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The Basic Seven (B7) Tools of Quality

The Basic Seven (B7) Tools of Quality. "As much as 95% of quality related problems in the factory can be solved with seven fundamental quantitative tools." - Kaoru Ishikawa. By Zaipul Anwar Business & Advanced Technology Centre, Universiti Teknologi Malaysia.

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The Basic Seven (B7) Tools of Quality

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  1. The Basic Seven (B7) Tools of Quality "As much as 95% of quality related problems in the factory can be solved with seven fundamental quantitative tools." - Kaoru Ishikawa By Zaipul AnwarBusiness & Advanced Technology Centre,Universiti Teknologi Malaysia

  2. What are the Basic Seven Tools of Quality? • Fishbone Diagrams • Histograms • Pareto Analysis • Flowcharts • Scatter Plots • Run Charts • Control Charts

  3. Where did the Basic Seven come from? Kaoru Ishikawa • Known for “Democratizing Statistics” • The Basic Seven Tools made statistical analysis less complicated for the average person • Good Visual Aids make statistical and quality control more comprehendible.

  4. The Basic Seven (B7) Tools of Quality Fishbone Diagrams • No statistics involved • Maps out a process/problem • Makes improvement easier • Looks like a “Fish Skeleton”

  5. Fishbone Diagram Overview (1 of 2) • Definition • Uses • Ishikawa • Use within organizations • benefits • Creation of the Diagram • Steps 1-9

  6. Fishbone Diagram Overview (2 of 2) • Example • Service example • Exercise • Ham Industries

  7. Fishbone (Cause and Effect or Ishikawa) Diagrams (1 of 4) • Named after Kaoru Ishikawa • Japanese Quality pioneer • Resembles skeleton of a fish • Focus on causes rather than symptoms of a problem • Emphasizes group communication and brainstorming • Stimulates discussion

  8. Fishbone (Cause and Effect or Ishikawa) Diagrams (2 of 4) • One of Seven basic tools of Japanese Quality • Leads to increased understanding of complex problems • Visual and presentational tool

  9. Fishbone (Cause and Effect or Ishikawa) Diagrams (3 of 4) • Typically done on paper or chalkboard • Recently some computer programs have been created to make Fishbone Diagrams • Ishikawa Environment

  10. Use in Organizations (1 of 2) • Can be used to improve any product, process, or service • Any area of the company that is experiencing a problem • Isolates all relevant causes

  11. Use in Organizations (2 of 2) • Helps bring a problem into light • Group discussion and brainstorming • Finds reasons for quality variations, and the relationships between them

  12. Creating Fishbone Diagrams (1 of 4) • As a group: 1. Establish problem (effect) -state in clear terms -agreed upon by entire group 2. Problem becomes the “head” of the fish -draw line to head (“backbone”)

  13. Creating a Fishbone Diagram (2 of 4) • Decide major causes of the problem - by brainstorming - if the effect or problem is part of a process the major steps in the process can be used 4. Connect major causes to backbone of the fish with slanting arrows

  14. Creating a Fishbone Diagram (3 of 4) 5. Brainstorm secondary causes for each of the major causes 6. Connect these secondary causes to their respective major causes 7. Repeat steps 5 & 6 for sub-causes dividing with increased specificity - usually four or five levels

  15. Creating a Fishbone Diagram (4 of 4) 8. Analyze and evaluate causes and sub-causes -may require the use of statistical, analytical, and graphical tools 9. Decide and take action

  16. Example (1 of 4) • Step 1 & 2: Poor Service (“backbone”) (“head”)

  17. Example (2 of 4) • Step 3 & 4: Responsiveness Appearance Poor Service Attention Reliability

  18. Example (3 of 4) • Step 5, 6, & 7: Responsiveness Appearance time equipment personnel facility Poor Service accuracy One on one service courtesy dependability Reliability Attention

  19. Example (4 of 4) • Step 8 & 9: • Use tools to analyze and evaluate causes • Pareto diagrams, charts, and graphs • Statistical analysis for causes in processes • Decide and take action • Use fishbone diagram, analysis and evaluations to find causes that can be fixed • Take action to eliminate and fix problem causes

  20. Summary (1 of 3) • Fishbone Diagrams - visual diagram - resembles fish skeleton - identifies the causes of a problem (effect), and their relationships - created by Kaoru Ishikawa for Quality Management

  21. Summary (2 of 3) • Organizational Uses • Increases communication about problems • Used to improve any product, process, or service • Important part of quality management

  22. Summary (3 of 3) • Creation of Fishbone diagrams • Problem or effect is head of fish • Identify major, secondary and tertiary causes, and attach to backbone identifying relationships • Analyze and Evaluate results • Act to fix the problem(s)

  23. Exercise • Create a Fishbone (cause and effect, Ishikawa) Diagram for the following: Management at Ham Industries has noticed that the productivity of its workers is well below the standard. After interviewing its employees, it was noticed that a vast majority felt dissatisfied and unhappy with their work. Your boss has asked you and a group of your peers to find the causes of worker dissatisfaction . Include all possible causes to at least the secondary level.

