The document discusses quality control tools used for problem solving. It introduces 7 statistical quality control tools - stratification, Pareto diagram, cause and effect diagram, check sheet, control chart, histogram, and scatter diagram. It provides examples and explanations of how to use Why-Why analysis and What-If analysis as problem solving tools. The document also discusses stratification, Pareto diagrams, and cause and effect diagrams in more detail, explaining their purpose and how they are used to analyze problems and identify countermeasures.

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Problem Solving
Tools
Training module
on

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What are 7 QC Tools ?
QC tools are the means for Colleting data ,
analyzing data , identifying root causes and
measuring the results.
THESE TOOLS ARE RELATED TO Numerical
DATA processing
USER HAS TO ARRIVE AT THE
SOLUTION & IMPLEMENT

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Problem Solving Tools
1.1 Why -Why Analysis
1.2 What If Analysis
1. Simple Tools for Problem Analysis
2 Simple 7 QC Tools (Statistical Tools)
•Stratification
•Pareto Diagram
•Cause and Effect Diagram
•Check Sheet
•Control Chart/Graph
•Histogram
•Scatter Diagram

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Problem Solving Tools
What is a “Problem “?
“Problem is an undesirable event” or ..
Any Gap between what is expected and what is obtained ,
can be called as a Problem, and any effort to reduce this gap can
be called as “Problem Solving”
Expected
Obtained
(Gap ?) A Problem!

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Problem Solving Tools
Symptoms and the Root Causes
An undesirable end result is only a starting point
or Symptom.
Example: When an equipment breaks down , It is an end
result or a Symptom of a Problem.
The abnormalities present in the responsible factors , are
referred to as root cause(s) of the problem.

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Problem Solving Tools Four types of Problems

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Problem Solving Tools
Why - Why analysis - An Example
Purpose : It is the simple tool used by the team
/observer to find out the cause of the
problem/Accident/ Breakdown at the Workplace.
Many times, the root cause of the problem can be identified by
asking Why 5 times and the repetition of such problems can be
prevented by taking countermeasure immediately.

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Water Dripping in Substation 1
WHY ?
WHY ?
WHY ?
WHY ?
Water accumulated at the roof
Outlet drain chocked
Atmospheric dust & dirt
Periodic cleaning of drain not done
Action
Proper scheduled procedure for roof cleaning is to be prepared
Problem Solving Tools
Why - Why analysis - An Example

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PROBLEM : Right hand fingers got seriously
injured
While fitting feed roller spiked rings, his
RH fingers got pressed with the F/Roller
WHY WHY ANALYSIS ( ACCIDENT )
JANUARY’2001
LOCATION :- WOOL COMBING ACCIDENT OCCURRED
TO SRI K.N.PAUL
WHY ?
Problem Solving Tools
Why - Why analysis - Example-2

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Since the job was being done for the first time, proper fastening
device suitable for the spiked feed roller could not be designed
Development of suitable fastening device being contemplated and to
be adopted for a repetitive jobs
The F/R shaft was lifted from the m/c & placed about 2 ft.high from
the floor by means of a chain-pulley block & a supporting device.
Suddenly the belt fastener got slipped off causing the feed roller to
fall down
WHY ?
WHY ?
ACTION
Problem Solving Tools
Why - Why analysis - Example-2(Contd..)

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Problem Solving Tools
What-If Analysis
Purpose : It is the simple Pro active tool used by the
team / observer, to identify problems before hand and take
appropriate counter measures to prevent such problems .

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Problem Solving Tools
What-If Analysis - An Example
SL. What If Results Countermeasures
Area : Equipment :Compressor
Team :
There is no Water in
the Radiator of an
Automobile ? And it
is not noticed.
The Engine heats
up and Piston may
get seized.
• Inspect the
Temperature of
outlet water .
• Provide the temp.
Indictor for the
driver
1.

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1.Pareto Diagram
a). What is Pareto diagram ?
A Pareto diagram is a combination of bar and line graphs of accumulated
data, where data associated with a problem (e.g., a defect found,
mechanical failure, or a complaint from a customer) are divided into
smaller groups by cause or by phenomenon and sorted, for example, by
the number of occurrences or the amount of money involved. (The name
“Pareto” came from an Italian mathematician who created the diagram.)

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1.Pareto Diagram
b). When is it used and what results will be obtained?
Please refer to the table on next slide for the usage and benefits of a
Pareto diagram. It is mainly used to prioritize matters, and because
of its easiness of use, the diagram is used in a wide variety of fields.

