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ABSTRACT
seven quality control (QC) tools in Small Medium Enterprise (SMEs) company. This
the understanding the basic of Kaizen approach, it aims is to eliminate or reduce waste
from production processes. The 7 quality control (QC) tools are one of the common
methods and techniques of the kaizen. Most of the SMEs, are confused and unable to
decide where to start, what and when to implement certain tools and techniques in their
total quality journey. These tools can be beneficial for any SMEs in order to assist them
to detect the problem that occurred in the process or products and analysed using 7 basic
quality tools. Additionally, these quality tools does not cost much capital, simplest and
1.0 INTRODUCTION
In recent years there has been an increase in global competition among various sectors
as a result of fast, deep and frequent changes all over the world and, therefore a fast
market, to improve productivity with best quality and to improve market share at least
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The quality of processes, products and services is an important factor in business
strategies, and therefore has been changed to suit the reality that businesses face.
Quality is very important in business today especially with product recalls and
investigations as to what went wrong. Also quality has become a crucial competitive
strategic tools and many organizations have realized that it is the key to developing
products and services that lead the organizations continuous success (Mustapha, Muda,
& Abu Hasan, 2011). One of the methods to solve quality issues is Kaizen. Kaizen is a
especially quality.
based on assumption that all employees possess skills which can be used in a better
way. Kaizen is Japanese philosophy which means continuous improvement. Kai mean
Change & Zen mean Good the whole purpose of which is betterment of work &
circles Plan, Do, Check and Act (PDCA) which focus on customer-driven processes to
improve productivity and the quality of products and services by build-up marginal
improvements over time (Desta, Asgedom, Gebresas, & Asheber, 2014). The kaizen
and production supervisors where they are assigned as team leaders for continuous
SME refers to small and medium enterprises. In the manufacturing sector, SMEs act as
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because these items can be produced at a cheaper price compared to the price large
companies must pay for in-house production of the same components (Singh, Garg, &
Deshmukh, 2010) . SMEs are found in every sector of the economy and play a vital
role. They are crucial for sustained, long-term growth, dynamism and employment.
SMEs are considered as the backbone of economic growth in all countries and they
contribute in providing job opportunities, act as supplier of goods and services to large
organizations. Although SMEs are playing an increasingly more important role, only a
There are many problems that manufacturing companies face today, such as unreliable
production processes, poor product quality, financial losses and delays in production
delivery. Companies do not often understand the root causes of these problems.
Problems in manufacturing can stem from various causes in a range of business areas.
satisfy their customers by continuously improving (Jevgeni, Eduard, & Roman, 2015).
According to Xu (2013), found that SMEs face several challenges are low profit
margins and relatively backward management. The author also stated that if SMEs do
not make change happen, then the problems will not get resolved and this will affect
The purpose of this paper is to present the quality improvement by using 7 quality
control (QC) tools will lead to solve the quality problems efficiently and effectively.
Furthermore it was assumed that the continued successes of SMEs might further be
improved if their knowledge sharing practices are placed on a sound footing. Quality
tools are considered to be the simplest and easiest tools that one can use to improve the
quality of their industrial process and no special skills or huge capital is required to use
these tools.
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2.0 LITERATURE REVIEW
They are also called the 7 "basic" or "old" tools. After that other new tools have been
developed for various purposes but the basis for every work is related to the 7 QC tools.
