learn about 7QC TOOLS ((STRATIFICATION, CHECK SHEET, TALLY SHEET, HISTOGRAM, PARETOGRAM, CAUSE AND EFFECT DIAGRAM, SCATTER DIAGRAM, CONTOL CHARTS, QUALITY CONTROL, X BAR AND R CHART, X BAR AND MR CHART, P CHART, C CHART, LEARN IN EXCEL, HOW TO BUILD IN EXCEL, X BAR CHART, )) AND ALSO LEARN HOW TO BUILD THEM IN EXCEL.

1. 7QC TOOLS
7 TOOLS used to CONTROL the QUALITY of
the product

2. 7QC TOOLS
1.) STRATIFICATION
2.) CHECK SHEET/TELLY SHEET
3.) HISTOGRAM
4.) PARETOGRAM
5.) CAUSE AND EFFECT DIAGRAM
6.) SCATTER DIAGRAM
7.) CONTROL CHARTS

3. 1). STRATIFICATION
• It simply mean the GROUPS of considerations.
• Or give a GROUP NAME, to considerations, on
which study is based.
Before to study any process , you must have to
make some GROUPS on which your study will
depends.
like:- time, type, reason, machine, shift, person,
effects…..etc

4. 2.) CHECK SHEET/ TELLY SHEET
• A check sheet is a FORM/TABLE, on which data is recorded systematically.
Like---below
DATE
5/11/2013
6/11/2013
7/11/2013
8/11/2013
9/11/2013
SHIFT
st
1
OPERATOR
Sam
1
st
mack
arun
Sam
1st
mack
arun
Sam
1st
mack
arun
Sam
st
mack
arun
Sam
1
mack
arun
DEFECTED PRODUCT
20
0
12
18
1
14
9
2
18
24
0
12
11
1
17
Stratification
Here, in this Form we are
trying to find number of
Defected Product made by
Operators in 1st shift of each
day.
You just have to
build a FORM, with
taking GROUPS
(stratification), on
which you want to
make investigation.

5. 3). HISTOGRAM




It is used to observe that , how is the process going.
Or we can say, use to predict future performance of a process.
Any change in process.
It is simply a bar chart, from which we get, info of the process- how
its going, it is in limits or not.
10
Lower
limit
Upper
limit
HISTOGRAM
8
6
4
Trend line
2
0
3
4
5
6
7
8
9
10
11
2
3
4
5
6
7
8
9
10

6. 8
Lower
limit
Lower
limit
8
dia
dia
6
10
Upper
limit
4
2
Upper
limit
6
4
2
0
0
3
4
5
6
7
8
9
10
11
3
4
5
6
7
8
9
10
11
2
3
4
5
6
7
8
9
10
2
3
4
5
6
7
8
9
10
Process is varying all over in/out of range
Process is Within Limits
Different Histograms showing
different Processes
8
10
Lower
limit
8
dia
dia
6
Upper
limit
4
Lower
limit
Upper
limit
6
4
2
2
0
0
3
4
5
6
7
8
9
10 11 12 13 14 15
1
2
3
4
5
6
7
8
9
10
11
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
10
10 11 12 13 14
Process is moving towards Upper
Limit
Process is moving towards Lower
Limit

7. How to build HISTOGRAM in Excel.(with example)
1.) 1st we have to Study/Collect specifications like -diameter (Data) for 24 products.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
D DIA 6 5 7 10 9 8 4 7 5 6 7 7 8 6 8 7 5 7 8 6 7 7 8 8
2.) Calculate RANGE.
RANGE= Maximum value - Minimum value
So here , maximum value= 10,
Minimum value = 4
So RANGE = 10- 4 =6
3.) Now decide the NUMBER OF CELLS.
We have 24 data points ,
and it fall in 1st group ,
so- No of cells = 6
Data Points
20 -50
51-100
101-200
201-500
501-1000
Over 1000
Number of Cells
6
7
8
9
10
11-20
4.) Calculate the approximately cell width.
Cell width= RANGE/ NO OF CELLS
= 6/6 =1
5.) Round Off the cell width.
If cell width come in a complicated manner, like 0.34, 0.89 or else , then
round off it to , one you want, like : 0.50 or 1 or else.

