2. Facts or figures from
which conclusions can be
drawn.
A basis for reasoning,
discussion or calculation.
Why Gather Data?
1. To identify problems to work on.
2. To analyze the selected problem as in
- assessing extent of problem
- identifying patterns
- verifying probable causes
3. To prevent problems from arising or
recurring.
4. To select possible action plans
5. To establish effectiveness of
implemented solutions.
3. A check sheet is a form prepared
to facilitate checking off or marking.
The function of a check sheet is to
provide a systematic technique for
recording observations and should be designed so that
data can be posted on them and used with minimum effort.
Check sheets serve many purposes and
should be designed so data can be
posted on them and used with
minimum effort.
1. Agree as to what event is being observed.
2. Decide on the time period during which
data will be collected.
3. Design a form which is clear complete
and easy to use.
4. Collect data consistently and honestly.
4. A Pareto Diagram is a special form of
vertical graphs which helps us to determine
which problems to solve in what order.
Doing a Pareto diagram based upon
check sheets or other forms of data
collection helps us direct our attention and
efforts to truly important problems.
Step 1. Select the standard for comparison,
e.g., annual cost, frequency of defects
Step 2. Select the time period to be studied.
Step 3. Gather data. Use a checklist
Step 4. Transfer information from a check sheet
to a column graph arranged in
descending order.
Step 5. Summarize data from the check sheet
to construct the cumulative line.
5. 1. To highlight main problems.
0
10
20
30
40
50
60
70
80
90
100 Missing
Parts
Misoriented
Parts
Scratch
Loose
Screw
Others
6. 2. To compare problems through the
use of different measurement
scales.
0
5
10
15
20
25
0
5
10
15
20
25
30
35
40
Customer complaints
No.
Wron
g
spec
$
loss
Wrong
spec
7. 3. To aid in root cause analysis
(Multi-level Pareto)
Effect Cause
0
5
10
15
20
25
30
Frequency
Eyes Legs Hand
Types of Injury
0
5
10
15
20
Frequency
Solder
Splash
Steam Dust
Causes of Injury
8. Multi Level Pareto Illustration
4500
3500
3000
2500
2000
0
1000
2000
3000
4000
5000
PPM
W/B MOLD D/A S/P TRIM
STATION
YIELD/STATION
1ST LEVEL
2000
1500
700
300
0
500
1000
1500
2000
2500
3000
PPM
22 LDS 16 LDS 18 LDS 48 LDS
LEAD TYPE
W/B YIELD/LEAD TYPE
2ND LEVEL
9. Multi Level Pareto Illustration
800
500
400
200
100
0
100
200
300
400
500
600
700
800
900
1000
PPM
Lif t e d ba ll Cr a t e r ing M ispla c e d bond
on le a d
Wr ong wir e siz e Te a r ing wir e
Defects
Defects on 22 LD Pkg.
3RD LEVEL
4TH LEVEL
15
10
5
0
10
20
30
40
50
Frequency
Machine Material Operator
Cause of Lifted Ball
10. Multi Level Pareto Illustration
8
4 3
0
10
20
30
40
50
Frequency
Bond force Time Temperature
Parameter
Adjustment on the Machine
5TH LEVEL
11. 4. To evaluate before and after corrective
action.
Before
0
10
20
30
EYE LEGS HAND
Frequency
AFTER
15
10
4
0
10
20
30
EYE LEGS HAND
Effective
12. A cause and effect diagram is a picture
composed of lines and arrows to represent
relationships between effects and its causes.
A primary use for Cause and Effect diagrams
is to analyze existing problems or situations so
that corrective measures can be taken.
The Cause and Effect diagram is a valuable
too to use in sorting out “non-contributing”
causes; leaving only the “true” causes.
Step 1. Pick a result, effect or problem to
be solved. Virtually display problem
statement.
Problem, Effect or
Result
13. Step 2. Categorize causes by major elements
and put boxes around them.
Start with 4Ms and 1E (Man, Machine,
Materials, Method, Environment)
Problem, Effect or
Result
Man Machine
Method Materials Environmen
t
14. Step 2. Categorize causes by major elements
and put boxes around them.
Start with 4Ms and 1E (Man, Machine,
Materials, Method, Environment)
Problem,
Effect or
Result
Man Machine
Method Materials Environmen
t
15. Step 2. Add smaller branches to main causes
and continue adding until all possible
causes are exhausted.
Problem,
Effect or
Result
Use brainstorming to generate a large number of specific
causes in each category.
Ask who, why, what, when, where, or how to stimulate
thinking.
