Project Charter, Check Sheet, Pareto Analysis & C&E Diagram & Matrix

1. QUALITY TOOLS &
TECHNIQUES
Q T T
PROJECT CHARTER, CHECK SHEET,
PARETO ANALYSIS, C & E DIAGRAM &
MATRIX
By: -
Hakeem–Ur–Rehman
IQTM–PU 1

2. PROJECT CHARTER
Project Title Project Title
Business Case  Why should you do this project?
 What are the benefits of doing this project?
Problem Statement What is the problem, issue and/or concern?
Goal What are your improvement objectives and targets?
Metrics (CTQ’s)  PRIMARY Metric(s): Key measures to be used for the objectives
 SECONDARY Metric(s): Those measures which indicates impacts on
secondary concerns and which indicates that problem is not shifted
to other key areas.
Project Scope  What authority do you have?
 Which processes/products you are addressing?
 What is not within this project?
Project Team  Who are the team leader, sponsor, and members?
 What are their roles and responsibilities in this project?
Project Plan How and when are you going to get this project done (DMAIC stages)
Communication Plan  What are your interfaces with each other?
 What are your meeting & reporting times?

3. 3

4. TYPES OF DATA
ATTRIBUTE DATA give you counts representing the presence
or absence of a characteristic or defect. These counts are
based on the occurrence of discrete events, e.g.,
 true/false statements
 Accepted or rejected
Passed or fail
An attribute is not numerically measured; it‟s either there or it‟s
not.
 VARIABLE DATA are based on numerical measurement of a
key quality characteristic produced by the process, e.g.,
 Diameter of a shaft
 Temperature of Oven
 Pressure of Steam, etc.

5. CHECK SHEET
 A check sheet is a Form, in Diagram or Table
format, prepared in advance for
Recording/Collecting Data. You can thus gather
necessary Data by just making a Check mark on
the Sheet.
 Main applications of a check sheet include
registering how often different problems occur and
registering the frequency of incidents that are
believed to cause problems.

6. TYPES OF CHECK SHEET
 There are five main types of check sheets used
for data collection (custom check sheets can
also be designed to fit specific needs):
1. Defective item check sheet / Attribute
Check Sheet
2. Variable Check Sheet
3. Defective Location Check Sheet
4. Defective Cause Check Sheet
5. Checkup Confirmation Check Sheet

7. TYPES OF CHECK SHEET
 DEFECTIVE ITEM (ATTRIBUTE) CHECK SHEET:
 used to identify what types of problems or defects are
occurring in the process.
 Usually these check sheets will have a list of the defects or
problems that may occur in the process.
 When each sample is taken, a mark is placed in the
appropriate column whenever a defect or a problem has
been identified.
 Countable data is used in the defective item check sheets.

8. TYPES OF CHECK SHEET
 VARIABLE CHECK SHEET:
 Gathering data about a process also involves the collection of
information about variables, such as size, length, weight, and
diameter. These data are best represented by organizing the
measurements into a frequency distribution on a variables
check sheet. The following Figure is variables check sheet
showing the frequency distribution of the length of logs in a
sample of 95trees.

9. TYPES OF CHECK SHEET
 DEFECTIVE LOCATION CHECK SHEET:
 Used to identify what types of problems or defects are occurring in the
process.
 Used to identify the location of the defect on the product.
 Used; when the external appearance of the product is important.
 Usually this type of check sheet consists of a picture of the product. On
this picture, marks can be made to indicate were defects are occurring on
the surface of the product.

10. TYPES OF CHECK SHEET
 DEFECTIVE CAUSE CHECK SHEET:
 used to identify causes of a problem or a defect.
 More than one variable or attribute is monitored when
collecting data for this type of check sheets.
 For example, we could be collecting data about the type of
machine, operator, date, and time on the same check
sheet.
Operators Time Machine 1 Machine 2
Operator A Morning X X
Afternoon XX XXXXX
Operator B Morning X XX
Afternoon XX XXXXXXXXXX
As we can see most of the error is occurring at machine 2
and at the afternoon shift. This could suggest that machine
2 has problems when it is run in the afternoon shift.

