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Review on Quality Management using 7 QC Tools

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Nikunjkumar A Parmar Shubham Awasthi

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 International Journal of Trend in Research and Development, Volume 5(2), ISSN: 2394-9333
[Link]

Review on Quality Management using 7 QC Tools

1
Nikunjkumar A. Parmar and 2Shubham Awasthi,
1,2
Department of Mechanical Engineering, Parul Institute of Technology, Vadodara, India

Abstract—Today’s competitive environment has, lower ma- quality control for separating the "vital few" problems from the
nufacturing cost, more productivity in less time, high quality "trivial many" now called the "useful many".
product, defect free operation are required to follow to every
2) Cause & Effect Diagram
foundry man. For the improvement of products quality there
are diff-diff quality tools used in various review papers. Here I A Cause-and Effect Diagram is a tool that shows systematic
am going to review on these papers and identify the different relationship between a result or a symptom or an effect and its
way of uses of those tools in manufacturing industries to possible causes. It is an effective tool to systematically
increase the quality of the product. There are so many defects generate ideas about causes for problems and to present these
in the manufacturing process and these defects directly affects in a structured form. This tool was devised by Dr. Kouro
on productivity, profitability and quality level of organization. Ishikawa and as mentioned earlier is also known as Ishikawa
This study is aimed to review the research work made by Diagram.
several researcher and attempt to get technical solution for the
various defects and to improve the entire process of the 3) Histogram
manufacturing. Histograms or Frequency Distribution Diagrams are bar charts
showing the distribution pattern of observations grouped in
Keywords— Quality Circle, 7 Quality Control Tools, PDCA,
convenient class intervals and arranged in order of magnitude.
DMAIC
Histograms are useful in studying patterns of distribution and
I. INTRODUCTION in drawing conclusions about the process based on the pattern.
The 7 QC Tools are simple statistical tools used for problem 4) Control Charts
solving. These tools were either developed in japan or intro-
Variability is inherent in all manufacturing processes. These
duced to japan by the Quality Gurus such as Deming and
variations may be due to two causes:
Juran. In terms of importance, these are the most useful. Kaoru
Ishikawa has stated that these 7 tools can be used to solve 95 i. Random / Chance causes (un-preventable).
percent of all problems. These tools have been the foundation
of Japan's astonishing industrial resurgence after the Second ii. Assignable causes (preventable).
World War. For solving quality problems seven QC tools used Control charts were developed by Dr. Walter A. Shewhart
are Pareto Diagram, Cause & Effect Diagram, Histogram, during 1920's while he was with Bell Telephone Laboratories.
Control Charts, Scatter Diagrams, Graphs and Check Sheets. These charts separate out assignable causes. Control chart
All this tools are important tools used widely at manufacturing makes possible the diagnosis and correction of many
field to monitor the overall operation and continuous process productions troubles and brings substantial improvements in
improvement. This tools are used to find out root causes and the quality of the products and reduction of spoilage and
eliminates them , thus the manufacturing process can be impr- rework. It tells us when to leave a process alone as well as
oved. The modes of defects on production line are investigated when to take action to correct trouble.
through direct observation on the Production line and
statistical tools. 5) Scatter Diagram

A. Quality Control tools When solving a problem or analyzing a situation one needs to
know the relationship between two variables. A relationship
1) Pareto Diagram may or may not exist between two variables. If a relationship
Pareto Diagram is a tool that arranges items in the order of the exists, it may be positive or negative; it may be strong or weak
magnitude of their contribution, thereby identifying a few and may be simple or complex. A tool to study the relationship
items exerting maximum influence. This tool is used in SPC between two variables is known as Scatter Diagram. It consists
and quality improvement for prioritizing projects for of plotting a series of points representing several observations
improvement, prioritizing setting up of corrective action teams on a graph in which one variable is on X-axis and the other
to solve problems, identifying products on which most variable in on Y-axis. If more than one set of values are
complaints are received, identifying the nature of complaints identical, requiring more points at the same spot, a small circle
occurring most often, identifying most frequent causes for is drawn around the original dot to indicate second point with
rejections or for other similar purposes. The origin of the tool the same values. The way the points lie scattered in the
lies in the observation by an Italian economist Vilfredo Pareto quadrant gives a good indication of the relationship between
that a large portion of wealth was in the hands of a few people. the two variables.
He observed that such distribution pattern was common in 6) Graphs
most fields. Pareto principle also known as the 80/20 rule is
used in the field of materials management for ABC analysis. Graphs of various types are used for pictorial representation of
20% of the items purchased by a company account for 80% of data. Pictorial representation enables the user or viewer to
the value. These constitute the A items on which maximum quickly grasp the meaning of the data. Different graphical
attention is paid. [Link] suggested the use of this principle to representations of data are chosen depending on the purpose of