16. It is a creative process for generating a large
quantity of ideas utilizing a group.
17. Compare all causes (What is)
against operational standard
(What should be).
Circle the causes for causing
“bad” effect.
The diagram can be used to
evaluate if operational standard
is inadequate.
18. Find out which of the circled
causes have a significant
effect on the problem.
How?
1. Use technical knowledge
2. Obtain opinion
3. Verify through data
gathering
4. Do more analysis of data
5. Possibly design an
experiment
19. 3. Construct a plan on how the
problems are to be resolved.
* the plan should include activities,
timetable and person responsible.
4. Because the Cause & Effect diagram
reflects graphically the results of
investigating a problem, it is a
good idea to post it in the work
area so that everyone can see
why action is necessary.
5. Continue improvements and revisions
to improvements.
20. A Histogram is a graph which shows
the frequency of occurrence in a
number of related measurements.
A histogram reveals how measurements
vary from one another and displays
the distribution of data. It can be
used to compare sample results with
specification.
22. Step 2. Identify the largest and smallest
measurement. Compute the range.
Range = Maximum - Minimum
reading reading
Range = 0.44 - 0.36
= .08
23. Step 3. Determine how many classes are
required to make a histogram.
Compute for the class interval.
R .08
Class Interval = ---- = ------
K 5
Class Interval = .016 or .02
K is a constant determined from a table.
24. For Constant K,
DATA and Class Amounts
Number of Appropriate No.
Observations of Classes
50 5 - 7
51 - 100 6 - 10
101- 250 7 - 12
Over 250 10 - 20
25. Step 4. Determine the boundary line between
classes.
Class Class Interval
1 0.36 - 0.37
2 0.38 - 0.39
3 0.40 - 0.41
4 0.42 - 0.43
5 0.44 - 0.45
26. Step 5. Transfer data to a tally sheet
CLASS TOTAL
1 0.36 - 0.37 IIII - I 6
2 0.38 - 0.39 IIII - IIII 9
3 0.40 - 0.41 IIII - IIII - IIII - IIII - IIII 25
4 0.42 - 0.43 IIII - IIII 9
5 0.44 - 0.45 I 1
TOTAL 50
CLASS
INTERVAL
FREQUENCY
Tally Sheet
27. Step 6. Transform data from tally sheet
to a Histogram.
1
6 9
25
9
0
10
20
30
40
0.36 - 0.37 0.38 - 0.39 0.40 - 0.41 0.42 - 0.43 0.44 - 0.45
Classes
Frequency
28. A Scatter Diagram is used to study the
possible relationships between one variable
and another.
The Scatter Diagram is used to test for
possible cause and effect relationships.
It cannot prove that one variable causes
the other, but it does make it clear
whether a relationship exists and the
strength of that relationship.
29. A Scatter Diagram is set up whereby the horizontal
axis (X-axis) represents the measurement values of
one variable and the vertical axis (Y-axis) represents
the measurement of the second variable.
V
a
r
i
a
b
l
e
2
Variable 1
30. Step 1. Collect 50 to 100 paired samples
of data that you think may be
related. Construct a data sheet
as follows:
Obs. # Auto (g/l)
y
1 42.48
2 41.54
3 42.01
4 *
5 *
6 *
* *
* 53.37
Manual (g/l)
*
54.21
x
*
*
*
41.33
42.53
42.53
Relationship between Manual & Auto Titration (Sn + 2)
31. Step 2. Draw the horizontal and Vertical Axes
of the diagram.
Manual g/l
X
40 42 43 44 45 46 47 48
50
43
42
40
Auto g/l
y
32. Step 3. Plot the data on the diagram. If you
find the values being repeated, circle
that point as many times as appropriate.
40
42
44
46
48
50
52
54
56
58
60
40 42 44 46 48 50 52 54
Manual g/l
Auto
g/l
34. Stratification is a process of classifying
data into subgroups based on categories
and characteristics.
Helps analyze cases in which data
actually masks the real facts.
Breaks down single numbers into
meaningful categories or classifications
to focus on the corrective action.
35. 1. During data gathering to design check
sheets, create checklist, scatter diagram
and cause and effect diagram.
2. During data analysis when using histograms,
pareto charts, scatter diagrams and
cause and effect analysis.
Stratification break down single numbers into
meaningful categories or classifications to focus
on corrective action.
36. Control Chart is a graphic representation of
a process.
Sample averages are plotted on the chart.
Statistically determine the upper and lower
control limits drawn on either side of the
process average.
Makes it possible to tell if a process is functioning normally
and to see immediately if malfunctioning has occurred.