8. 6.) Now construct the Cell Groups with keep in mind cell width( cell width=1)
2
3
4
5
6
7
8
9
10
11
3
4
5
6
7
8
9
10
11
12
Cell width=1
Cell width same for
all cell groups =1
7.) Now find number of data values/ Frequencies in each Cell Group.
You can do this manually , by counting itself or by using formula .(frequency
formula) Mean how many values fall in each group.
A
B
C
cell groups frequency
1
2
3
0
2
3
4
1
3
4
5
3
4
5
6
4
5
6
7
8
6
7
8
6
7
8
9
1
8
9
10
1
9
10
11
0
10
11
12
0
(D1:D24) values are on previous page)
Go to yellow block, type, =frequency( D1:D24, B1:B10), and
press Enter.
Then select yellow block and all sky blue blocks, press
F2, and press CTRL , SHIFT, ENTER. ( frequency formula
will get implement in all sky blue blocks as in yellow block )
And you will get frequency of data values in each group,
As in group (7 – 8) , frequency is 6.

9. 8.) Now we got frequency data in each group, now we can build Histogram.
frequency data is our final data.
now select this data a build a bar chart. That’s it.
10
Frequency
8
6
4
2
0
3
4
5
6
7
8
9
10
11
2
3
4
5
6
7
8
9
10
Dia (mm)
Group 4 - 5, show values from 4.1 to 5
Group 5 - 6, show values from 5.1 to 6
So this rule for all groups.
Trend line – also give an
visual idea of moving
process.

10. In short how to build histogram
1.
Study / collect data.
2.
Find Range.( range =max value - min value)
3.
Find Number of cells.
4.
Calculate Cell width ( cell width= range/no of cells)
5.
Round off , if needed.
6.
Create cell groups, using cell width
7.
Find frequency.
8.
Plot bar chart.

11. 4). PARETOGRAM
• By this we can separate , most important causes from less
important causes for a problem.
Example- you have a high waste , and you have
many causes for that, so you have to work, first on
those causes, which are most responsible for the
waste.
So Paretogram help us to find these, most responsible causes
for a problem.

12. A
1
2
3
4
5
6
7
8
9
10
11
12
13
B
C
D
waste in
cumulative
kg
percentage percentage
Waste types
cal wrinkle ply
400
roll end
320
/coat off
234
angle change
140
splice press
90
passenger short pices
87
damaged bands 65
mechanical waste 60
bead wrap edges 45
scorchy
23
short piece
11
chaffer
9
passenger ply
7
TOTAL
1491
26.83
26.8
21.46
48.3
15.69
64.0
9.39
73.4
6.04
5.84
79.4
85.2
4.36
89.6
4.02
93.6
3.02
96.6
1.54
0.74
98.2
98.9
0.60
99.5
0.47
100.0
So from this Paretogram, we got that by
working on first 3 causes, we can reduce
waste up to 64%.
So first work on these causes, and after that
go for other 10 causes, which are less
responsible, for waste generation (36%).
So paretogram, give us a clean view, of
most important area, where we have to
work first to solve the current problem.