These tools are also fundamental to Kaizen approach to quality improvement. For
solving quality problems these 7 quality control tools which are basic used are flow
chart, check sheets, Pareto diagram, histogram, cause & effect diagram, scatter diagram,
and control charts (Ishikawa, 1985; Sokovi, Jovanovi, & Vujovi, 2009). The 7quality
tools were first emphasized by Ishikawa (in the 1960s), who is the one of the quality
management experts. All this tools are important tools used widely at manufacturing
field to monitor the overall operation and continuous process improvement. This tools
mainly used to find out root causes and eliminates them, thus the process can be
improved (Magar & Shinde, 2014). Even though there are other quality tools that can
be used such as quality function development (QFD) and design of experiments (DOE)
but 7 quality control tools still became the first choice in quality control tools (Shahin,
Arabzad, & Ghorbani, 2010). The 7 basic quality tools and techniques is one of the
quality tools and most of the company using these tools to make an improvement in
Tools of quality can be implemented through many ways in the process industry but
PDCA cycle and DMAIC methodology are the most famous and widely used technique
process improvement. When the process improvement starts with careful planning it
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results in corrective and preventive actions, supported by appropriate quality assurance
tools, which leads to true process improvement (Pavletic, Sokovi, & Paliska, 2008).
DMAIC methodology is also same as PDCA cycle but the steps of DMAIC are a bit
more explanatory than the PDCA cycle. DMAIC is the abbreviation of Define, Measure,
Analyse, Improve and Control. DMAIC methodology is used for process improvement
and the use of 7 quality tools in each of the DMAIC steps are shown in table 1
(Muhammad, 2015).
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According to Mach and Guhqueta (2001), the 7 quality tools and six sigma have an
important relationship. The quality tools are important elements that belong to the
Statistical Process Control (SPC) which is an essential part for the implementation of
the six sigma strategy. Even six sigma is a new strategy but it also based in old statistical
and management tools. As the 7 quality tools can be applied in several steps of the flow
chart of the six sigma strategy. Sokovi et al. (2009), also stated that each of phases in
six sigma methodology can be realized with different quality tools and techniques,
while some tools can be used in more than one processes (phases). The combination of
powerful way; evaluate areas that cause the most problems; give direction for areas to
be prioritized; show relationships between variables; establish causes for failure; show
distribution of data; and determine whether the process is acting in a state of statistical
control; and highlight the effect of special causes of variation where present (Shahin et
al., 2010).
Flow chart is one the basic tool. It is used to study the whole process where flow charts
are pictorial representation of process by breaking the process down into its constitute
steps. Flowcharts are helpful in identifying where errors are likely to found in the
system and control the process after defect removal (Muhammad, 2015). In quality
improvement process flowcharts are particularly useful for displaying how a process
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2.1.2 Check Sheet
A check sheet is a structured, prepared form for collecting in real-time and analysing
data. Tool used to collect data and record that which process occurs how many times.
The data collected through check sheet can be used in other tools like Pareto diagram
and Histogram. Check sheets help analysts to find the facts or patterns that may aid
subsequent analysis. Those collected data from the check sheets help to organize data
of the data so that further analysis can be planned and the improvement actions can be
taken.
A Pareto chart, is the technique develop by Italian economist named Vilfredo Pareto
has been started to be commonly used in management area. According to Pareto rule,
generally 80% of the faults in a system stems from 20% of the reasons constituting the
faults (Grener & Toker, 2013). It is a type of chart that contains both bars and a line
graph, where individual values are represented in descending order by bars, and the
cumulative total is represented by the line. These are extremely useful to find the factors
which have greatest effect on system and allow the users to focus attention on these
2.1.4 Histogram
Histogram is a special bar chart for measurement data. It is used to chart the frequency
shows the data distributed across several class intervals and the frequency of occurrence
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2.1.5 Cause and Effect Diagram
This tool was devised by Dr. Kouro Ishikawa and as mentioned earlier is also known
and identifies systematic relationships between an effect and its possible causes.
Besides, it can be used to structure a brainstorming session. In this technique all the
possible causes of a problem are taken into account and try to find out the reason of
every cause which makes the problem happen. The root cause in cause and effect
diagram are frequently arranged into four majors categories. These categories can be
classified into manpower, methods, materials and machinery (Bhagwat, Desale, Khatib,
is used to display what happens to one variable when another variable changes in order
to test a theory that the two variables are related. The data displayed on the scatter
diagram clearly show if there is a positive, negative or no relationship between the two
a graph in which one variable is on X-axis and the other variable in on Y-axis
(Montgomery, 2009).
