Review on Quality Management using 7 QC Tools

International Journal of Trend in Research and Development, Volume 5(2), ISSN: 2394-9333
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IJTRD | Mar - Apr 2018
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Review on Quality Management using 7 QC Tools
1
Nikunjkumar A. Parmar and 2
Shubham Awasthi,
1,2
Department of Mechanical Engineering, Parul Institute of Technology, Vadodara, India
Abstract—Today’s competitive environment has, lower ma-
nufacturing cost, more productivity in less time, high quality
product, defect free operation are required to follow to every
foundry man. For the improvement of products quality there
are diff-diff quality tools used in various review papers. Here I
am going to review on these papers and identify the different
way of uses of those tools in manufacturing industries to
increase the quality of the product. There are so many defects
in the manufacturing process and these defects directly affects
on productivity, profitability and quality level of organization.
This study is aimed to review the research work made by
several researcher and attempt to get technical solution for the
various defects and to improve the entire process of the
manufacturing.
Keywords— Quality Circle, 7 Quality Control Tools, PDCA,
DMAIC
I. INTRODUCTION
The 7 QC Tools are simple statistical tools used for problem
solving. These tools were either developed in japan or intro-
duced to japan by the Quality Gurus such as Deming and
Juran. In terms of importance, these are the most useful. Kaoru
Ishikawa has stated that these 7 tools can be used to solve 95
percent of all problems. These tools have been the foundation
of Japan's astonishing industrial resurgence after the Second
World War. For solving quality problems seven QC tools used
are Pareto Diagram, Cause & Effect Diagram, Histogram,
Control Charts, Scatter Diagrams, Graphs and Check Sheets.
All this tools are important tools used widely at manufacturing
field to monitor the overall operation and continuous process
improvement. This tools are used to find out root causes and
eliminates them , thus the manufacturing process can be impr-
oved. The modes of defects on production line are investigated
through direct observation on the Production line and
statistical tools.
A. Quality Control tools
1) Pareto Diagram
Pareto Diagram is a tool that arranges items in the order of the
magnitude of their contribution, thereby identifying a few
items exerting maximum influence. This tool is used in SPC
and quality improvement for prioritizing projects for
improvement, prioritizing setting up of corrective action teams
to solve problems, identifying products on which most
complaints are received, identifying the nature of complaints
occurring most often, identifying most frequent causes for
rejections or for other similar purposes. The origin of the tool
lies in the observation by an Italian economist Vilfredo Pareto
that a large portion of wealth was in the hands of a few people.
He observed that such distribution pattern was common in
most fields. Pareto principle also known as the 80/20 rule is
used in the field of materials management for ABC analysis.
20% of the items purchased by a company account for 80% of
the value. These constitute the A items on which maximum
attention is paid. Dr.Juran suggested the use of this principle to
quality control for separating the "vital few" problems from the
"trivial many" now called the "useful many".
2) Cause & Effect Diagram
A Cause-and Effect Diagram is a tool that shows systematic
relationship between a result or a symptom or an effect and its
possible causes. It is an effective tool to systematically
generate ideas about causes for problems and to present these
in a structured form. This tool was devised by Dr. Kouro
Ishikawa and as mentioned earlier is also known as Ishikawa
Diagram.
3) Histogram
Histograms or Frequency Distribution Diagrams are bar charts
showing the distribution pattern of observations grouped in
convenient class intervals and arranged in order of magnitude.
Histograms are useful in studying patterns of distribution and
in drawing conclusions about the process based on the pattern.
4) Control Charts
Variability is inherent in all manufacturing processes. These
variations may be due to two causes:
i. Random / Chance causes (un-preventable).
ii. Assignable causes (preventable).
Control charts were developed by Dr. Walter A. Shewhart
during 1920's while he was with Bell Telephone Laboratories.
These charts separate out assignable causes. Control chart
makes possible the diagnosis and correction of many
productions troubles and brings substantial improvements in
the quality of the products and reduction of spoilage and
rework. It tells us when to leave a process alone as well as
when to take action to correct trouble.
5) Scatter Diagram
When solving a problem or analyzing a situation one needs to
know the relationship between two variables. A relationship
may or may not exist between two variables. If a relationship
exists, it may be positive or negative; it may be strong or weak
and may be simple or complex. A tool to study the relationship
between two variables is known as Scatter Diagram. It consists
of plotting a series of points representing several observations
on a graph in which one variable is on X-axis and the other
variable in on Y-axis. If more than one set of values are
identical, requiring more points at the same spot, a small circle
is drawn around the original dot to indicate second point with
the same values. The way the points lie scattered in the
quadrant gives a good indication of the relationship between
the two variables.
