06-Mar-15

Recap Lecture 3: Measured data and Statistics

Able to do measurement: significant figures, rounding, rules on

multiplication, division, additional and subtraction, rounding rules
& errors
Understand the variations and attributes
Know what statistic is and its applications, distributions and how they
are used in SPC
Able to calculate the mean, median, mode, range and standard
deviation and to draw a histogram

Photo by tj.blackwell - Creative Commons Attribution-NonCommercial License https://www.flickr.com/photos/8185633@N07 Created with Haiku Deck

Descriptive Statistics
Histogram Measure of central tendency- describes the center position of the
data (mean, median, mode)
Measure of dispersion describe the spread of data (range, variance,
standard deviation)

1 N
Mean, X i 1 Xwhere
i Xi is one observation, N is number of sample
N
Interval, i Median is the middle point of a data series (observation in the middle of sorted data
Frequency

Mode the most frequently occuring value

Mid-point

Upper boundary
100 91 85 84 75 72 72 69 65

Category Mean = 79.22 Mode

Lower boundary Median

Descriptive Statistics Descriptive Statistics

Measure of Dispersion - Kurtosis Measure of dispersion (range, variance and standard deviation)
Kurtosis Measure the peakness of the data. It is a dimensionless value. The The range is calculated by taking the maximum value and subtracting
value must be compared to a normal distribution to determined if it more the minimum value.
peaked or flatter peaked distribution. Variance is the squared of the summation of the difference between each
value and the mean divided by number of samples

n n
1, 3, 5, 7, 9, 11
( xi

f i ( xi X) / n
4
i 1
Range = 11-1 = 10
a4 i 1
= population mean
n
Note: S = = std dev s4
Std deviation is the square-root of variance. Measures spreading
tendency of the data

If is small, high probability of getting

n the values close to mean value
( xi

i 1
n If is large, high probability of getting
Leptokurtic (more peaked) Mesokurtic (normal) Platykurtic (flatter)
the values away from mean value

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 06-Mar-15

Descriptive Statistics Lecture 4: Basic QC Tools

Other measure of dispersion (skewness, kurtosis, coefficient of
variation)
Skewness - lack of symmetry of data distribution. A negative values indicate
skewed to the left, positive indicates skewed to the right.
<0 left 0 = symmetrical >0 right

n
fi ( xi x) / n
3

a3 i 1
Note: S = = std dev s3
Introduces the QC tools
When to use, how to use the tools
Example problems

Outline Learning Objectives

Statistical ISO 9000
Process Control Construct a Pareto diagram.
Quality Products Explain how to construct a cause and effect diagram.
Acceptance ISO 14000
Function Liability
Deployment
Sampling Explain how to construct a check sheet.
Know the major sections of ISO 9000 and briefly describe their emphasis.
Failure Mode Quality by
Benchmarking
Effect Analysis Reliability Design Know the objectives, techniques, procedures, and benefits of an internal audit.
(FMEA)
List the quantitative and qualitative TQM tools and techniques
Management
Taguchis Design of Total Productive
and Planning
Quality Experiments Maintenance
Tools
Engineering (DOE)

Information Technology
Computer Program

TQM Tools and Techniques TQM Tools and Techniques

1. Statistical Process Control (SPC) 2. Acceptance Sampling
Pareto Diagram 3. Reliability
Cause-Effect Diagram 4. Design of Experiments (DOE)
Check Sheets 5. Taguchis Quality Engineering
Process Flow Diagram 6. Failure Mode and Effect Analysis (FMEA)
Scatter Diagram
7. Quality Function Deployment (QFD)
Histogram
8. ISO 9000
Control Charts

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TQM Tools and Techniques Other TQM Tools

9. ISO 14000
Acceptance Sampling
10. Benchmarking
See Chapters 8 and 9
11. Total Productive Maintenance
Reliability
12. Management and Planning Tools
See Chapter 11
13. Quality by Design
14. Information Technology

TQM Tools TQM Tools

Design of Experiments (DOE) Taguchis Quality Engineering
Used to determine those variables in a process Loss function concept
that are critical and their target values Concept of robustness
Three approaches Failure Mode Effect Analysis (FMEA)
Classical Combines technology and experience of
Taguchi people to identify failure modes and planning
Shainin for its elimination
It is a before-the-event action
Two types of FMEA-Design and Process

TQM Tools TQM Tools

Quality Function Deployment (QFD) Quality Function Deployment (QFD) Contd.
Ensuresaccurate deployment of the voice-of-the- Answers the following questions contd:
customer How does an engineering decision affect
Answers the following questions: customer perception?
What do customers want? Does an engineering change affect other
Are all wants equally important? technical descriptors?
Will delivering perceived needs yield a competitive What is the relationship to parts deployment,
advantage? process planning, and production planning?
How can we change the product, service or
process?

