TQM tools and techniques

1. UNIT – III
TQM TOOLS
AND
TECHNIQUES I

2. SEVEN TOOLS OF QUALITY
(1) Flow chart
(2) Check sheet,
(3) Histogram,
(4) Pareto chart,
(5) Cause-and-effect diagram,
(6) Scatter diagram,
(7) Control chart

4. Relation between 7 QC tools and PDCA

5. (1) Flowchart

9. (2) Check sheet
 Systematic way of collecting and recording data.
 Also called ‘Tally sheets’.
 Used to indicate frequency of certain occurrence.
 Can be used even by shop floor personnel.
 Facilitate quick decisions from the data collected.
 format is tailored to suit each situation/application.
 Counts are marked as | , || , ||| , |||| and |||| in
groups of five. Totals can be quickly calculated.
 Can be used to analyze types of defects, causes of
defects, nature of complaints, etc.

11. Example: Check sheet for customer complaints.
Nature of complaint Frequency
Delayed delivery |||| || 07
Missing items ||| 03
Damaged items |||| |||| || 12
Invoice errors |||| 04
TOTAL 26

13. (3) Histogram
 Type of bar graph showing frequency distribution.
 Shows the variation in a process.
 Consists of a set of rectangles that represent the
frequency of observed values in each category.
 Range of values (of a variable) is divided into a
number of groups, called class intervals or cells.
 Above is shown on the x-axis while their
frequencies of occurrence are shown on y-axis.
 The width of all cells are equal.

19.  The shape of the histogram can indicate whether the
frequency distribution is normal, skewed, peaked, flat, etc.
 Frequency tables, check sheets can be converted into
histograms.

20. (4) Pareto Diagram

26. (5) Cause and Effect Diagram

31. (3) Scatter Diagram
 Helps to analyze cause-and-effect relationship between two
variables.
 Independent variable is plotted on the x-axis and the
dependent, response variable on the y-axis.
 Data is plotted as a cloud of points.
 Density and the direction of the cloud indicate how the two
variables influence each other.
 Various possibilities being: positive correlation, negative
correlation, no correlation, etc.
 Advantage of scatter diagram is that once the exercise is
carried out, it is possible to extrapolate the results for any
given situation.
 Eg. Level of training vs No. of errors
Equipment age vs No. of breakdowns
Work experience vs No. of accidents

35. (4) Control Charts
‘
 Run chart’ is a chart that plots data pertaining to a
variable or characteristic over time.
 Control chart – type of run chart – used in Statistical
Quality Control (SQC) to monitor the quality of a
process continuously.
 Developed by Walter A. Shewhart in 1924 to identify
common cause & special cause variations in a process.
 Graph consists of three horizontal lines: central line,
Upper Control Limit , & Lower Control Limit.
 Random samples from a process are drawn at specific
intervals, the sample serial number is shown on the x-
axis while the quality characteristic being measured is
plotted on the y-axis.

36. (4) Control Charts
 Central line is set at the mean value while the UCL
and LCL are set at ±3 sigma limits above and below
the mean.
 If all readings fall between the UCL and LCL, the
process is inferred to be in control and if the
readings fall beyond the limits, the process is
deemed to be out of control.
 Various types of control charts are:
X-chart and R-chart (for variables)
p-chart, np-chart, c-chart, and u-chart (for attributes)

39. NEW SEVEN MANAGEMENT TOOLS
(1) Affinity Diagram
(2) Relationship Diagram
(3) Tree Diagram
(4) Matrix Diagram
(5) Matrix Data Analysis
(6) Decision Tree (PDPC)
(7) Arrow Diagram (PERT)

40. Affinity Diagram

43. Relationship Diagram

45. Tree Diagram

49. Matrix Diagram

54. Matrix Data Analysis Diagram

57. Process Decision Programme Chart
/Decision Tree

61. Arrow Diagram

64. Six Sigma

69. Six Sigma Process

76. Six Sigma Organization

77. Advantages of Six Sigma Process

78. B e n c h m a r k i n g

79. Benchmarking

81. Benchmarking

86. Steps in Benchmarking Process

88. Benefits of Benchmarking

89. Failure Mode Effect Analysis
(FMEA)

90. Types of FMEA

92. Benefits of FMEA

93. Stages of FMEA

95. FMEA Procedure