13. How to build a Paretogram in Excel
For a problem. Example- waste problem, so collect what
are causes, and how much waste is coming because of each cause. ((its
down in table))
2.) Sum Up(Total) Sum all wastes from all causes. ((its down in table)
1.) Collect data
3.) Calculate The Percentage of each individual Find individual percentage
of waste by each cause contributing in all total waste.
(Individual waste/total)*100
((its down in table))
A
1
2
3
4
5
6
7
8
9
10
11
12
13
B
C
D
waste in
cumulative
kg
percentage percentage
Waste types
cal wrinkle ply
400
roll end
320
/coat off
234
angle change
140
splice press
90
passenger short pices
87
damaged bands 65
mechanical waste 60
bead wrap edges 45
scorchy
23
short piece
11
chaffer
9
passenger ply
7
TOTAL
1491
26.83
26.8
21.46
48.3
15.69
64.0
9.39
73.4
6.04
5.84
79.4
85.2
4.36
89.6
4.02
93.6
3.02
96.6
1.54
0.74
98.2
98.9
0.60
99.5
0.47
100.0
4.)Calculate the cumulative
percentage. ( mean take 1st
percentage, and add 1-by-1, all
percentage to that) mean :- D1=C1,
D2=D1+C2,
D3=D2+C3
D4=D3+C4
D5=D4+C5,
D6=D5+C6,
D7=D6+C7,
D8=D7+C8,
D9=D8+C9,
D10=D9+C10,
D11=D10+C11,
D12=D11+C12,
D13=D12+C13,

14. 5.) That’s it now let build paretogram.
6.) Insert a bar chart ( taking data, B1:B13 and D1:D13) ( from previous
page) you will get below chart.
400
300
200
100
waste (Kg)
0
cumulative
%
7.) Now click on cumulative bars (Red bars), right click and go to change
chart type, and select a line chart , and you will get below chart.
400
300
200
100
waste (Kg)
0
cumulative
%

15. 8.) Now select line chart (Red line), right click , go to format data
series, and you got two option primary axis and secondary axis, click on
secondary axis, and you will get below graph.
120.0
400
300
200
paretogram
100.0
80.0
60.0
40.0
100
0
20.0
0.0
waste (Kg)
cumulative %
9.) that’s it , now study this graph , and make some decisions about , on
which area you have to work first, to solve a problem.
( like if you work on 1st cause – you can reduce waste up to 26 %
if you work on 1st and 2nd causes – you can reduce waste up to 48%
if you work on 1st ,2nd and 3rd causes – you can reduce waste up to 64 %)
So from 13 causes, if you work on first three causes you can reduce waste
up to 64 %.

16. 5). CAUSE AND EFFECT DIAGRAM
•
It give us relationship between Effects and its Possible Causes with
M-approach- ( man, method, material, machine)

17. 6). SCATTER DIAGRAM
Y-axis
7
6
5
4
3
2
1
0
0
1
2
3
4
5
7
6
5
4
3
2
1
0
6
0
X-axis
1
2
3
X-axis
4
5
6
+ve relationship (Y-increase as X-
-ve relationship (Y- decrease as X-
increase )
increase )
Y-axis
Y-axis
 It is used to study relationship between two variables.
7
6
5
4
3
2
1
0
0
1
2
3
4
5
X-axis
No -Relationship
6
7

18. Example
• Let we have a product , and we have to study its life cycle with respect
to temperature.
life
25
23
20
16
10
4
20
18
15
12
30
LIFE (YEARS)
temp
40
45
50
55
60
65
35
30
25
20
25
20
15
10
5
0
0
10
20
30
40
50
60
70
TEMP (DEGREE CELSICUS)
CONCULSION- product has maximum life at 400 C, and after on increasing or
decreasing of temperature , Life of product get decrease.

19. 7). CONTROL CHARTS
 Control charts are Trend Chards, for Analysis and Presentation of data.
•
•
Control charts in itself a big topic.
Many Calculations.
Type of
Control Charts
Variable
attribute
defects
X and
σ chart
X and
S chart
X and
R
chart
X and
MR
chart
C - chart
U - chart
defective
nP- chart
We will study here only these important charts
P - chart

20. (X - bar) and R chart.
It Simply tell us
where the process is going.
Is the process under control ?
Are we have to increase the no of inspections ?
R chart
1
R
0.8
0.6
UCL
0.4
LCL
0.2
center line
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
X-bar Chart
5.5
5.4
X-bar
5.3
5.2
UCL
5.1
LCL
5
center line
4.9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

21. Lets build it.
Formulas for
-- R chart
UCLR = D4 x R
LCLR = D3 x R
UCLX = X + A2 R
LCLX = X - A2 R
In these formulas, we have
constants, D4, D3, A2, values of
these constants we will get
from table 1.1 ( last slide)
But 1st learn below things .
-- X bar ( average)
-- X double bar (average of average)
(its also center line of X-bar chart)
R – Average of Range
(its also center line for R-bar chart)
UCLR – upper control limit for R chart
LCLR – lower control limit for R chart
UCLX – upper control limit for X-bar chart
LCLX – lower control limit for X-bar chart
Lets take an example- in which we will took a lot from, running line, after
every 30 minute for inspection of weight of product.
In each lot we take 5 samples.