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Statistical Process Control (SPC) Statistical Process Control

Seven Tools:
A methodology for monitoring a process
1. Pareto Diagram
to identify special causes of variation 2. Cause-Effect Diagram
and signal the need to take corrective 3. Check Sheets
action when appropriate 4. Process Flow Diagram
5. Scatter Diagram
6. Histogram
7. Control Charts

The Pareto Principle The Pareto Principle

Vilfredo Pareto was an economist who is credited Some Sample 80/20 Rule Applications
with establishing what is now widely known as 80% of process defects arise from 20% of the process issues.
the Pareto Principle or 80/20 rule. When he 20% of your sales force produces 80% of your company

discovered the principle, it established that 80% revenues.

of the land in Italy was owned by 20% of the
population. Later, he discovered that the pareto
principle was valid in other parts of his life, such
as gardening: 80% of his garden peas were
produced by 20% of the peapods.
80% of delays in schedule arise from 20% of the possible causes
of the delays.
80% of customer complaints arise from 20% of your products or
services.
(The above examples are rough estimates.)

The Pareto Diagram The Pareto Diagram

Graph that ranks data classifications in
descending order from left to right
Pareto diagrams are used to identify the most
important problems
Advantage: Provide a visual impact of those vital
few characteristics that need attention
Resources are then directed to take the necessary
corrective action
Helps a team focus on causes that have the
greatest impact
Displays the relative importance of problems in a
simple visual format
Helps prevent shifting the problem where the
solution removes some causes but worsens
others

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Pareto Chart Pareto Chart

A plot look like histogram, but prioritize the data according to their significance in
relation to a problem/effect. For example, the types of defects on a painted surface Exercise: given below the types of complaints and the number of complaints in customer
can be blisters, spot, bubbles, blur mark. These defects can be organized according to satisfaction survey at a restaurant, construct a Pareto Chart
their significance/contribution to the poor paint quality.
Pareto Chart separates the vital few problems from the trivial many. Complaints Number of complaints Complaints Number of Complaints
Example of nonconforming shirt in a week. Cold food 105 Poor Service 13
Flimsy Utensils 2 Food too greasy 9
Food tastes bad 10 Lack of courtesy 2
Salad not fresh 94 Lack of cleanliness 25

When to use Pareto Chart?

When analysing data about the frequency of problems or causes in a process.

When there are many problems or causes and you want to focus on the most
significant.
When analysing broad causes by looking at their specific components.
When communicating with others about your data.

Scatter Diagram Scatter diagram

Poor correlation Positive correlation Even there is
correlation, it does For each first item measurement,
not tell causal there maybe a range of possible
Sale of ice-cream

Sale of ice-cream

relationship (e.g. Second item measurement

second item measurements, and vice
what cause what). versa
Other tool need to be
used
At best correlation
can tell a potential
relationship which
may be confirmed by
Each time the first is measured, the
People drowning People drowning other method second item is also measured, and
this pair is plotted on the Scatter
Diagram
Negative correlation The degree to which two sets of data are related and may
Sale of ice-cream

be mathematically calculated with the correlation coefficient

The simplest way of visualizing the correlation is with a
Scatter Diagram, where perfect correlation is a straight line
and no correlation is a random cloud of points.
No correlation is a positive result: it tells you clearly that First item measurement
the two sets of data are not related. The most frustrating
picture is when there is a weak correlation which only says
that there might be a weak or distant relationship.
People drowning