  24. Bibliography //home.t-online.de/home/kfmaas/q_ishika.html www.zi.unizh.ch/software/unix/statmath/sas/sasdoc/qc/chap17/sect1.htm www.dti.gov.uk/mbp/bpgt/m9ja00001/m9ja0000110.html Foster, S. Thomas. Managing Quality: An Integrative Approach. 2001, Prentice-Hall

  25. The Basic Seven (B7) Tools of Quality Histograms • Bar chart • Used to graphically represent groups of data

  26. Overview • What is a Histogram? • What are some possible uses for a Histogram? • Where did the Histogram come from? • How do Histograms work? • A real world example. • An exercise.

  27. What is a Histogram? • A Histogram is a variation of a bar chart in which data values are grouped together and put into different classes. • This grouping allows you see how frequently data in each class occur in the data set.

  28. What is a Histogram (cont.) • Higher bars represent more datavalues in a class. • Lower bars represent fewer datavalues in a class. • On the next slide is an example of what a Histogram looks like.

  29. Example of a Histogram

  30. Uses for a Histogram A Histogram can be used: • to display large amounts of data values in a relatively simple chart form. • to tell relative frequency of occurrence. • to easily see the distribution of the data. • to see if there is variation in the data. • to make future predictions based on the data.

  31. Where did the Histogram Come From? • The Histogram was first implemented by Kaoru Isikawa, one of Japans’ most renowned experts on quality improvement. • Isikawa spent his life trying to improve quality in Japan.

  32. Where did the Histogram Come From? (cont.) • His major contributions to quality improvement are known as the basic seven tools of quality. • Included in his basic seven tools of quality is the Histogram.

  33. How do Histograms Work? • First, you need need to pick a process to analyze. • Next, you need a large amount of data, at least 100 data values so that patterns can become visible. • Then, you need to assemble a table of the data values that you collected with regards to frequency of data values.

  34. How do Histograms Work? (cont) • Next, you need to calculate some statistics for the Histogram, including: mean, minimum, maximum, standard deviation, class width, number of classes, skewness, and kurtosis. • Then, you actually create the Histogram using these statistics.

  35. How do Histograms Work? (cont) • After you have created a Histogram, it will take one of five shapes: • Normal Distribution:

  36. How do Histograms Work? (cont) • Positively Skewed: • Negatively Skewed:

  37. How do Histograms Work? (cont) • Bi-Modal Distribution: • Multi-Modal Distribution:

  38. How do Histograms Work? (cont) • Once your Histogram is complete, you can analyze its shape, as well as the statistics that you came up with. • This analysis will help you to make better decisions toward quality improvements.

  39. Constructing a Histogram From a set of data compute • sum • mean (x) • Max • Min • Range (max-min)

  40. Constructing a Histogram • Use range to estimate beginning and end • Calculate the width of each column by dividing the range by the number of columns Range = Width # of Columns

  41. Acme Pizza Example • Let’s say the owner wants a distribution of Acme’s Thursday Night Sales Data Set from last Thursday(slices) 0 2 1 2 2 4 1 3 1 2 1 2 2 4 3 4 1 4 3 2 2 3 2 1 2 2 1 2 2 1 4 2 2 1 2 1 2 2 1 2 1 2 1 2 1 2 1 2 1 2 2 2 1 2 1 2 1 1 2 2 2 3 1 4 2 2 3 2 2 2 1 2 3 2 2 4 2 2 4 4 1 2 2 2 3 2 2 1 2 2 4 2 1 2 4 2 1 7 2 1 2 2 3 1 2 1 1 2 1 2 2 2 1 2 2 1 2 1 2 2 2 4 2 4

  42. Acme Pizza Example Mean = 2.032258 Max = 7 Min = 0 Range = 7 Question For 7 columns what would the width be? Range/Columns=7/7=1 slice

  43. Acme Pizza Example Histogram # times ordered Slices of Pizza

  44. Constructing a Histogram How is this helpful to Acme? • 2 slices of pizza most common order placed • Distribution of sales useful for forecasting next Thursday’s late night demand If you were an Acme manager how could you apply this information?

  45. The Basic Seven (B7) Tools of Quality Pareto Analysis • Very similar to Histograms • Use of the 80/20 rule • Use of percentages to show importance

  46. Pareto Analysis, how to use it • 1. Gather facts about the problem, using Check Sheets or Brainstorming, depending on the availability of information. • 2. Rank the contributions to the problem in order of frequency. • 3. Draw the value (errors, facts, etc) as a bar chart. • 4. It can also be helpful to add a line showing the cumulative percentage of errors as each category is added. This helps to identify the categories contributing to 80% of the problem. • 5. Review the chart – if an 80/20 combination is not obvious, you may need to redefine your classifications and go back to Stage 1 or 2.

  47. Acme Pizza (Example 1) SlicesFrequency% 0 1 .3 1 33 13.09 2 65 25.79 3 8 3.17 4 12 4.76 5 0 0 6 0 0 7 1 .3

  48. Acme Pizza (Example 1) • The completed Pareto Analysis results in the following graph: # times ordered 2 1 4 3 7 5 6 Slices of Pizza

  49. Acme Pizza (part 2) Critical Thinking • How does the Pareto Analysis differ from the Histogram? • How can this be a useful tool to the Acme boss?

  50. A series of Pareto charts drill down to more detail (Example 2) : 1st level Analysis gives “Design” as main cause of failure 2nd level Analysis gives breakdown of “Design”

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