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 International Journal of Trend in Research and Development, Volume 5(2), ISSN: 2394-9333
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the analysis and preference of the audience. The different types  Act - Adoption or reaction to the changes or running
of graphs used are as given below: the PDCA-cycle through again. Keeping
improvement on-going
1. Bar Graph -To compare sizes of data
2. Line Graph- To represent changes of data II. LITERATURE SURVEY
3. Gantt chart -To plan and schedule
4. Radar chart -To represent changes in data (before and The literature survey consists of ten papers which explain the
after) flexibility of different Quality tools and its scope. Here, in
5. Band Graph -Same as above survey I am going to review on different Quality tools which
are used in small scale industries. The importance of QC tools
7) Check Sheets is explained by various authors in this survey.
As measurement and collection of data forms the basis for any Jitendra A. Panchiwala [1] presented Brief study and his
analysis, this activity needs to be planned in such a way that understanding about Quality and Productivity improvement in
the information collected is both relevant and comprehensive. small scale foundry industry. In this paper he is aimed to
Check sheets are tools for collecting data. They are designed review the research work made by several researchers and an
specific to the type of data to be collected. Check sheets aid in attempt to get technical solution for minimizing various
systematic collection of data. Some examples of check sheets casting defects and improve the entire process of casting
are daily maintenance check sheets, attendance records, manufacturing. he conclude from several research work that
production log books, etc. Data collected using check sheets modem method of casting component using various software
needs to be meaningfully classified. Such classification helps and simulation techniques is really a boon for the industrial
gaining a prelim-nary understanding of relevance and sector. To complete globally, foundry men have to move ahead
dispersion of the data so that further analysis can be planned to from the slogan of “satisfying customer” and adopt and
obtain a meaningful output. Meaningful classification of data ruinously endeavour for “customer delight”. Meeting
is called stratification. Stratification may be by group, location, customers’ demands will not be sufficient. requirements will
type, origin, symptom, etc. be to exceeding them through quality and productivity
improvement. After preferring paper he select some of tools
7 QC TOOLS THROUGH PDCA-CYCLE:
and techniques for future work like SPC are quite expensive to
In successful application of quality tools an implemented implement in small scale industries but this method gives
quality management system is an advantage. The quality better results than any other techniques. These techniques can
management principles are a starting point for the company’s be useful not only to reduce the rejection rate but also in other
management striving for continuous efficiency improvement various departments in industries like inventory control at
over a long period of time and customer satisfaction. A quality various machines in machine shop to get process variation and
management system is based on the integrity of all production to identify optimum values of parameters etc. many
and support resources of a certain company. It enables a researchers have conducted experiments to find out the sand
faultless process flow in meeting related contracts, standards process parameters to get better quality casting. They have
and market quality requirements. Implementation of a quality successfully reduced the casting defects considerably up to 6%
management system is always a part of a company’s by proper selecting techniques and parameters. DoE is the
development process entification and/or process analysis. technique which can be implemented in any processing
Continuous improvement as a fifth principle of QMS (ISO industry and in India there are number of small scale industries
9001:2000) could not be realized without quality tools which which can implement such techniques to improve the yield
are presented through four groups of activities of Deming’s which give standard process parameter and increase the
quality cycle or PDCA-cycle, The PDCA-cycle is an integral effective capacity of the unit.
part of process management and is designed to be used as a
Shyam H. Bambharoliya [2] reviews some selected factors to
dynamic model because one cycle represents one complete
reducing rejection rate in small scale machining unit using 7
step of improvement. The PDCA-cycle is used to coordinate
Quality Control Tools. This paper aims to identify the
continuous improvement efforts. It emphasizes and
problems related to different products and probable solutions
demonstrates that improvement programs must start with
based on that problem. Use of 7 QC Tools is best way to
careful planning, must result in effective action, and must
reduce rejection and defect of product after analysing of
move on again to careful planning in a continuous cycle – the
manufacturing process. Another advantage is increasing
Deming’s quality cycle is never-ending. It is a strategy used to
customer satisfaction by use of 7 QC Tools in today compet-
achieve breakthrough improvements in safety, quality, morale,
itive market. Based on application of these tools will increase
delivery cost, and other critical business objectives. The
the level of standard products which they required as vision of
completion of one cycle continues with the beginning of the
an organization. After reviewing all research papers different
next. A PDCA-cycle consists of four consecutive steps or
defects are observed by application of 7 QC tools and
phases, as follows:
individual solution is given with probable root causes. After
 Plan - analysis of what needs to be improved by studying all problems related to each research papers
taking into consideration areas that hold opportunities individual solutions are provided as per requirement .based on
for change. Decision on what should be changed. that problems effect on production is changed as increase in
 Do - implementation of the changes that are decided productivity or reduction of rejection rats.
on in the Plan step. Varsha M. Magar [3] investigate in this paper about the
 Check - Control and measurement of processes and systematic use of 7QC tools. The main aim of this paper is
products in accordance to changes made in previous about to provide an easy introduction of 7 QC tools and to
steps and in accordance with policy, goals and improve the quality level of manufacturing processes by
requirements on products. Report on results. applying it. QC tools are the means for collecting data,
analysing data, identifying root causes and measuring the