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Pareto DiagramPareto Diagram
(No. of Occurrences)
Pareto DiagramPareto Diagram
(No. of Occurrences)
Used to prioritize
actions.(Used during phases
to monitor the situation,
analyze causes, and review
effectiveness of an action.)
Used to identify and prioritize a
problem.
Used to review the effects of an
action taken.
Allows clarification of
important tasks.
Allows identification of a
starting point (which task
to start with).
Allows projection of the
effects of a measure to be
taken
Method Usage Result
Pareto Diagram

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Pareto Diagram
To identify a course of action to
be emphasized
using a variety of data.
Example
Assessment using Pareto
diagram (prioritization)
Confirmation of Effect
(Comparison)
Details of “ A”
Frequently used to check
the effect of an
improvement.
Improved

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2.Cause & Effect Diagram
a). What is Cause & effect Diagram ?
A cause and effect diagram is “a fish-bone diagram that presents a
systematic representation of the relationship between the effect (result)
and affecting factors (causes).”
Solving a problem in a scientific manner requires clarification of a cause
and effect relationship, where the effect (e.g., the result of work) varies
according to factors (e.g., facilities and machines used, method of work,
workers, and materials and parts used). To obtain a good work result, we
must identify the effects of various factors and develop measures to
improve the result accordingly.

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2.Cause & Effect Diagram
b). When is it used and what results will be obtained?
A cause and effect diagram is mainly used to study the cause of a certain
matter. As mentioned above, the use of a cause and effect diagram allows
clarification of causal relation for efficient problem solving. It is also
effective in assessing measures developed and can be applied to other
fields according to your needs.

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Cause & Effect Diagram
Can obtain a clear overall
picture of causal relation.
(A change in the cause
triggers a variation in the
result.)○ Can clarify the
cause and effect
relationship.
Can list up all causes to
identify important causes.
Can determine the
direction of action
(countermeasure).
Method Usage Result
Used when clarifying
a cause and effect
relationship.[Used
during a phase to
analyze causes.]
 Used to develop
countermeasures.
[Used during a phase to plan
countermeasures.]
Material Method
ManMachine
Cause (4M’s) Result
(Controlled State)
EffectCause and EffectCause and Effect
DiagramDiagram
Material Method
ManMachine
Cause (4M’s) Result
(Controlled State)
EffectCause and EffectCause and Effect
DiagramDiagram

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Cause & Effect Diagram
Mechanism of
Copying Machine
Quality of
Copying Paper
User Surrounding
Environment
Smudges on the
copied surface
Internal devices not
working smoothly
Malfunction of
the roller
Printing too
lightly
Too thin
Folded
Running out
of stock
Dampened
Keyboard handling
error
Error in selecting a
scale of reduction
Error in
placement of
paper (setting
its face up)
Error in
selecting
shading
Deterioration of
performance due
to high
temperatures
Nicotine-
stained
Dirt on the
glass
surface
Dust
ManyCopyingErrors!
Mechanism of
Copying Machine
Quality of
Copying Paper
User Surrounding
Environment
Smudges on the
copied surface
Internal devices not
working smoothly
Malfunction of
the roller
Printing too
lightly
Too thin
Folded
Running out
of stock
Dampened
Keyboard handling
error
Error in selecting a
scale of reduction
Error in
placement of
paper (setting
its face up)
Error in
selecting
shading
Deterioration of
performance due
to high
temperatures
Nicotine -
stained
Dirt on the
glass
surface
Dust
ManyCopyingErrors!

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3.Stratification
a). What is Stratification ?
Stratification means to “divide the whole into smaller portions according
to certain criteria.” In case of quality control, stratification generally
means to divide data into several groups according to common factors or
tendencies (e.g., type of defect and cause of defect).
Dividing into groups “fosters understanding of a situation.” This
represents the basic principle of quality control.

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3.Stratification
b). When is it used and what results will be obtained?
The “common and basic principle” of quality control is
stratification, i.e., to think a matter out by breaking it into smaller
portions. Stratification has a number of useful purposes. The
table below shows only a few examples of these purposes.

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Stratification
Method Usage Result
Grouping by day,
time, place, worker,
or process
X
Y
Z
Number of Units
★★★★★★★
△△△△
○○○
•Used to observe variations
among strata.
•Used to identify the
relationship between cause and
effect.
•Used to identify a purpose and
means to serve the purpose
[Used during phases to monitor the
situation, analyze causes, review
effectiveness of an action, perform
standardization, and implement a
selected control measure.]
•Allows observation of
variations among
strata.
•By performing a cause
analysis using the
stratified data, the
following can be
accomplished.
1.Identification and control of a
problem
2.“Division of data (obtained by
using each QC tool) into several
groups”

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Stratification
Item Method of Stratification
Elapse of time
Hour, a.m., p.m., immediately after start of work, shift,
daytime, nighttime, day, week, month
Variations among workers
Worker, age, male, female, years of experience, shift,
team, newly employed, experienced worker
Variations among work
methods
Processing method, work method, working conditions
(temperature, pressure, and speed), temperature
Variations among
measurement/inspection
methods
Measurement tool, person performing measurement,
method of measurement, inspector, sampling, place of
inspection

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4.Check Sheet
a). What is Check sheet ?
A check sheet is “a sheet designed in advance to allow easy collection and
aggregation of data.” By just entering check marks on a check sheet, data
can be collected to extract necessary information, or a thorough inspection
can be performed in an efficient manner, eliminating a possibility of
skipping any of the required inspection items.
A check sheet is also effective in performing stratification
(categorization).