22. 1.) Collect data.
sample
sample
sample
sample
sample
sample
lot
1
2
3
4
5
( as in figure below).
1
2
3
5.5
5 5.4
5.1
5
5
5
5 5.1
5.2 5.5 5.3
5.4 5.1 5.4
sample
lot
5
5.1
5
5
5.1
5.1
6
7
5.1 5.4
5.2
5
5
5
5.2 5.5
5.5
5
8
5.5
5.1
5
5.4
5.2
9
5
5
5.5
5.1
5.2
10
5
5.1
5.1
5
5
11 12 13
5.2 5.7 5.4
5.4
5
5
5 5.2 5.4
5.3 5.5 5.2
5.1 5.4 5.4
14
5.2
5.2
5
5
5.1
15
5.2
5
5
5.1
5.4
(average) and R(range) for each lot. (as in figure below)
2.) Now Calculate the
As like for
lot 1.
4
5.2
5.2
5.4
5.5
5.4
R (range)= max- min
= (5.5+5.1+5+5.2+5.4)/5
=5.24
1
sample 1
5.5
sample 2
5.1
sample 3
5
sample 4
5.2
sample 5
5.4
Average(X bar) 5.24
Range(R ) 0.5
2
5
5
5
5.5
5.1
5.1
0.5
3
5.4
5
5.1
5.3
5.4
5.2
0.4
4
5.2
5.2
5.4
5.5
5.4
5.3
0.3
5
5.1
5
5
5.1
5.1
5.1
0.1
6
5.1
5.2
5
5.2
5.5
5.2
0.5
7
5.4
5
5
5.5
5
5.2
0.5
= 5.5 - 5
= 0.5
8
5.5
5.1
5
5.4
5.2
5.2
0.5
9
10
5
5
5.5
5.1
5.2
5.2
0.5
5
5.1
5.1
5
5
5.04
0.1
11 12 13
5.2 5.7 5.4
5.4
5
5
5 5.2 5.4
5.3 5.5 5.2
5.1 5.4 5.4
5.2 5.4 5.28
0.4 0.7 0.4
14
5.2
5.2
5
5
5.1
5.1
0.2
15
5.2
5
5
5.1
5.4
5.1
0.4

23. 3.) Now Calculate .
(average of average for X) (as in figure below)
4.) Now Calculate . R ( average of Range) ( as in figure below)
sample lot
1
sample 1
5.5
sample 2
5.1
sample 3
5
sample 4
5.2
sample 5
5.4
Average(X bar) 5.24
Range(R ) 0.5
2
5
5
5
5.5
5.1
5.1
0.5
3
5.4
5
5.1
5.3
5.4
5.2
0.4
4
5.2
5.2
5.4
5.5
5.4
5.3
0.3
5
5.1
5
5
5.1
5.1
5.1
0.1
6
5.1
5.2
5
5.2
5.5
5.2
0.5
7
5.4
5
5
5.5
5
5.2
0.5
So,
8
5.5
5.1
5
5.4
5.2
5.2
0.5
9
10
5
5
5.5
5.1
5.2
5.2
0.5
5
5.1
5.1
5
5
5.04
0.1
5.19
11 12 13
5.2 5.7 5.4
5.4
5
5
5 5.2 5.4
5.3 5.5 5.2
5.1 5.4 5.4
5.2 5.4 5.28
0.4 0.7 0.4
R
14
5.2
5.2
5
5
5.1
5.1
0.2
15
5.2
5
5
5.1
5.4
5.1 5.19
0.4 0.4
average
0.4
5.) Now Calculate , limits. as below
UCLR = D4 x R
LCLR = D3 x R
UCLX = X + A2 R
LCLX = X – A2 R
=2.114 x 0.4 = 0.8456
Find constants values From table
1.1 for 5 samples, in a lot. ( last
slide)
= 0 x 0.4 = 0
=5.19 + 0.577x 0.4 = 5.420
=5.19 – 0.577x 0.4 = 4.969
D4 = 2.114
D3 = 0
A2 = 0.577