6) Graphs
Graphs of various types are used for pictorial representation of
data. Pictorial representation enables the user or viewer to
quickly grasp the meaning of the data. Different graphical
representations of data are chosen depending on the purpose of

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the analysis and preference of the audience. The different types
of graphs used are as given below:
1. Bar Graph -To compare sizes of data
2. Line Graph- To represent changes of data
3. Gantt chart -To plan and schedule
4. Radar chart -To represent changes in data (before and
after)
5. Band Graph -Same as above
7) Check Sheets
As measurement and collection of data forms the basis for any
analysis, this activity needs to be planned in such a way that
the information collected is both relevant and comprehensive.
Check sheets are tools for collecting data. They are designed
specific to the type of data to be collected. Check sheets aid in
systematic collection of data. Some examples of check sheets
are daily maintenance check sheets, attendance records,
production log books, etc. Data collected using check sheets
needs to be meaningfully classified. Such classification helps
gaining a prelim-nary understanding of relevance and
dispersion of the data so that further analysis can be planned to
obtain a meaningful output. Meaningful classification of data
is called stratification. Stratification may be by group, location,
type, origin, symptom, etc.
7 QC TOOLS THROUGH PDCA-CYCLE:
In successful application of quality tools an implemented
quality management system is an advantage. The quality
management principles are a starting point for the company’s
management striving for continuous efficiency improvement
over a long period of time and customer satisfaction. A quality
management system is based on the integrity of all production
and support resources of a certain company. It enables a
faultless process flow in meeting related contracts, standards
and market quality requirements. Implementation of a quality
management system is always a part of a company’s
development process entification and/or process analysis.
Continuous improvement as a fifth principle of QMS (ISO
9001:2000) could not be realized without quality tools which
are presented through four groups of activities of Deming’s
quality cycle or PDCA-cycle, The PDCA-cycle is an integral
part of process management and is designed to be used as a
dynamic model because one cycle represents one complete
step of improvement. The PDCA-cycle is used to coordinate
continuous improvement efforts. It emphasizes and
demonstrates that improvement programs must start with
careful planning, must result in effective action, and must
move on again to careful planning in a continuous cycle – the
Deming’s quality cycle is never-ending. It is a strategy used to
achieve breakthrough improvements in safety, quality, morale,
delivery cost, and other critical business objectives. The
completion of one cycle continues with the beginning of the
next. A PDCA-cycle consists of four consecutive steps or
phases, as follows:
 Plan - analysis of what needs to be improved by
taking into consideration areas that hold opportunities
for change. Decision on what should be changed.
 Do - implementation of the changes that are decided
on in the Plan step.
 Check - Control and measurement of processes and
products in accordance to changes made in previous
steps and in accordance with policy, goals and
requirements on products. Report on results.
 Act - Adoption or reaction to the changes or running
the PDCA-cycle through again. Keeping
improvement on-going
II. LITERATURE SURVEY
The literature survey consists of ten papers which explain the
flexibility of different Quality tools and its scope. Here, in
survey I am going to review on different Quality tools which
are used in small scale industries. The importance of QC tools
is explained by various authors in this survey.
Jitendra A. Panchiwala [1] presented Brief study and his
understanding about Quality and Productivity improvement in
small scale foundry industry. In this paper he is aimed to
review the research work made by several researchers and an
attempt to get technical solution for minimizing various
casting defects and improve the entire process of casting
manufacturing. he conclude from several research work that
modem method of casting component using various software
and simulation techniques is really a boon for the industrial
sector. To complete globally, foundry men have to move ahead
from the slogan of “satisfying customer” and adopt and
ruinously endeavour for “customer delight”. Meeting
customers’ demands will not be sufficient. requirements will
be to exceeding them through quality and productivity
improvement. After preferring paper he select some of tools
and techniques for future work like SPC are quite expensive to
implement in small scale industries but this method gives
better results than any other techniques. These techniques can
be useful not only to reduce the rejection rate but also in other
various departments in industries like inventory control at
various machines in machine shop to get process variation and
to identify optimum values of parameters etc. many
researchers have conducted experiments to find out the sand
process parameters to get better quality casting. They have
successfully reduced the casting defects considerably up to 6%
by proper selecting techniques and parameters. DoE is the
technique which can be implemented in any processing
industry and in India there are number of small scale industries
which can implement such techniques to improve the yield
which give standard process parameter and increase the
effective capacity of the unit.
