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Aditya Kurniawan
POLITEKNIK KOTA MALANG
Mind MAP of QUALITY
QPE is the TARGET parameter SIX SIGMA is the ASSESMENT method SEVEN TOOLS is the QUALITY tools
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Seven BASIC tools of quality
• Check Sheet
• Stratification
• Histogram
• Pareto Charts
• Ishikawa Diagram / Fishbone Diagram
• Scatter Diagram
• Control Chart
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Check Sheet / Tally sheet
Taken From QPE
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Check sheet procedure
• Classification: A trait such as a defect or failure mode must be classified into a category.
• Location: The physical location of a trait is indicated on a picture of a part or item being evaluated.
• Frequency: The presence or absence of a trait or combination of traits is indicated. Also number of occurrences of a trait on a part can be indicated.
• Measurement Scale: A measurement scale is divided into intervals, and measurements are indicated by checking an appropriate interval.
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Check sheet- Classification
• Classification: A trait such as a defect or failure mode must be classified into a category.
Classification of defects/failure must be technically identified
example:
Dimension
Motor speed
Wheel clearance
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Check Sheet / Tally sheet
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Check sheet- Location
• Location: The physical location of a trait is indicated on a picture of a part or item being evaluated. Location of defects/failure must be identified
example: Schneider manuf.Cikarang Dripper line 2 Molding room 14 Hyundai machine ltd
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Check Sheet / Tally sheet
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Check sheet- Frequency
• Frequency: The presence or absence of a trait or combination of traits is indicated. Also number of occurrences of a trait on a part can be indicated.
Frequency of defects/failure must be identified (by a check or stripe)
example:
√ √ √ √ √ √
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Check Sheet / Tally sheet
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Check sheet- Scale
• Measurement Scale: A measurement scale is divided into intervals, and measurements are indicated by checking an appropriate interval.
Measurements scale of defects/failure must be identified
example: Dimension : mm – failure tolerance OUT > 100mm High 60-100mm Medium 30-59mm Low 3 – 29mm
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Check Sheet / Tally sheet ???
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Check sheet – even A simple one works
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Stratification
A classification order of a problem Example : Classification by DATE Classification by DEFECTS Classification by SHIFT Classification by LOCATION
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Stratification A sample taken everyday SUNDAY to SATURDAY
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Stratification By dates
DATES Month 1 Month 2 Month 3
Sunday 0 0 0
Monday 10 9 8
Tuesday 13 15 14
Wednesday 10 9 7
Thursday 5 3 4
Friday 4 3 5
Saturday 0 0 0
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Stratification By location
DATES Month 1 Month 2 Month 3
Line 1 42 44 41
Line 2 36 33 34
Line 3 54 66 56
Line 4 22 23 23
Line 5 12 11 10
Line 6 44 42 43
Line 7 34 33 31
Aditya Kurniawan
POLITEKNIK KOTA MALANG
HISTOGRAM
A classification order of a problem GRAPH Example : Histogram by DATE Histogram by DEFECTS Histogram by SHIFT Histogram by LOCATION
Aditya Kurniawan
POLITEKNIK KOTA MALANG
HISTOGRAM
A classification order of a problem GRAPH Example : Histogram by DATE Histogram by DEFECTS Histogram by SHIFT Histogram by LOCATION
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Make a Check sheet • Make a check sheet design for the production of
your previous internship (prakerin) in excel
Make stratification • Make a stratification design for the production
of your previous internship (prakerin) in excel
Make histogram • Make a histogram design for the production of
your previous internship (prakerin) in excel
DATE
S
Month
1
Month
2
Month
3
Line 1 42 44 41
Line 2 36 33 34
Line 3 54 66 56
Line 4 22 23 23
Line 5 12 11 10
Line 6 44 42 43
Line 7 34 33 31
Aditya Kurniawan
POLITEKNIK KOTA MALANG
PARETO chart
A classification order / prioritizing order
– Pareto charts are used to identify and prioritize problems to be solved.
– They are actually histograms aided by the 80/20 rule adapted by Joseph Juran.
•Remember the 80/20 rule states that approximately 80% of the problems are created by approximately 20% of the causes.