24. 6.) Calculations are now over, so plot the graph.
1
2
3
4
5
6
7
8
9
10 11
12
13 14
15
Average(X bar) 5.24 5.12 5.24 5.34 5.06 5.2 5.18 5.24 5.16 5.04 5.2 5.36 5.28 5.1 5.14
Range(R )
0.5 0.5 0.4 0.3 0.1 0.5 0.5 0.5 0.5 0.1 0.4 0.7 0.4 0.2 0.4
UCLR = 0.8456
LCLR = 0
R = 0.4
R chart
1
R
0.8
0.6
UCL
0.4
LCL
0.2
center line
0
1
2
3
4
5
6
7
9
10 11 12 13 14 15
X-bar Chart
5.5
UCLX = 5.420
LCLX = 4.969
8
5.4
X-bar
5.3
UCL
5.1
= 5.19
5.2
LCL
5
center line
4.9
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15

25. X-bar and MR chart
When we can’t take multiple samples, in a lot. We use X-bar and MR chart.
Processes like- chemical process, where the cost of test is so high, that we
can’t get, multiple samples.
Here
UCL MR = MR x D4
LCLMR = MR x 0 = 0
UCL X = X + 3( MR / 1.13)
LCLX = X – 3( MR / 1.13)
Central line = X
MR = difference between the value and value immediately proceeding.
As we have only 1 sample in each lot, so mean n=1 , for X bar chart.
But for MR chart , as MR is comes out, by differencing two samples, mean in
each lot we have 2 samples, mean n=2, for MR chart.
D4 = 3.267 , for 2 samples, for MR chart,
from table 1.1 (last slide).

26. X
5.5
5
5.4
5.2
5.1
5.1
5.4
5.5
5
5
5.2
5.7
5.4
5.2
5.2
5.26
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
AVERAGE
Make all values of MR +ve IN TABLE
MR
MR
-0.5
0.4
-0.2
-0.1
0
0.3
0.1
-0.5
0
0.2
0.5
-0.3
-0.2
0
0.5
0.4
0.2
0.1
0
0.3
0.1
0.5
0
0.2
0.5
0.3
0.2
0
0.2357
X = 5.26
MR = 0.235
UCL MR = MR x D4 = 0.235 x 3.267 = 0.767
LCLMR = MR x 0 = 0.235 x 0 = 0
UCL X = X + 3( MR / 1.13) = 5.26 + 3(0.235 / 1.13)= 5.883
LCLX = X – 3( MR / 1.13) = 5.26 – 3(0.235 / 1.13)= 4.636
Central line = X = 5.26
Central line = MR = 0.235
0.9
MR -chart
0.7
MR
LCL
0.3
UCL
0.1
MR
X
0.5
-0.1
6
1
2
3
4
5
6
7
8
9
10 11 12 13 14 15
X-bar chart
5.5
X
5
LCL
4.5
UCL
central line
4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
center line

27. P-Chart (fraction defective)
•
Ratio of number of items rejected to the number of items inspected is
known as fraction defective.
P=
Total Number of Defected Samples
Total Number of Samples Inspected
UCL = P + 3 P( 1- P )/n
LCL = P - 3 P( 1- P )/n
n= sample size
Lets take an example of studying n=100 samples each day for 10 days.
days (100 sample each day) 1
2
No. of defected items
11 10
fraction defective each day 0.11 0.10
3
4
5
6
7
8
12
15
7
11
10
14
0.12
0.15
0.07
Total number of defected samples = 110
Total number of samples inspected = 100x10 =1000
So, P = 110/1000 = 0.11
UCL = 0.203866 ( after calculation)
LCL =0.016134 (after calculation)
0.11 0.10
9 10
10
10
0.14 0.10 0.10
110