Shyam H. Bambharoliya [2] reviews some selected factors to
reducing rejection rate in small scale machining unit using 7
Quality Control Tools. This paper aims to identify the
problems related to different products and probable solutions
based on that problem. Use of 7 QC Tools is best way to
reduce rejection and defect of product after analysing of
manufacturing process. Another advantage is increasing
customer satisfaction by use of 7 QC Tools in today compet-
itive market. Based on application of these tools will increase
the level of standard products which they required as vision of
an organization. After reviewing all research papers different
defects are observed by application of 7 QC tools and
individual solution is given with probable root causes. After
studying all problems related to each research papers
individual solutions are provided as per requirement .based on
that problems effect on production is changed as increase in
productivity or reduction of rejection rats.
Varsha M. Magar [3] investigate in this paper about the
systematic use of 7QC tools. The main aim of this paper is
about to provide an easy introduction of 7 QC tools and to
improve the quality level of manufacturing processes by
applying it. QC tools are the means for collecting data,
analysing data, identifying root causes and measuring the

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results. These tools are related to numerical data processing.
All of these tools together can provide great process tracking
and analysis that can be very helpful for quality improvements.
These tools make quality improvements easier to see,
implement and track. The work shows continuous use of these
tools upgrades the personal characteristics of the people
involved. It enhances their ability to think generate ideas, solve
problems and do proper planning. The development of people
involved. It enhances their ability to think generate ideas, solve
problem and do proper planning. The development of people
improves the internal environment of the organization, which
plays a major role in the total quality culture. Statistical QC is
chiefly concerned in making sure that several procedures and
working arrangements are in place to provide for effective and
efficient statistical processes, to minimize the risk of errors or
weaknesses in procedures or systems or in source material
seven QC tools are most helpful in troubleshooting issues
related to quality. All processes are affected by multiple
factors and therefore statistical QC tools can be applied to any
process. The continuous use of these tools upgrades the
personal characteristics of the people involved. it enhances
their ability to think generate ideas, solve problems and do
proper planning.
Sanjeev Kadian [4] Present the influence of using Lean
Manufacturing Technology to increase the production in
scientific equipment’s manufacturing industry in this paper. In
this case study the scientific equipment’s manufacturing
company employs part of the “seven basic quality control (QC)
tools” to significantly improved the process rejection and
rework. By implementing these quality tools as the problem
solving techniques the rejection rate was reduced from 7.3% to
4% and Rework rate from 20% to 11.33%.the competitive
business in the scientific market has enhanced the company in
this study to provide lower cost quality product. Quality
improvement program had been designed and been
implemented to increase the potential of profit. By improving
the quality, it is also mean to improve the productivity and
lower the rejection rate. The key of quality improvement of
this company is not only focusing an external customer but its
internal customer. The purpose of this study is to improve the
quality of circular 15x lenses used in scientific equipment’s.
the objective of this study is to reduce the rework rate from
20% to 11.33% and rejection rate from 7.3% to 4%. An
improvement action plan had been set up, then the data had
been collected for the 4 weeks from 10 lots and re-examine the
rework and rejection results. The rework has reduced to
11.33% from 20% and rejection has reduced 4% from 7.3%.
from the analysis he find that after removing the various root
cause of rejection and rework, the rejection of lenses is
reduced by 45.20% and rework of lenses is reduced by
43.35%. this also have a positive effect on the productivity of
the lenses as the start of this project the productivity of lens
was noted as:(278/300)x100=92.6%.As after the implement-
ation, the productivity was noted as : (288/300)x100=96%. It
was noted that even a simple QC tools can make significant
improvement to the company.
Mayank Dev Singh [5] in their paper, “Productivity
improvement by using quality control tools- A Case study of
chartered Rubber Product”, have study about the productivity
improvement of the chartered rubber product. They are
following various orthodox customs, improper utilization of
space & inaccurate arrangement of machineries with respect to
one another. Hence they are taking a lot of time for
undertaking various tasks and also more human effort is
required. Thus the help of SLP techniques & with the help of
various quality control tools, the non- value added activities
are eliminated. Thus the productivity has been increased with
reduced human efforts & employees work satisfaction. Here on
the basis of SLP he have studied & analyses the layout &
working process of chartered rubber products. We have
identified the degree of necessity of placing the equipment
close to each with the help of SLP. We tried to eliminate the
wasteful elements from the plant & on the basis of SLP. We
have designed a new plant layout. The new layout on the basis
of SLP reduces about 185.3ft of the distance travelled during
the entire manufacturing process. Hence the entire
manufacturing time gets reduced. Thus the over-all
productivity of the chartered rubber gets increased.