Aditya Kurniawan
POLITEKNIK KOTA MALANG
PARETO chart
Aditya Kurniawan
POLITEKNIK KOTA MALANG
PARETO CHART A sample taken with 10 types of defect
Aditya Kurniawan
POLITEKNIK KOTA MALANG
PARETO CHART Monthly view table
Type of defects Month 1 Month 2 Month 3
Supply part rusted 22 29 21
Misaligned weld 2 4 3
Improper test 4 5 2
Wrong part 2
Void in casting 2 4
Film on part 4 4 4
Incorrect dimension 10 9 10
Adhesive failure 2 2
Aditya Kurniawan
POLITEKNIK KOTA MALANG
PARETO CHART Monthly view chart
0
5
10
15
20
25
Month 1
Month 1
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Ishikawa diagram / fishbone
A brainstorming of cause and effect
Created by defining some general casualties Example : MAN ENVIRONMENT MACHINE METHOD
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Ishikawa diagram / fishbone
A brainstorming of cause and effect
And by defining some SUB general casualties Example : MAN -skills -experience -pride
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Ishikawa diagram / fishbone
A brainstorming of cause and effect
And even by defining some MORE minor SUB general casualties Example : MAN -skills - training - educational background -experience -pride
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Ishikawa diagram / fishbone
A brainstorming of cause and effect
And one effect Example : Supply part rusted Misaligned weld Improper test Wrong part Void in casting Film on part Incorrect dimension Adhesive failure
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Ishikawa diagram / fishbone
A brainstorming of cause and effect
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Scatter Diagram
A diagram showing relationship between independent X and dependent Y variables
– Opt one casualty as independent variable X
(from the control variable casualties)
– Opt one effect as dependent variable Y (from the dependent variable effect)
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Ishikawa diagram / fishbone
EXAMPLE of picking x variable
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Scatter Diagram
A diagram showing relationship between independent X and dependent Y variables
– Opt one casualty as independent variable X
(from the Communication branch) =>
(lack of information) =>
(Add new information item)
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Scatter Diagram
A diagram showing relationship between independent X and dependent Y variables
– Opt one casualty as independent variable X
Adding quantities of information (confirmation) from 1 to 6 1. Telephone number 2. Mobile phone number 3. Email address 4. Secondary address 5. Office address 6. Mail box address
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Ishikawa diagram / fishbone
EXAMPLE of picking x variable
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Scatter Diagram
A diagram showing relationship between independent X and dependent Y variables
– Opt one casualty as independent variable Y
(Incorrect delivery)
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Scatter Diagram
A diagram showing relationship between independent X and dependent Y variables
– Opt one casualty as independent variable Y
The quantity of incorrect delivery in 1 month / in 1000 order
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Ishikawa diagram / fishbone
EXAMPLE of picking x variable
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Scatter Diagram Showing degree of correlation and dependency
Bivarian Pearson Analysis
Trivarian Pearson Analysis
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Bivarian Scatter Diagram Analysis
Pearson product-moment correlation coefficient (PPMCC)
Axes variable Y Dependent
Axes variable X Independent / test variable
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Trivarian Scatter Diagram Analysis
Pearson product-moment correlation coefficient (PPMCC) Single control variable
Axes variable Z Dependent
Axes variable X Independent / test variable
Axes variable Y Dependent
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Trivarian Scatter Diagram Analysis
Pearson product-moment correlation coefficient (PPMCC) Double control variable
Axes variable Z Dependent
Axes variable X Independent / test variable
Axes variable Y Independent / test variable
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Scatter Diagram
Correlation table PEARSON COEFFICIENT
Correlation Negative Positive
None −0.09 to 0.0 0.0 to 0.09
Small −0.3 to −0.1 0.1 to 0.3
Medium −0.5 to −0.3 0.3 to 0.5
Large −1.0 to −0.5 0.5 to 1.0
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Scatter Diagram
Correlation test 2 3 4 3 2 3 4 5 4 3
4 5 6 5 6 5 4 3 4 6
7 8 6 7 6 5 6 7 5 6
7 8 6 5 4 5 6 7 8 6
7 6 7 8 6 5 6 7 8 5
4 3 3 3 2 3 5 5 3 2
3 4 3 2 3 4 5 3 2 3
3 4 2 4 5 5 4 3 4 3
X = X
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Scatter Diagram
Correlation test 4 3 4 3 4 4 4 4 3 4
3 4 3 4 3 5 5 5 5 5
4 4 5 6 6 7 6 5 7 6
5 6 5 4 5 6 7 6 5 4
6 5 4 5 6 5 4 5 6 4
6 5 4 5 6 5 4 5 6 5
4 4 5 4 6 6 6 5 6 7
5 6 7 7 7 6 6 7 6 5
X = X
Aditya Kurniawan
POLITEKNIK KOTA MALANG
Scatter Diagram
Correlation test 2 3 3 3 4 4 5 5 6 6
7 7 8 9 8 9 7 8 9 10
11 12 11 3 3 4 5 5 6 5
6 7 6 7 6 7 8 7 8 7
8 9 8 9 8 9 10 10 11 11
12 12 12 13 14 14 14 12 11 9
8 9 8 7 8 9 8 7 6 7
8 9 10 11 11 12 13 11 12 13
X = X