28. We calculated everything , so just build it.
0.25
0.2
0.15
0.1
0.05
0
P-Chart
fraction defective
UCL
LCL
center line
1
2
3
4
5
6
7
8
9
10

29. C- Chart
• We use it when , a defected product , is also accepted.
• It depends on how many defects are there in the defected product.
C=
Total number of defects in all .
Total Number of Samples Inspected
UCL = C + 3
LCL = C - 3
If LCL, comes –ve, take it zero.
C
C
Lets take an example, of studying GALASS ITEM, having number of bubbles, in
that as defects. We studied 10 items.
No. of defects in each item
1
3
2
21
3
5
4
3
5
7
6
8
7
10
8
0
9
14
10
9
80
So , C = 80/10 = 8
UCL = 16.484
LCL = - 0.484 = 0
( so if any defected item, has defects below 16.484, that item will we be accepted.)

30. Now we calculated everything, so just build C-chart
Item Rejected ( because number of defects, in
that item are more than UCL= 16.484 )
22
C - Chart
16.484
17
12
Series 1
UCL
7
8.00
LCL
2
0.00
center line
-3
1
2
3
4
5
6
7
8
9
10
Don’t get confuse between P chart, and C chart.
P- chart, use
C- chart use
for DEFECTED ITEMS.
for NUBER OF DEFECTS, IN EACH ITEM.

31. Table 1.1
X-bar Chart
Sample
Size = N
for sigma
R Chart Constants
LCL
UPL
S Chart Constants
LCL
UCL
A2
A3
dn
D3
D4
B3
B4
2
3
4
1.88
1.023
0.729
2.659
1.954
1.628
1.128
1.693
2.059
0
0
0
3.267
2.574
2.282
0
0
0
3.267
2.568
2.266
5
0.577
1.427
2.326
0
2.114
0
2.089
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
0.483
0.419
0.373
0.337
0.308
0.285
0.266
0.249
0.235
0.223
0.212
0.203
0.194
0.187
0.18
0.173
0.167
0.162
0.157
0.153
1.287
1.182
1.099
1.032
0.975
0.927
0.886
0.85
0.817
0.789
0.763
0.739
0.718
0.698
0.68
0.663
0.647
0.633
0.619
0.606
2.534
2.704
2.847
2.97
3.078
3.173
3.258
3.336
3.407
3.472
3.532
3.588
3.64
3.689
3.735
3.778
3.819
3.858
3.895
3.931
0
0.076
0.136
0.184
0.223
0.256
0.283
0.307
0.328
0.347
0.363
0.378
0.391
0.403
0.415
0.425
0.434
0.443
0.451
0.459
2.004
1.924
1.864
1.816
1.777
1.744
1.717
1.693
1.672
1.653
1.637
1.622
1.608
1.597
1.585
1.575
1.566
1.557
1.548
1.541
0.03
0.118
0.185
0.239
0.284
0.321
0.354
0.382
0.406
0.428
0.448
0.466
0.482
0.497
0.51
0.523
0.534
0.545
0.555
0.565
1.97
1.882
1.815
1.761
1.716
1.679
1.646
1.618
1.594
1.572
1.552
1.534
1.518
1.503
1.49
1.477
1.466
1.455
1.445
1.435

32. •
•
•
•
•
•
6SIGMA
http://www.youtube.com/watch?v=kiUXCezYFTM
7QC TOOL
http://www.youtube.com/watch?v=2OdGNLEXtlI
HOW TO UPLOAD POWER POINT ON YOUTUBE
https://www.youtube.com/watch?v=WbSTsG2klWQ
That’s it .
• I Hope you got it.
• Have any question, please let me know.