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4.Check Sheet
b). When is it used and what results will be obtained?
Please refer to the table on next slide for the usage and benefits of a
check sheet. It is frequently used in daily business operations, often not
specifically for QC purposes.

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Check Sheet
Ensures collection of
required data.
Allows a thorough
inspection of all check
items.
Can understand
tendencies and variations.
Can record required data.
Method Usage Result
Check SheetCheck Sheet
Day
Process
Process 1
Process 2
Process 3
Check SheetCheck Sheet
Day
Process
Process 1
Process 2
Process 3
Used to collect data.
Used when
performing a thorough
inspection.
Used during phases to monitor the
situation, analyze causes, review
effectiveness of an action, perform
standardization, and implement a
selected control measure

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Check Sheet
A check sheet used to identify defects
Date
Defect
Vertical Scratch
Scratch
Dent
Total
Date
Defect
Vertical Scratch
Scratch
Dent
Total

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5.Control Chart (Control Chart / Graph 1)
a). What is Control Chart ?
A control chart is used to examine a process to see if it is stable or to
maintain the stability of a process.
This method is often used to analyze a process. To do so, a chart is
created from data collected for a certain period of time, and dots plotted
on the chart are examined to see how they are distributed or if they are
within the established control limit. After some actions are taken to
control and standardize various factors, this method is also used to
examine if a process is stabilized by these actions, and if so, to keep the
process in a stable state.

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b). When is it used and what results will be obtained?
There are two types of control charts: one used for managerial purposes
and the other for analytical purposes. A control chart is used to identify
dots that are outside the control limit, which indicate some anomalies in
a process. In addition, seven consecutive dots showing values that are
below or above the mean (central) value, or an increasing or a
decreasing trend represented by seven consecutive dots also indicate
“a problem in a process.”
We need to examine what has caused such a tendency.
5.Control Chart (Control Chart / Graph 1)

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Method Usage Result
Control Chart
Control ChartControl Chart
x-R Control Chart
Control ChartControl Chart
x-R Control Chart
[Used during phases to
monitor the situation,
analyze causes, review
effectiveness of an action,
perform standardization,
and implement a selected
control measure
Used to observe a
change caused by
elapse of time.
In the example “x bar ” -R control
chart, “X bar” represents the
central value, while “R” indicates
the range.
Can identify a change
caused by elapse of time.
Can judge the process if
it is in its normal state or
there are some
anomalies by examining
the dots plotted on the
chart.
Control Chart for Managerial Purposes: Extends the line indicating the control limit used for
analytical purposes to plot data obtained daily to keep a process in a good state.
Control Chart for Analytical Purposes: Examines a process if it is in a controlled state by
collecting data for a certain period of time. If the process is not controlled, a survey is performed
to identify its cause and develop countermeasures.

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Control Chart

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5.Graph
a). What is Graph ?
A graph is “a graphical representation of data, which allows a person
to understand the meaning of these data at a glance.” Unprocessed
data simply represent a list of numbers, and finding certain tendencies
or magnitude of situation from these numbers is difficult, sometimes
resulting in an interpretational error. A graph is a effective means to
monitor or judge the situation, allowing quick and precise
understanding of the current or actual situation.
A graph is a visual and summarized representation of data that need to
be quickly and precisely conveyed to others.

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5.Graph
b). When is it used and what results will be obtained?
A graph, although it is listed as one of the QC tools, is commonly
used in our daily life and is the most familiar means of assessing
a situation.

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Graph
Method Usage Result
0
20
40
60
80
100
120
1st Qtr 2nd Qtr 3rd Qtr 4th Qtr
East
1st Qtr
13%
2nd Qtr
17%
3rd Qtr
57%
4th Qtr
13%
Changes in a time-sequential
order – line graph
Amounts – bar graph, etc.
Ratios – pie graph, band chart,
etc.
(The items listed above are
representative examples.)
Can observe changes in a
time-sequential order,
ratios, and amounts.
A graph is the most
frequently used tool to
examine the various
matters such as those listed
on the left.