Control charts are also known as statistical process control charts (SPC). A control chart
is a line graph used to assess and validate the stability of a process. These are most
important and powerful quality tool to study variation of process with time. Control
charts are used to check stability of process. Control charts have two control limits.
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These limits define boundaries for minimum (lower control limit) and maximum (upper
control limit) values. The points are connected by straight lines. The spread and position
of the points on the graph relative to the centre line and the control limits indicate the
state of control of the process. When all the points are within the control limits, and
these points do not exhibit any abnormal pattern, then the underlying process is said to
be under statistical control. In such cases no action may be necessary and the process
is allowed to continue. If the points fall outside the control limits or display any
abnormal pattern, then the process is deemed to be out of control and under the
influence of special causes. In such cases the process would be stopped and investigated
for causes.
Many researches have been done using 7 quality control tools. Mandavgade and Jaju
(2009), study the used of 7 quality control tools to optimization the cost and proven
these tools able to overcome problem and get to save amount cost of product and
improved company reputation. Besides that, Rohani and Chan (2001), presents a case
study in plastic injection moulding company deployed check sheets, Pareto chart, cause
and effect diagram and control chart to improve the monthly defect quality from 13.49%
to 7.4%.
A study conducted by Fouad and Mukattash (2010), in steel industry helps to reduce
majority of problems related to the quality and possible remedies were proposed with
the used of 7 quality tools. Jha, Tyagi, and Gupta (2013), conducted a case study to
reduce the scrap in automotive assembly lines using quality control tools. It results in
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In the study conducted by Bhagwat et al. (2014), researcher implemented quality tools
in TORNOS Sigma 20II to detect the major possible causes contribution to the high
rate rejection. Researchers use check sheets for the first phase to collect the data, later
transfer data to the Pareto analysis to determine the critical dimension. Lastly, Ishikawa
diagram is to detect every possible cause based on 6 possible major causes, there are
The quality tools as a continuous improvement tool was use in a process. The researcher
used Pareto diagram to clarify the reason for the selection the problem, then followed
by cause and effect diagram tool to ascertain the root cause for major problem (Yunus,
Quality control tools also used in bicycle rims production industry by researcher
Dhingra (2016). The Quality tools such as Pareto chart, Fishbone diagram have been
applied to improve the quality of the products. The results showed that the rejection of
the rims has been reduced from 9.45% to 7.75% for overall production of the
components.
Singh, Singh, Pal, and Sidhu (2017) used two types of quality control tools in
competitive market there are Pareto analysis and fishbone diagram (cause and effect
diagram). It shown a positive outcome where the root cause for the defects product able
to be identify and capable for the manufacturing company to reduce the reject products
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3.0 METHODOLOGY
This study starts with identifying suitable company to do this project. The main criteria
used to select a company are SME. The reason behind is because SME companies did
not have enough capital to hire expertise to help them to improve their production line
productivity, quality of the product produced and at the same time reduce the number
of defect products. The adopted methodology contain initial research on related field,
previous records and observations, generation of alternative solutions & final selection
of best possible solutions,. Those relevant information have been taken into account
and analysed by inspecting the pitfalls of the existing system of the concerned SME.
4.0 CONCLUSION
The use of quality tools is a vital component of any successful improvement process
and quality of the products. Principle of Kaizen approach using the 7 basic quality tools
which enable SMEs to move from static to dynamic improvement status. These tools
can only be beneficial for any SMEs after the proper guidance and training of their
employees so that they understand these tools effectively. Based on the evident from
process can be realized with the used of quality tools and techniques. As it is shown in
selected examples, quality tools has important place in data collecting, analysing,
visualizing and making sound base for data founded decision making. The literature of
this investigation also bring further knowledge on the application of quality tools in
other companies either than SMEs. Moreover, the proposed framework not only is
helpful in effective utilization of a wider range of approaches, but also can provide more
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