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results. These tools are related to numerical data processing. various quality control tools, the non- value added activities
All of these tools together can provide great process tracking are eliminated. Thus the productivity has been increased with
and analysis that can be very helpful for quality improvements. reduced human efforts & employees work satisfaction. Here on
These tools make quality improvements easier to see, the basis of SLP he have studied & analyses the layout &
implement and track. The work shows continuous use of these working process of chartered rubber products. We have
tools upgrades the personal characteristics of the people identified the degree of necessity of placing the equipment
involved. It enhances their ability to think generate ideas, solve close to each with the help of SLP. We tried to eliminate the
problems and do proper planning. The development of people wasteful elements from the plant & on the basis of SLP. We
involved. It enhances their ability to think generate ideas, solve have designed a new plant layout. The new layout on the basis
problem and do proper planning. The development of people of SLP reduces about 185.3ft of the distance travelled during
improves the internal environment of the organization, which the entire manufacturing process. Hence the entire
plays a major role in the total quality culture. Statistical QC is manufacturing time gets reduced. Thus the over-all
chiefly concerned in making sure that several procedures and productivity of the chartered rubber gets increased.
working arrangements are in place to provide for effective and
Shantanu kulkarni [6] in their paper, “Quality circle to improve
efficient statistical processes, to minimize the risk of errors or
productivity: A case study in a medium scale alumi-num
weaknesses in procedures or systems or in source material
coating industry”, have study about the QC concept in a
seven QC tools are most helpful in troubleshooting issues
coating unit which illustrates how the QCs help in improving
related to quality. All processes are affected by multiple
the productivity. The factors which are important for the
factors and therefore statistical QC tools can be applied to any
success of the quality circles were also explained here and the
process. The continuous use of these tools upgrades the
study can serve as s guide which would be useful for the small
personal characteristics of the people involved. it enhances
and medium scale industries who are interested in introducing
their ability to think generate ideas, solve problems and do
the quality circles. Here the main objective was to improve the
proper planning.
productivity of the chromating process which is one of the
Sanjeev Kadian [4] Present the influence of using Lean important processes in the plant. For that they were form one
Manufacturing Technology to increase the production in quality circle of 8 members working in the chromating section
scientific equipment’s manufacturing industry in this paper. In of the plant with 1 manager as a facilitator. After the formation
this case study the scientific equipment’s manufacturing of the quality circle they are able to identify the problem and
company employs part of the “seven basic quality control (QC) after the brainstorming meeting with the team members and
tools” to significantly improved the process rejection and discussion with the plant head about the various ways to
rework. By implementing these quality tools as the problem improve the productivity of the process some areas of
solving techniques the rejection rate was reduced from 7.3% to improvement were identified. To select the problem to be
4% and Rework rate from 20% to 11.33%.the competitive solved 3P analysis was performed. By adopting the “3P
business in the scientific market has enhanced the company in SYSTEM” proprietary priority preferential method, they were
this study to provide lower cost quality product. Quality able to classified all category of problems based in their
improvement program had been designed and been approach to maintenance and nature of work. Here in first P
implemented to increase the potential of profit. By improving they identified five sensible aspects of their work area as the
the quality, it is also mean to improve the productivity and proprieties of their company. Then in P2 they have been
lower the rejection rate. The key of quality improvement of further prioritized by weight age system and it was observed
this company is not only focusing an external customer but its that highest cost was being incurred in pre-treatment which
internal customer. The purpose of this study is to improve the was 67% compared to others. 3P- preference shows
quality of circular 15x lenses used in scientific equipment’s. consumption cost of various components of pre-treatment unit.
the objective of this study is to reduce the rework rate from From the data collection they were able to identified that the
20% to 11.33% and rejection rate from 7.3% to 4%. An gas consumption maximum in all sensible groups. Now they
improvement action plan had been set up, then the data had were move towards the next step which is to reduce the gas
been collected for the 4 weeks from 10 lots and re-examine the consumption for that they are making action plan. A solution
rework and rejection results. The rework has reduced to of putting a solar heater was proposed and implemented
11.33% from 20% and rejection has reduced 4% from 7.3%. through the quality circle. The various steps for the
from the analysis he find that after removing the various root implementation of the quality circle were followed around
cause of rejection and rework, the rejection of lenses is 38% of saving and hence increase in the productivity was
reduced by 45.20% and rework of lenses is reduced by achieved by the implemented modification.
43.35%. this also have a positive effect on the productivity of
Sulaman Muhammad[7] in their paper, “Quality Improvement
the lenses as the start of this project the productivity of lens
of Fan Manufacturing Industry by using basic seven tools of
was noted as:(278/300)x100=92.6%.As after the implement-
Quality: A Case Study” investigate about total five type of
ation, the productivity was noted as : (288/300)x100=96%. It
defect occurring in fan manufacturing process of “Fecto Fan
was noted that even a simple QC tools can make significant
Company”. Who are specialized in manufacturing all type of
improvement to the company.
ceiling Fans. There were two sections in plant, manufacturing
Mayank Dev Singh [5] in their paper, “Productivity and assembling. After identifying the problems now the goal
improvement by using quality control tools- A Case study of was to eliminate all these problems and to ensure flawless
chartered Rubber Product”, have study about the productivity manufacturing process. For this purpose basic seven tools of
improvement of the chartered rubber product. They are quality were implemented. Tools were implemented through
following various orthodox customs, improper utilization of DMAIC methodology. Every tool was used in different step of
space & inaccurate arrangement of machineries with respect to DMAIC methodology for better results. This better result was
one another. Hence they are taking a lot of time for get because of managerial staff of the company who removes
undertaking various tasks and also more human effort is these defects from the manufacturing process. After the
required. Thus the help of SLP techniques & with the help of removal of defects from manufacturing process control chart

