CQE Handbook 3 rd edition Ch 27 Quality

CQE Handbook 3 rd edition Ch. 27 Quality Control Tools Presented by Dr. Joan Burtner Certified Quality Engineer Associate Professor of Industrial Engineering and Industrial Management

Seven Basic Tools as defined by the American Society for Quality (ASQ) Check Sheet Pareto Chart Scatter Diagram Histogram Cause-and-Effect Diagram Flowchart Control Chart ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 2

Basic Quality Tool : Check Sheet Also known as a tally sheet Helps gather data on the frequency of occurrence of particular events or defects Check sheet design often requires prior knowledge of the process ISE 428 ETM 528 Spring 2016 Poor Performance on Statistics Exam Check Sheet didn't eat breakfast not enough sleep didn't study too many exams that day didn't understand topic poor math skills unfair test forgot to bring calculator SS √ MS √ JB √ √ RR √ GB √ √ √ √ √ √ Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 3

Basic Quality Tool : Check Sheet Mechanics Design the check sheet for a given application. sheet 2. Record the data. 3. Use the data for analysis or input to additional graphical tools such as Pareto charts or histograms. 1. ISE 428 ETM 528 Spring 2016 Poor Performance on Statistics Exam Check Sheet SS didn't eat breakfast √ not enough sleep didn't study too many exams that day didn't understand topic √ poor math skills √ unfair test √ forgot to bring calculator MS √ JB √ √ RR √ GB √ √ √ √ √ √ √ Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 4

Basic Quality Tool : Pareto Chart Pareto (an 1800 s Italian economist) noted that 80 percent of the wealth in Italy was held by 20 percent of the population. This is called the Pareto Principle. Juran (20 th century) applied the Pareto Principle to quality improvement ◦ vital few ◦ useful many (sometimes called trivial many) Mechanics ◦ Minitab offers a built-in function for the Pareto chart ◦ Manual method: Count items in each category. Plot on graph in order of descending frequency. ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 5

Basic Quality Tool : Pareto Chart Causes are frequently documented in a check sheet which is used to generate a Pareto chart Managers use Pareto charts to help focus or prioritize process improvement efforts The chart to the right was generated in Minitab ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 6

Basic Quality Tool : Scatter Diagram Also known as an X-Y Quiz Grade 120 graph 100 Purpose is to graphically display indications of a 80 relationship between two variables 60 Caution: A statistical 40 correlation does not 20 guarantee a direct cause and effect. 0 0. 0 1. 0 2. 0 3. 0 4. 0 5. 0 6. 0 7. 0 Caution: Excel will yield Hours Studied the equation for a straight ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering line “best fit” 8. 0 9. 0 10. 0 Slide 7

Basic Quality Tool : Scatter Diagram Mechanics Select two variables of 120 interest. Set a scale for the axes. Collect and chart the data. Evaluate the results. 100 ◦ Linear/nonlinear ◦ Positive/negative ISE 428 ETM 528 Spring 2016 Quiz Grade 80 60 40 20 0 0. 0 1. 0 2. 0 3. 0 4. 0 5. 0 6. 0 7. 0 8. 0 9. 010. 0 Hours Studied Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 8

Basic Quality Tool : Histogram Purpose is to graphically Histogram of Quiz Grades Frequency depict the frequency of occurrence , where 9 8 occurrences are sorted into 7 6 categories of a defined 5 4 range along a continuous 3 2 scale 1 0 X-axis shows cell 30. 5 40. 5 50. 5 60. 5 70. 5 80. 5 90. 5100. 5 Bin Upper Bound boundaries Y-axis shows cell frequency Shape of the bars is only a ISE 428 ETM 528 Spring rough indication of the 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 9

Basic Quality Tool : Histogram Mechanics Determine the amount of Histogram of Quiz Grades Frequency data to be collected Determine number of columns or bins to be used Collect and record data Prepare the graphic and graph the data (Minitab and Excel have built-in functions for histograms) 9 8 7 6 5 4 3 2 1 0 30. 5 40. 5 50. 5 60. 5 70. 5 80. 5 90. 5100. 5 Bin Upper Bound ◦ X-axis shows bin boundaries ◦ Y-axis shows bin frequency ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 10

Basic Quality Tool : Cause-and-Effect Diagram Used to show the many different causes that may contribute to a problem (effect) Causes are frequently generated through brainstorming sessions Other names ◦ ◦ ◦ Fishbone diagram Ishikawa diagram C-E diagram 4 M diagram 4 P diagram 6 M diagram ISE 428 ETM 528 Spring 2016 Methods Machine Flat Tire Man Materials Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 11

Basic Quality Tool : Cause-and-Effect Diagram Mechanics Select a single problem or People opportunity (effect) 2. Identify major causes 3. Identify the minor causes associated with each major cause. (Add structure. ) 4. Identify additional cause structure. (Add detail. ) Plant Note: Ideas are frequently generated through brainstorming sessions conducted BEFORE major/minor causes are identified. ISE 428 ETM 528 Spring 1. 2016 Policy Difficulty finding billing office Procedure Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 12

Basic Quality Tool : Popular C-E Diagram Categories 4 M Chart ◦ ◦ Man Machine Methods Materials 4 P Chart ◦ ◦ People Policies Procedures Plant ISE 428 ETM 528 Spring 2016 6 M Chart ◦ ◦ ◦ Man Machine Methods Materials Mother Nature Measurement Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 13

Basic Quality Tool : Flowchart Purpose is to provide a Load graphic representation of the elements, Was components, or tasks h associated with a Dry process Maps the sequence of Paint steps and decision points in a process Cure Helps group to have common Distribute Scra understanding of the p ISE 428 ETM 528 Spring process 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 14

Basic Quality Tool : Flowchart Mechanics Select a start and stop point. Start 2. List major steps/tasks and Basic decision points. (Show in processi sequential order. ) ng 3. Use standardized graphical Flow symbols to document the process. 4. Review results. (Verify and Decision refine as necessary. ) Note: It is standard protocol to have more than one person ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering independently verify results. 1. Slide 15

Basic Quality Tool : Control Chart Purpose ◦ Indicates how a process behaves over time ◦ Shows when a process is being influenced by special causes Chart consists of UCL, LCL, and data points Examined for nonrandom patterns See Chapter 37 for ISE 428 ETM 528 Spring mechanics of 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 16

Contact Information Email: Burtner_J@Mercer. edu US Mail: Dr. Joan Burtner, Chair Department of Industrial Engineering and Industrial Management Mercer University School of Engineering 1501 Mercer University Drive Macon, GA 31207 Phone: (478) 301 - 4127 ISE 428 ETM 528 Spring 2016 Dr. Joan Burtner, Associate Professor of Industrial Engineering Slide 17