Shantanu kulkarni [6] in their paper, “Quality circle to improve
productivity: A case study in a medium scale alumi-num
coating industry”, have study about the QC concept in a
coating unit which illustrates how the QCs help in improving
the productivity. The factors which are important for the
success of the quality circles were also explained here and the
study can serve as s guide which would be useful for the small
and medium scale industries who are interested in introducing
the quality circles. Here the main objective was to improve the
productivity of the chromating process which is one of the
important processes in the plant. For that they were form one
quality circle of 8 members working in the chromating section
of the plant with 1 manager as a facilitator. After the formation
of the quality circle they are able to identify the problem and
after the brainstorming meeting with the team members and
discussion with the plant head about the various ways to
improve the productivity of the process some areas of
improvement were identified. To select the problem to be
solved 3P analysis was performed. By adopting the “3P
SYSTEM” proprietary priority preferential method, they were
able to classified all category of problems based in their
approach to maintenance and nature of work. Here in first P
they identified five sensible aspects of their work area as the
proprieties of their company. Then in P2 they have been
further prioritized by weight age system and it was observed
that highest cost was being incurred in pre-treatment which
was 67% compared to others. 3P- preference shows
consumption cost of various components of pre-treatment unit.
From the data collection they were able to identified that the
gas consumption maximum in all sensible groups. Now they
were move towards the next step which is to reduce the gas
consumption for that they are making action plan. A solution
of putting a solar heater was proposed and implemented
through the quality circle. The various steps for the
implementation of the quality circle were followed around
38% of saving and hence increase in the productivity was
achieved by the implemented modification.
Sulaman Muhammad[7] in their paper, “Quality Improvement
of Fan Manufacturing Industry by using basic seven tools of
Quality: A Case Study” investigate about total five type of
defect occurring in fan manufacturing process of “Fecto Fan
Company”. Who are specialized in manufacturing all type of
ceiling Fans. There were two sections in plant, manufacturing
and assembling. After identifying the problems now the goal
was to eliminate all these problems and to ensure flawless
manufacturing process. For this purpose basic seven tools of
quality were implemented. Tools were implemented through
DMAIC methodology. Every tool was used in different step of
DMAIC methodology for better results. This better result was
get because of managerial staff of the company who removes
these defects from the manufacturing process. After the
removal of defects from manufacturing process control chart

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was implemented to make it sure that process is now under
control. At the last author of this paper was Strengthen the
famous statement of quality guru Dr. Ishikawa that “95% of
quality related industrial problems can be solved simply by
applying seven basic tools of quality”
Shantanu Welekar [8] in their paper, “Quality Circle to
improve Productivity”, deals with various aspects of Quality
Circle and how improvement can be made by adopting
practices of Quality Circle in chemical industries. The paper
also presents a comparative discussion of various features of
Quality Circle, Quality Improvement Group and work
Group/project team. The paper describes a case study of QC
concept in a chemical industry which illustrates the
effectiveness of QC approach. Here Alka industry
manufactures anodizing of aluminum products and powder
coating of GI and CI sheets. In Alka industry Implementation
of Quality Circle led to identification of excessive gas
consumption in the furnaces due to reasons attributed to
deficiency in man, material, method and machine. Each
deficiency was handled separately and corrective measures are
implemented to optimize the gas Consumption in the plant.
CONCLUSION Quality Circle technique proved to be very
effective for the problem selected by the quality circle
members for the powder coating industry. Optimization of gas
consumption in the furnaces led to reduction in maintenance
costs, enhancement in reliability and availability of the
equipment, enhancement in morale and development of a sense
of team dynamics among the employees, which proved to be
beneficial to the employees and the organization as a whole.
Dr. Mahesh M. Bhagwati [9] in their paper, “Cause & Effect
Analysis for the Productivity improvement of TORNOS Sigma
20II : A Case Study” the issue of low productivity of
TORNOS 20II w.r.t another mentioned products is deal with.in
this case study investigated table describes the recommended
and actual rate of production. All the major possible causes
contributing to the high rate of rejection, as mentioned in case
study are found and discussed with the management of an
organization. As a part of First phase of implementation, check
sheets have been designed and data has been collected. As a
part of proposed work, it is decided to collect data of 25 groups
each having 4 parts and carry out the Pareto analysis to
determine the critical dimension. Further construct the control
charts and determine the process capability to check whether
the process is in control or not. If the process is not in control,
then the assignable causes need to be tackled referring the
Cause & Effect Diagram & if it is in control then natural
causes need to be focused so that the process will not only be
in control but would also be centered and this process to be
conducted on regular basis so that it leads to continuous
improvement which ultimately results in improved
productivity.