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 International Journal of Trend in Research and Development, Volume 5(2), ISSN: 2394-9333
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was implemented to make it sure that process is now under be analyzed and various solving methods will be present. The
control. At the last author of this paper was Strengthen the best solving method will be chosen and proposed to the
famous statement of quality guru Dr. Ishikawa that “95% of company and compared to the previous result and production.
quality related industrial problems can be solved simply by There are several approaches to choose from when the goal is
applying seven basic tools of quality” to increase the quality and productivity of a spur gear
manufacturing company. The techniques used in this paper
Shantanu Welekar [8] in their paper, “Quality Circle to
have been limited due to insufficient time and resources. In
improve Productivity”, deals with various aspects of Quality
this paper only the quality tools have been used and tried to
Circle and how improvement can be made by adopting
find the most effective way of quality testing and improving
practices of Quality Circle in chemical industries. The paper
productivity. These have given a better solution. But if any one
also presents a comparative discussion of various features of
uses other technique of industrial engineering then he will get
Quality Circle, Quality Improvement Group and work
more benefit than this paper. If it is decided to use the data in
Group/project team. The paper describes a case study of QC
future studies it would be interesting .By this way it may be
concept in a chemical industry which illustrates the
possible to specify high quality and productivity. The quest for
effectiveness of QC approach. Here Alka industry
higher quality and productivity will never stop and the project
manufactures anodizing of aluminum products and powder
extreme spur gear manufacturing will proceed. An important
coating of GI and CI sheets. In Alka industry Implementation
suggestion for future work is to test if the findings are
of Quality Circle led to identification of excessive gas
applicable to other products and machines within the factory.
consumption in the furnaces due to reasons attributed to
A deeper understanding could possibly make the conclusions
deficiency in man, material, method and machine. Each
from this study more understandable and easier to apply to
deficiency was handled separately and corrective measures are
other products.
implemented to optimize the gas Consumption in the plant.
CONCLUSION Quality Circle technique proved to be very Acknowledgment
effective for the problem selected by the quality circle
I would like to present thanks to my college/institute guide Mr.
members for the powder coating industry. Optimization of gas
Shubham Awasthi and my internal guide [Link] Mewada
consumption in the furnaces led to reduction in maintenance
even my colleagues.
costs, enhancement in reliability and availability of the
equipment, enhancement in morale and development of a sense CONCLUSION
of team dynamics among the employees, which proved to be
These following conclusion were derived from the review of
beneficial to the employees and the organization as a whole.
above mentioned papers.
Dr. Mahesh M. Bhagwati [9] in their paper, “Cause & Effect
1. 7 All majority industries are use Quality Circle Tools
Analysis for the Productivity improvement of TORNOS Sigma
20II : A Case Study” the issue of low productivity of beca-use they are very simple and easy to use.
TORNOS 20II w.r.t another mentioned products is deal [Link] 2. By reducing rework and rejection rate using 7 Quality
control tools we are able to improve the Quality.
this case study investigated table describes the recommended
3. Reduction in rejection is indirectly improving both
and actual rate of production. All the major possible causes
prod-uctivity and profitability of the organization.
contributing to the high rate of rejection, as mentioned in case
4. 7 Quality control tools have shown more better results
study are found and discussed with the management of an
organization. As a part of First phase of implementation, check in quality improvement as referred many use studies.
sheets have been designed and data has been collected. As a References
part of proposed work, it is decided to collect data of 25 groups
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