE OF THE DATA
RANGE = HIGHEST VALUE – LOWEST VALUE
3. DIVIDE THE DATA VALUES IN GROUPS OR CLASSES AND
COUNT THE NUMBER OF VALUES IN EACH CLASS.
4. DETERMINE THE WIDTH OF THE CLASS
WIDTH OF THE CLASS = RANGE / NO. OF CLASS
5. DRAW A FREQUENCY TABLE FOR ALL VALUES.
6. CONSTRUCT A HISTOGRAM BASED ON THE FREQUENCY TABLE.
MARK CLASS LIMITS ON HORIZONTALAXIS AND FREQUENCY
ON VERTICAL AXIS.
7. FINALLY WRITE TITLE AND NUMBER OF VALUES ON THE
DIAGRAM

21. PARETO DIAGRAM
• PARETO DIAGRAM IS A DIAGNOSTIC TOOL
COMMONLY USED FOR SEPARATING THE VITAL FEW
CAUSES THAT ACCOUNT FOR A DOMINANT SHARE OF
QUALITY LOSS.
• TOOL USED TO SINGLE OUT THE ‘VITAL FEW’ FROM
THE ‘TRIVIAL MANY’.
• ALSO CALLED AS 80/20 RULE AND AS ABC ANALYSIS.
• IT MEANS ONLY 20% OF PROBLEMS ACCOUNT FOR 80%
OF THE EFFECTS.

22. CONSTRUCTION
1. OBTAIN DATA USING A CHECK SHEET OR
BRAINSTORM.
2. ARRANGE THE DATA IN DESCENDING ORDER
STARTING FROM LARGEST CATEGORY TO
SMALLEST.
3. CALCULATE THE TOTAL AND % OF TOTAL THAT
EACH CATEGORY REPRESENTS.
4. COMPUTE THE CUMULATIVE %
5. DRAW BAR CHART
6. PLOT CUMULATIVE % LINE.

23. PARETO ANALYSIS

24. PARETO ANALYSIS

25. PARETO ANALYSIS

26. CAUSE & EFFECT DIAGRAM
• IT IS A GRAPHICAL TABULAR CHART TO LIST AND
ANALYSE THE POTENTIAL CAUSES OF A GIVEN
PROBLEM.
• ALSO CALLED AS FISH BONE DIAGRAM OR ISHIKAWA
DIAGRAM.

27. USE
• SEVERAL APPLICATION IN RESEARCH,
MANUFACTURING, MARKETING, OFFICE OPERATIONS,
SERVICES ETC..
• TO ANALYZE CAUSE & EFFECT RELATIONSHIPS
• TO FACILITATE THE SEARCH FOR SOLUTIONS OF
RELATED PROBLEMS.
• TO STANDARDIZE EXISTING AND PROPOSED
OPERATIONS.
• TO EDUCATE AND TRAIN PERSONNEL IN DECISION
MAKING AND CORRECTIVE ACTION ACTIVITIES.

28. CONSTRUCTION
1. DEFINE THE EFFECT CLEARLY & CONCISELY.
2. MARK THE SHORT DESCRIPTION OF THE EFFECT IN
A BOX. THEN DRAW A LINE FROM THIS BOX
TOWARDS LEFT.
3. LIST DOWN ALL POSSIBLE MINOR & MAJOR CAUSES
THROUGH BRAINSTORMING SESSION.
4. MARK THE MAJOR CAUSES ON THE BRANCHES AND
MINOR CAUSES ON THE SUB-BRANCHES
5. LOOK FOR POSSIBLE SOLUTIONS FOR THESE
CAUSES
6. INTRODUCE THE CHANGE.

29. CAUSE & EFFECT DIAGRAM

30. CAUSE & EFFECT DIAGRAM

31. SCATTER DIAGRAM
• SCATTER DIAGRAM IS A SIMPLE GRAPHICAL DEVICE TO
DEPICT THE RELATIONSHIP BETWEEN TWO VARIABLES.
• GRAPHICAL COMPONENT OF REGRESSION ANALYSIS.
• A SCATTER DIAGRAM CONSISTS OF HORIZONTAL AXIS
CONTAINING THE MEASURED VALUES OF ONE VARIABLE
(CAUSE)
• VERTICAL AXIS REPRESENTING THE MEASUREMENTS OF
THE VARIABLES (EFFECT).
• THE DENSITY AND DIRECTION OF THE CLOUD INDICATE
HOW THE TWO VARIABLES INFLUENCE EACH OTHER.
• THIS DIAGRAM CANNOT PROVE THAT ONE VARIABLE
CAUSES THE OTHER BUT THEY INDICATE THE EXISTENCE OF
RELATIONSHIP

32. CONSTRUCTION

33. SCATTER DIAGRAM

34. SCATTER DIAGRAM

35. SCATTER DIAGRAM

36. CONTROL CHART
• MOST WIDELY USED TOOL IN SPC.
• IS A GRAPH THAT DISPLAYS DATA TAKEN OVER TIME
AND THE VARIATIONS OF THIS DATA.
• CAN BE USED TO CHECK WHETHER THE PROCESS IS
BEING CONTROLLED STATISTICALLY.
• HISTOGRAM GIVES A STATIC PICTURE OF PROCESS
VARIABILITY WHEREAS CONTROL CHART GIVES THE
DYNAMIC PERFORMANCES.

37. CONTROL CHART

38. TYPES OF CONTROL CHARTS
1. CONTROL CHARTS FOR VARIABLES:
TIME, LENGTH, TEMPERATURE, PRESSURE ETC..
1. CONTROL CHARTS FOR ATTRIBUTES
NO. OF DEFECTS, TYPING ERRORS ETC…