The Basic Seven (B7) Tools of QualityA PowerPoint Training PresentationBy Keith H. CooperBy Keith H. CooperAs much as 95% of quality related problems in the factory can be solved As much as 95% of quality related problems in the factory can be solved with seven fundamental quantitative tools. - Kaoru Ishikawawith seven fundamental quantitative tools. - Kaoru Ishikawa 1What are the Basic Seven Tools of Quality?Fishbone DiagramsFishbone DiagramsHistogramsHistogramsPareto AnalysisPareto AnalysisFlowchartsFlowchartsScatter PlotsScatter PlotsRun ChartsRun ChartsControl ChartsControl Charts2Where did the Basic Seven come from?Kaoru Ishikawa Known for “Democratizing Statistics”Known for “Democratizing Statistics” The Basic Seven Tools made statistical The Basic Seven Tools made statistical analysis less complicated for the average analysis less complicated for the average personperson Good Visual Aids make statistical and Good Visual Aids make statistical and quality control more comprehendible.quality control more comprehendible.3The Basic Seven (B7) Tools of QualityFishbone Diagrams No statistics involvedNo statistics involved Maps out a process/problemMaps out a process/problem Makes improvement easierMakes improvement easier Looks like a “Fish Skeleton”Looks like a “Fish Skeleton”4Constructing a Fishbone Diagram Step 1 - Identify the ProblemStep 1 - Identify the Problem Step 2 - Draw “spine” and “bones”Step 2 - Draw “spine” and “bones”Example: Example: High Inventory Shrinkage at local Drug High Inventory Shrinkage at local Drug StoreStoreShrinkage5Constructing a Fishbone Diagram Step 3 - Identify different areas where Step 3 - Identify different areas where problems may arise fromproblems may arise fromEx. : Ex. : High Inventory Shrinkage at local Drug StoreHigh Inventory Shrinkage at local Drug StoreShrinkageemployeesshoplifters6Constructing a Fishbone Diagram Step 4 - Identify what these specific Step 4 - Identify what these specific causes could becauses could beEx. : Ex. : High Inventory Shrinkage at local Drug StoreHigh Inventory Shrinkage at local Drug StoreShrinkageshopliftersAnti-theft tags poorly designedExpensive merchandise out in the openNo security/ surveillance7Constructing a Fishbone Diagram Ex. : Ex. : High Inventory Shrinkage at local Drug StoreHigh Inventory Shrinkage at local Drug StoreShrinkageshopliftersAnti-theft tags poorly designedExpensive merchandise out in the openNo security/ surveillanceemployeesattitudenew traineetrainingbenefitspractices8Constructing a Fishbone Diagram Step 5 Use the finished diagram to Step 5 Use the finished diagram to brainstorm solutions to the main problems.brainstorm solutions to the main problems.9The Basic Seven (B7) Tools of QualityHistogramsBar chartBar chartUsed to graphically represent groups Used to graphically represent groups of dataof data10Constructing a HistogramFrom a set of data computesummean (x)MaxMinRange (max-min)11Constructing a HistogramUse range to estimate beginning and end Calculate the width of each column by dividing the range by the number of columnsRange# of Columns= Width12Acme Pizza ExampleLets say the owner wants a distribution of Acmes Thursday Night SalesData Set from last Thursday(slices)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 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 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 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 41 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 413Acme Pizza ExampleMean = 2.032258 Mean = 2.032258 Max = 7 Max = 7 Min = 0 Min = 0 Range = 7 Range = 7 QuestionQuestionFor 7 columns what would the width For 7 columns what would the width be?be?Range/Columns=7/7=1 slice14Acme Pizza ExampleSlices of Pizza# times orderedHistogram15Constructing a HistogramHow is this helpful to Acme?How is this helpful to Acme?2 slices of pizza most common order 2 slices of pizza most common order placedplacedDistribution of sales useful for Distribution of sales useful for forecasting next Thursdays late forecasting next Thursdays late night demandnight demandIf you were an Acme manager how If you were an Acme manager how could you apply this information?could you apply this information?16The Basic Seven (B7) Tools of QualityPareto AnalysisVery