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Sales
Sales
Office
Iwate Tokyo Osaka Shizuoka
[Bar Graph of Sales]
・ Survey Period: Dec. 1999
・ Prepared by: M/T
[Band Chart of Expenses]
(¥ million)
Before
Taking
Actions
After
Taking
Actions
ChemicalsChemicals
(430)(430)
ChemicalsChemicals
(240)(240)
OilsOils
(200)(200)
OilsOils
(150)(150)
ElectricityElectricity
(170)(170)
ElectricityElectricity
(108)(108)
(Total: ¥8 million)
(Total: ¥4.95 million)
Sales
million)
Sales
Office
A B C D
[Bar Graph of Sales]
・ Survey Period: Dec. 1999
・ Prepared by: M/T
[Band Chart of Expenses]
million)
Before
Taking
Actions
After
Taking
Actions
ChemicalsChemicals
(430)(430)
ChemicalsChemicals
(240)(240)
OilsOils
(200)(200)
OilsOils
(150)(150)
ElectricityElectricity
(170)(170)
ElectricityElectricity
(108)(108)
(Total: 8 million)
(Total: 4.95 million)
Graph

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6.Histogram
a). What is Histogram ?
When creating a histogram, “a range of data is divided into smaller
sections having a uniform span, and the number of data contained in
each section (the number of occurrences) is counted to develop a
frequency distribution table.” Then, “a graph is formed from this table
by using vertical bars, each having the height proportional to the
number of occurrences in each section.”

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6.Histogram
b). When is it used and what results will be obtained?
A histogram is mainly used to analyze a process by examining the
location of the mean value in the
graph or degree of variations, to find a problem point that needs to be
improved. Its other applications are listed in the table below.

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Histogram
Method Usage Result
HistogramHistogram
Standard
Range
Range of
Variations
X Axis (Values
Actually
Measured)
HistogramHistogram
Standard
Range
Range of
Variations
X Axis (Values
Actually
Measured)
•Used to assess the actual conditions.
•Used to analyze a process to identify a
problem point that needs to be
improved by finding the location of the
mean value or degree of variations in
the graph.
•Used to examine that the target
quality is maintained throughout the
process.
•Others
[Used during phases to monitor
the situation, analyze causes, and
review effectiveness of an action.]
•Can identify the location
of the mean (central)
value or degree of
variations.
•Can find out the scope of
a defect by inserting
standard values.
•Can identify the
condition of distribution
(e.g., whether there is an
isolated, extreme value).

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7.Scatter Diagram
a). What is Scatter Diagram ?
A scatter diagram is used to “examine the relationship between the two,
paired, interrelated data types, ” such as “height and weight of a
person.” A scatter diagram provides a means to find whether or not
these two data types are interrelated. It is also utilized to determine how
closely they are related to identify a problem point that should be
controlled or improved.

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7.Scatter Diagram
b). When is it used and what results will be obtained?
The table on next slide shows some examples of scatter diagram’s
usage. If, for example, there is a relationship where “an increase in the
number of rotations (x) causes an increase in abrasion (y),” there exists
“positive correlation.” If, on the other hand, the existence of a
relationship where “an increase in the number of rotations (x) causes a
decline in abrasion (y)” indicates that there is “negative correlation.”

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Scatter Diagram
Method Usage Result
•Used to identify a relationship
between two matters.
•Used to identify a relationship
between two matters and establish
countermeasures based on their cause
and effect relation.
Example Usage
1.Relationship between thermal
treatment temperature of a steel
material and its tensile strengths
2.Relationship between visit made by a
salesman and volume of sales
3.Relationship between the number of
persons visiting a department store and
volume of sales
4 Others
Scatter DiagramScatter Diagram
ｙ Axis
x Axis
Abrasion
Number of
Rotations
Scatter DiagramScatter Diagram
ｙ Axis
x Axis
Abrasion
Number of
Rotations
[Used during phases to monitor the situation, analyze causes, and review
effectiveness of an action.]
•Can identify cause
and effect relation.
•Can understand the
relationship between
two results.

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Scatter Diagram
Abrasion(micron)
ｙAxis
x Axis
Number of
Rotations

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Process control
( Standardization )
Evaluation of result
Implementation
Develop Improvement
method ( Solution )
Detecting causes of
problem
Record of facts
Defining the problem
Identification of
problem
Control
Chart
Scatter
DiagramHistogram
Cause &
Effect
Diagram
Pareto
Diagram
Stratifi
cation
Check
sheet
Graphs
Application of QC tools in Problem Solving

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• Stratification - Basic processing performed when
collecting data
• Pareto Diagram - To identify the current status and issues
• Cause and Effect Diagram - To identify the cause and effect relationship
• Histogram - To see the distribution of data
• Scatter Diagram - To identify the relationship between two
things
• Check Sheet - To record data collection
• Control Chart/Graph - To find anomalies and identify the current
status
To sum up 7 QC tools (Numerical data ) are used as follow:

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Any
Questions,
???
Thank you