11. TYPES OF CHECK SHEET
 CHECKUP CONFORMATION CHECK SHEET:
 Used to ensure that proper procedures are being
followed.
 These check sheets usually will have a list of tasks
that need to be accomplished before the action
can be taken.
 Examples of checkup confirmation check sheets
are final inspection, machine maintenance,
operation checks, and service performance check
sheets.

12. PARETO ANALYSIS
 A bar graph used to arrange information in such a way that priorities for
process improvement can be established.
P a r e to C ha r t o f F a ult D e s c .
2500
100
2000
80
Pe r c e nt
1500
Co unt
60
1000
40
500 20
0 0
F a ult De s c. t. t. g t. d d s r
S S in S am f ie am f ie ct he
n
ki
p er n e i e i fe t
e k e S ec S ec De
O
ok S uc ev n Sp e Sp
Br P Un pe s dg s c.
O A E A is
t M
No aw No
t
R
s t. im
on Tr
C
C o unt 707 674 205 164 97 96 78 45 43 107
Pe r ce nt 3 1 .9 3 0 .4 9 .3 7 .4 4 .4 4 .3 3 .5 2 .0 1 .9 4 .8
C um % 3 1 .9 6 2 .3 7 1 .6 7 9 .0 8 3 .3 8 7 .7 9 1 .2 9 3 .2 9 5 .2 1 0 0 .0
 The 80–20 theory was first developed in 1906, by Italian economist,
Vilferdo Pareto, who observed an unequal distribution of wealth and power
in a relatively small proportion of the total population.
 Joseph M. Juran is credited with adapting Pareto‟s economic observations
to business applications.
 Separates the "vital few" from the "trivial many" (Pareto Principle)

13. PARETO ANALYSIS (Cont…)
 The 80:20 Rule Examples:
 80% of your phone calls go to 20% of the names
of your list
 20% of the roads handle 80% of the traffic
 80% of the meals in a restaurant come from 20%
of the menu
 20% of the people causes 80% of the problems

14. PARETO ANALYSIS (Cont…)
 Pareto Chart Using Minitab– EXAMPLE:
Suppose you work for a company that
manufactures motorcycles. You hope to
reduce quality costs arising from defective
speedometers. During inspection, a certain
number of speedometers are rejected, and
the types of defects recorded.
You enter the name of the defect into a
worksheet column called Defects, and the
corresponding counts into a column called
Counts.
You know that you can save the most
money by focusing on the defects
responsible for most of the rejections.
A Pareto chart will help you identify which
defects are causing most of your problems.
Open the worksheet EXH_QC.MTW

15. PARETO ANALYSIS (Cont…)
 Pareto Chart Using Minitab– EXAMPLE:
 EXH_QC.MTW (Cont…)
Step – 1:
Choose Stat  Quality Tools 
Pareto Chart
Step – 2:
 Choose Chart defects table.
 In Labels in, enter a column of
Defects.
 In Frequencies in, enter a
column of Counts

16. PARETO ANALYSIS (Cont…)
 Pareto Chart Using Minitab– EXAMPLE:
 EXH_QC.MTW (Cont…)

17. PARETO ANALYSIS (Cont…)
 Pareto Chart Using Minitab– EXAMPLE:
 EXH_QC.MTW (Cont…)
Analyze the Chart:
Focus on improving the
number of missing screws
because over half of your
speedometers are
rejected due to this
defect.

18. SIPOC DIAGRAM (Cont…)
The figure below shows the linkage of the SIPOC to future tools used in the
DMAIC process:

19. OVERVIEW OF THE
BRAINSTORMING TECHNIQUES
A commonly used tool to seek ideas by using categories to stimulates causes
and effect relationship with a problem. It uses verbal inputs in a team
environment.
Categories
The “Y”
The “Problem”
The “X’s”
“Causes”

20. CAUSE & EFFECT DIAGRAM
 Cause-and-Effect Diagram (also
known as a "Fishbone Diagram") is
a graphical technique for grouping
people's ideas about the causes of a
problem.
 Invented by Professor Kaoru
Ishikawa of Tokyo University;
Japanese expert in quality
management.
PRODUCTS Categories for the legs of the TRANSACTIONAL
1. Measurement diagram can use templates for 1. People
2. People 2. Policy
products or transactional
3. Method 3. Procedure
4. Materials symptoms. Or you can select 4. Place
5. Equipment the categories by process step 5. Measurement
6. Environment or what you think appropriate 6. Environment
for the situation.