similar to HistogramsVery similar to HistogramsUse of the 80/20 ruleUse of the 80/20 ruleUse of percentages to show Use of percentages to show importanceimportance17Acme Pizza (part 2)SlicesSlicesFrequencyFrequency% 0 01 1.3.31 1 33 33 13.09 13.092 2 65 65 25.79 25.793 38 8 3.17 3.174 4 12 12 4.76 4.765 50 00 06 60 00 07 71 1 .3 .318Acme Pizza (part 2) The completed Pareto Analysis results in the The completed Pareto Analysis results in the following graph:following graph:Slices of Pizza# times ordered214375619Acme Pizza (part 2)Critical ThinkingHow does the Pareto Analysis differ from the Histogram?How can this be a useful tool to the Acme boss?20The Basic Seven (B7) Tools of QualityFlowchartsA graphical picture of a PROCESSA graphical picture of a PROCESSProcessDecisionThe process flow21FlowchartsDont Forget to:Dont Forget to:Define symbols before beginningDefine symbols before beginningStay consistentStay consistentCheck that process is accurateCheck that process is accurate22Acme Pizza Example (Flowchart) Window WindowTake CustomerTake Customer Money?Money? (start) (start) Order OrderGet PizzaGet PizzaLockupLockupPut More inPut More in Oven Oven 2 Pies 2 Pies Available?Available? Time Time to close? to close? Take to Customer Take to Customernoyesnoyesnoyes23How can we use the flowchart to analyze improvement ideas from the Histogram? Window WindowTake CustomerTake Customer Money?Money? (start) (start) Order OrderGet PizzaGet PizzaLockupLockupPut More inPut More in Oven Oven 2 Pies 2 Pies Available?Available? Time Time to close? to close? Take to Customer Take to Customernoyesnoyesnoyes24Want some practice?Make a flowchart for:Make a flowchart for:Taking a showerTaking a showerCooking dinnerCooking dinnerDriving a carDriving a carHaving a partyHaving a partyCreating a FlowchartCreating a FlowchartAny other processes you can think of?Any other processes you can think of?25The Basic Seven (B7) Tools of QualityScatter Plots2 Dimensional X/Y plotsUsed to show relationship between independent(x) and dependent(y) variables26Acme Pizza (Scatter Diagram)Minutes CookingMinutes Cooking Defective Pies Defective Pies10101 145458 830305 57575 20 206060 14 1420204 425256 6In this simple example, you can find the existing In this simple example, you can find the existing relationship without much difficulty butrelationship without much difficulty but27Scatter DiagramsEasier to see direct relationshipTime Cooking (minutes)Defective Pizzas28Scatter DiagramsAs a quality toolWhat does this tell Acme management about their processes?Improvements?Time Cooking (minutes)Defective Pizzas29The Basic Seven (B7) Tools of QualityRun chartsTime-based (x-axis)CyclicalLook for patterns30Run Charts8 9 10 11 12 1 2 3 48 9 10 11 12 1 2 3 4 8 9 10 11 12 1 2 3 4PM- AMPM- AMPM- AMThursdayWeek 1ThursdayWeek 2ThursdayWeek 35 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100Slices/hourTime31The Basic Seven (B7) Tools of QualityControl ChartsDeviation from MeanUpper and Lower SpecsRange32Control ChartsUpper LimitUpper LimitLower LimitLower LimitUnacceptable deviationX33Control ChartsAcme Pizza Management wants to get in on the control chart actionAverage Diameter = 16 inchesUpper Limit = 17 inchesLower Limit = 15 inches34Acme example Control ChartsUpper LimitUpper Limit17 inches17 inchesLower LimitLower Limit15 Inches15 InchesSmall PieX16 inches=35Acme example #50Control ChartsPies within specifications were acceptableOne abnormally small pie is “uncommon”Should be examined for quality control36SummaryBasic Seven Tools of QualityMeasuring dataQuality Analysis“Democratized statistics”37Bibliography Foster, Thomas. Foster, Thomas. Managing Quality. An Integrative Managing Quality. An Integrative ApproachApproach. Upper Saddle River : Prentice Hall, . Upper Saddle River : Prentice Hall, 2001.2001. Stevenson, William. “Supercharging Your Pareto Stevenson, William. “Supercharging Your Pareto Analysis.” Analysis.” Quality ProgressQuality Progress October 2000: October 2000: 51-55.51-55. “ “Dr Kaoru Ishikawa.” Internet Dr Kaoru Ishikawa.” Internet “ “a0000110.html.” a0000110.html.” 16 February 2001.16 February 2001. “Chemical and Process Engineering.” Internet. “Chemical and Process Engineering.” Internet. “.” 17 “.” 17 February 2001.February 2001.38