Cause-and-Effect Diagram Cause-and-Effect Diagram

People Materials Work Methods
It was developed by Dr. Kaoru Ishikawa in 1943
Picture composed of lines and symbols Primary
Cause

designed to represent a meaningful relationship C

a
E
f
u
between an effect and its causes s
Quality f
e
e Secondary Cause Characteristic
c
Effect (characteristics that need improvement) s t

on the right and causes on the left

Environment Equipment Measurement

Figure 3.3 Cause-and-Effect Diagram

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 06-Mar-15

Cause-and-Effect Diagram Cause-and-Effect Diagram

Enables a team to focus on the content of a problem, Steps in the construction of a
not on the history of the problem or differing personal Cause-and-Effect Diagram:
interests of team members
1. Identify the effect or quality problem
Creates a snapshot of collective knowledge and
2. Determine the major causes
consensus of a team; builds support for solutions
3. Determine all the minor causes. Request a
Focuses the team on causes, not symptoms brainstorming session
Used to investigate either a bad effect and to take 4. Once the diagram is complete, evaluate it to
action to correct the causes or a good effect and to determine the most likely causes
learn those causes responsible 5. Develop solutions

Cause-and-Effect Diagram Cause-and-Effect Diagram

Advantages: Types of Diagrams:
1. Analyzing actual conditions for the purpose of 1. The dispersion-analysis type.
product or service quality improvement Each major branch is filled in completely
2. Elimination of conditions causing nonconforming before starting work on any of the other
product or service and customer complaints branches. The objective is to analyze the
3. Standardization of existing and proposed causes of dispersion or variability
operations
4. Education and training in decision-making

Cause-and-Effect Diagram
Cause-and-Effect Diagram
Types of Diagrams:
2. The process-analysis type.
In order to construct it, it is necessary to write
each step of the production process. The
advantage of this type of diagram is the ease
of construction and its simplicity, since it
follows the production sequence
Also Called:, Ishikawa Diagram, Fishbone Diagram
Variations: cause enumeration diagram, process fishbone, time-delay fishbone, CEDAC
(cause-and-effect diagram with the addition of cards), desired-result fishbone, reverse
fishbone diagram.
Identifies many possible causes for an effect or problem. It can be used to structure a
brainstorming session. It immediately sorts ideas into useful categories
Materials Procedures
Quality
Problem

People Equipment

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 06-Mar-15

Cause-and-Effect Diagram Procedures Check Sheet

Agree problem statement (effect). Also known as defect concentration diagram, data collection sheet or tally
Brainstorm the major categories : chart
Methods, Generic, flexible for any purpose of data collection and analysis
Machines (equipment),
People (manpower),
Materials, Measurement,
Environment
Causes as branches from the main arrow.
Ask: Why does this happen?
idea
Causes
categories.
Again ask why does this happen?
sub-causes branching off the causes. Why? generate deeper levels of causes. Layers of
branches indicate causal relationships.
No more ideas
focus attention to places on the chart where ideas are few.

Applications : Problem statements, Interview, Recruitment and etc.

Check Sheets Check Sheets

Figure 3-5 Check Sheet for paint non-conformities

27 28
Figure 3-6 Check Sheet for swimming pool

Check Sheet When to Use Check Sheet

data observed and collected repeatedly -same person or location.
collecting data -frequency or patterns of events, problems, defects, defect
location, defect causes, etc.
collecting data -a production process.
Data to be recorded manually-accurate direct interpretation or for
transcription, example into a computer.
recording involves counting, classifying, checking or locating.
checking each measurement as it is recorded, for example within normal
bounds.
the distribution of measures as built up

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Bar Charts Bar Charts

difference between a small set of related data.
Variety of fruits in a
flexible, show multiples sets of data in stacked, grouped display.
door gift pack
Data pattern can simple, portray data in a visual and easily-understood form.
6 be visualised Organize numeric measurements -tables -to understand, but lacks visual impact, with
trends and relative sizes difficult to discern.
measurements in discrete physical bars, The area of the bar is proportional to the size of
4 the measurement, visual impression.
the relative sizes physically by separated bars. Even complex trends across multiple bars
may be apparent (Line Graphs and Control Charts better -measuring trends).
2 flexible format -used in a wide number of situations (this may be contrasted with the
specific purpose of the Histogram or Pareto Chart). The independent nature of each bar
enables even quite disconnected items to be compared.
A O B P

Apple Orange Banana Plum

2 5 6 1

Histogram Histogram
Shows data distribution and how frequent a range of value occur
Can tell the capability of a process
Only numerical values can be used
25