21. CAUSE & EFFECT DIAGRAM
CLASSIFYING THE X’s (Cont…)
The CAUSE & EFFECT DIAGRAM is simply a tool to generate
opinions about possible causes for defects.
For each of the X‟s identified in the Fishbone diagram classify them
as follows:
 Controllable – C (Knowledge)
 Procedural – P (People, System)
 Noise – N (External or Uncontrollable)
Think of procedural as a subset of controllable. Unfortunately, many
procedures within a company are not well controlled and can cause
the defect level to go up. The classification methodology is used to
separate the X‟s so they can be used in the X–Y (Correlation or
Cause & Effect) Matrix and the FMEA taught later.
WHICH X’s CAUSE DEFECTS?

22. C & E DIAGRAM USING MINITAB
 EXAMPLE:
 Using a Pareto Chart, You discovered that your
parts were rejected most often due to surface
flaws. This afternoon, You are meeting with
members of various departments to brainstorm
potential causes for these flaws. Beforehand, you
decide to print a cause & Effect (Fishbone)
diagram to help organize your notes during the
meeting. The example below illustrates how to
generate a complete Cause & Effect diagram with
sub–branches.
 OPEN THE FILE:
 SURFACEFLAWS.MTW

23. C & E DIAGRAM USING MINITAB

24. C & E DIAGRAM USING MINITAB

25. C & E DIAGRAM USING MINITAB

26. DEFINITION OF X–Y MATRIX
 The (X–Y) CAUSE & EFFECT Matrix is:
 A tool used to identify potential X‟s and assess their
relative impact on multiple Y‟s (including all Y‟s that are
customer focused)
 Based on the team‟s collective “opinions”
 Created for every project
 Updated whenever a parameter is changed
 To summarize, the X–Y is a team based prioritization tool for
the potential X‟s
 WARNING! This is not real data, this is organized
brainstorming!! At the conclusion of the project you may
realize that the things you thought were critical are in fact
not as important as was believed.

27. THE X–Y MATRIX (Cont…)
THE VITAL FEW:
 A Six Sigma Belt does not just discover which X‟s are
important in a process (the Vital few).
The team considers all possible X‟s that can contribute or cause the
problem observed.
The team uses three primary sources of „X‟ identification:
1. Process Mapping
2. Fishbone Analysis
3. Basic Data Analysis – Graphical and Statistical
A List of X‟s is established and compiled.
The team then prioritizes which X‟s it will explore first, and
eliminates the “obvious” low impact X‟s from further
consideration.
The X–Y Matrix is this Prioritization Tool!

28. THE X–Y MATRIX (Cont…)
PROCEDURE FOR MAKING AN X-Y MATRIX:
1. List out the CTQ (Y‟s) for the targeted process.
2. Make a table with numbers of rows and columns.
3. Write down the CTQ against individual column.
4. Write the weight-age for each CTQ.
5. Find out input process parameters (X‟s) by brainstorming
and write them against individual rows.
6. Put suitable numbers in the intersection of rows and
columns to show the relationship between X‟s and Y‟s.
7. Finally calculate the weighted sum against each X‟s.

29. THE X–Y MATRIX (Cont…)
EXAMPLE: Let‟s take the example of the newspaper printing process. After transforming the
VOC we find the CTQ (Y‟s) as below:
 Clearly readable print
 Good quality photo
 Harmless to health
Upon brainstorming, the input process parameters (X‟s) have been found as below:
 Good quality ink
 Less vibration during operation of printing press
 Paper quality
For the above sets of X‟s and Y‟s the X-Y matrix table will look like the example below:
 Wherever there is a strong relation between X‟s and Y‟s, put 9. For weak relations put
3 or 1. Keep the intersection field blank if there is significant relation.
 Weighted sum for “Good quality ink” is calculated as 15*9 + 10*9 + 10*1 = 235.
 The calculation is similar for the rest of the X‟s. The input parameters with a higher
weighted sum should be selected for further FMEA.

30. QUESTIONS
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