Ghazi Abu Taher [10], in their paper “Improving Quality and
Productivity in Manufacturing process by using Quality
Control chart and Statistical Process Control Including
Sampling and Six Sigma.” Investigate about to increase the
quality and productivity of a spur gear manufacturing
company. In this case study the main aims to find out the
effective way of improving the quality and productivity of a
production line in manufacturing industry. The objective is to
identify the defect of the company and create a better solution
to improve the production line performance. For that data of
the selected assembly line factory are collected, studied and
analyzed. The defect with the highest frequency will be the
main target to be improved. various causes of the defect will
be analyzed and various solving methods will be present. The
best solving method will be chosen and proposed to the
company and compared to the previous result and production.
There are several approaches to choose from when the goal is
to increase the quality and productivity of a spur gear
manufacturing company. The techniques used in this paper
have been limited due to insufficient time and resources. In
this paper only the quality tools have been used and tried to
find the most effective way of quality testing and improving
productivity. These have given a better solution. But if any one
uses other technique of industrial engineering then he will get
more benefit than this paper. If it is decided to use the data in
future studies it would be interesting .By this way it may be
possible to specify high quality and productivity. The quest for
higher quality and productivity will never stop and the project
extreme spur gear manufacturing will proceed. An important
suggestion for future work is to test if the findings are
applicable to other products and machines within the factory.
A deeper understanding could possibly make the conclusions
from this study more understandable and easier to apply to
other products.
Acknowledgment
I would like to present thanks to my college/institute guide Mr.
Shubham Awasthi and my internal guide Mr.Keyur Mewada
even my colleagues.
CONCLUSION
These following conclusion were derived from the review of
above mentioned papers.
1. 7 All majority industries are use Quality Circle Tools
beca-use they are very simple and easy to use.
2. By reducing rework and rejection rate using 7 Quality
control tools we are able to improve the Quality.
3. Reduction in rejection is indirectly improving both
prod-uctivity and profitability of the organization.
4. 7 Quality control tools have shown more better results
in quality improvement as referred many use studies.
References
[1] Jitendra A.Panchiwala,“Review On Quality And Productivity
Improvement In Small Scale Foundry Industry”, “Vol – 4,Issue-2015
(Ijirset)”
[2] Shyam H. Bambharoliya, “Reducing Rejection Rate In Small Scale
Machining Unit Using 7 Quality Control Tools - A Review”, “Vol- 3,
Issue – 4, 2015( Ije-Dr)”
[3] Varsha M. Magar, “Application Of 7 Quality Control (7 Qc) Tools For
Continuous Improvement Of Man-Ufacturing Processes”, “ Vol -2,
Issue- 4, June -2014 (Ijeres)”
[4] Sanjeev Kadian ,“Increase Production In Small Scale Industry Of India
By Use Of Lean Manufacturing Technology”, “ Vol -3, Issue -4 , April
2015(Iijme)”
[5] Mayank Dev Singh, “Productivity Improvement By Using Quality
Control Tools- A Case Study Of Chartered Rubber Product”, “Vol -12,
Issue -1,Feb-2015 (Iosr-Jmce)”
[6] Shantanu Kulkarni, “Quality Circle To Improve Productivity: A Case
Study In A Medium Scale Aluminum Coating Industry”, “Vol – 8,
Issue-12,Dec-2017 (Ijmet)”
[7] Sulaman Muhammad, “Quality Improvement Of Fan Manufacturing
Industry By Using Basic Seven Tools Of Quality: A Case Study”, “Vol -
5, Issue-2,April-2015 (Ijera)”
[8] Dr. Mahesh M. Bhagwati [9] In Their Paper, “ Cause & Effect Analysis
For The Productivity Improvement Of Tornos Sigma 20ii : A Case
Study” , “ Vol – 3, Issue -11, April 2013 (Itera)”
[9] Shantanu Welekar [8] In Their Paper, “Quality Circle To Improve
Productivity”, “Vol -4,Issue -11 ,Nov 201 4 (Ijetae)”
[10]Ghazi Abu Taher [10], In Their Paper “Improving Quality And
Productivity In Manufacturing Process By Using Quality Control Chart
And Statistical Process Control Including Sampling And Six Sigma.” , “
Vol -14, Issue -3 ,2014(Gjre)”

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