20
Frequency

15

10

Category

When to use Histogram Stem and leave plot

Sort-out data into an array that can be read easily
Numerical data.
Easy and efficient method of organizing data from smallest to largest when
shape of the datas distribution, determining the output of a process is data are of the same accuracy and very close to each other.
distributed approximately normally.
analysing whether a process - meet the customers requirements. Example: Create a stem plot from the measurements data for diameter of a
Analysing the output from a suppliers process looks like. rod:
seeing whether a process change has occurred 2.36, 2.39, 2.51, 2.43, 2.56, 2.72, 2.45, 2.83, 2.75, 2.27, 2.63, 2.92, 2.88, 2.44, 2.57, 2.61, 2.58,
2.81, 2.81, 2.43, 2.62, 2.96, 2.48, 2.31, 2.67
Determining the outputs of two or more processes are different.
to communicate the distribution of data quickly and easily to others. Stem plot (not in order) Ordered Stem plot
2.2 7 2.2 7
2.3 6 9 1 2.3 1 6 9
2.4 3 5 4 3 8 2.4 3 3 4 5 8
2.5 1 6 7 8 2.5 1 6 7 8
2.6 3 1 2 7 2.6 1 2 3 7
2.7 2 5 2.7 2 5
2.8 3 8 1 1 2.8 1 1 3 8
2.9 2 6 2.9 2 6

Location: Middle value is between 2.5 and 2.6

Spread: Smallest value is 2.27, largest value is 2.96
Shape: Bimodal pattern with high points at the stem 2.4 and 2.8

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Flow Diagram/Chart Process Flow Diagram

Flow Chart Graphical description how a work is done. Uses symbols.
Used to describe processes to be improved
Symbols used by
General Motors Corp

I Inspection Operation

Storage To next process step

Product movement

Delay

Process Chart Other Process Descriptive Tool - Story Board

Date: 9-30-00 Location: Nibong Tebal Mountain
Analyst: RMN Process: Mango Sauce Story board is a recording a related events/effects from the source to the end
(results of those events)
Originally developed by Walt Disney in creating their storyline. Story boards are
Distance
Operation

Description
Transport

Storage

(feet)
(min)
Inspect

Time
Delay

put over walls where everyone involved look at it and try different things.
Step

of
process
Subroutine can also be added.
Allows for tracing back the source of a problem.
1 Unload mango from truck 20
2 Move to inspection station 100 ft
3 Weigh, inspect, sort 30
4 Move to storage 50 ft
5 Wait until needed 360
6 Move to peeler 20 ft
7 Mango peeled and cored 15
8 Soak in water until needed 20
9 Place in conveyor 5
10 Move to mixing area 20 ft
11 Weigh, inspect, sort 30
Page 1 0f 3 Total 480 190 ft

Control Chart Run Chart Control Chart

27
Run Chart is a time series plot that monitor the process changes
associated with a particular characteristic over time 24
Can use either variable or attribute data 21
UCL = 23.35
x-axis shows time, y-axis shows attribute or variable value
Number of defects

c = 12.67
Run Chart is the basis for Control Chart 18

15

12

6
LCL = 1.99
3

2 4 6 8 10 12 14 16
Sample number

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Benchmarking Total Productive Maintenance

Benchmarking is a new way of doing business
that was developed by Xerox in 1979. The idea
is to find another company that is doing a
particular process better than your company,
and then, using that information to improve the
process
Total Productive Maintenance (TPM) is a
technique that utilizes the entire work force to
obtain the optimum use of equipment.
The technical skills in TPM are: daily equipment
checking, machine inspection, fine-tuning
machinery, lubrication, trouble-shooting, and
repair.

Management and Planning Tools Quality by Design

Management and Planning Tools (Chapter 12): Quality by Design is the practice of using a
1. Affinity diagram multidisciplinary team to conduct product or
2. Interrelationship diagram service conception, design, and production
planning at one time.
3. Tree diagram
The major benefits are faster product
4. Prioritization matrices
development, shorter time to market, better
5. Matrix diagram quality, less work-in-process, fewer engineering
6. Process decision program chart change orders, and increased productivity
7. Activity network diagram

Products Liability Information Technology

Consumers are initiating lawsuits in record numbers as a
result of injury, death, and property damage from faulty
product or service design of faulty workmanship.
Reasons for injuries:
Behavior or knowledge of a user
Information Technology is defined as computer
technology (either hardware or software) for
processing and storing information, as well as
communications technology for transmitting
information.

Environment where the product is used

Whether or not the factory has designed and the
product using safety analysis and quality control

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Thank you for your attention.

Then Quiz 1 covers 1 hour 12-1 pm(open book)
at DK5 after 1 hour lecture

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