Basic Statistical Data Analysis

Quality Control Tools

Module 4

1
 Module Objectives

 This is a module for Quality Control Tools. Upon

completion of this module, you should be able to;
 describe the application of each of quality control tools in
conducting basic statistical analysis.
 use the tools effectively to interpret a statistical outcome into
a practical explanation.

2
 Content

1. Quality Control Tools

2. Data Collection Tools
3. Graphical Analysis Tools

3
 Quality Control Tools

Introduction Basic QC Tools

4
 Key Learning

 Quality Concept
 The importance of Quality, Cost of Poor Quality, Quality is
FREE
 QC Tools
 Types of Data
 Continuous Improvement

5
 Quality & QC Tools

 Quality means, “Fit to Use”, Juran

 Lack of quality in product / service leads to customer
dissatisfaction.
 The QC basic tools use to sustain and improve quality in
the product /service.

6
 Basic Statistical QC Tools

2. Scatter Plot
3. Pareto chart
1. Check Sheet
4. Histogram
Graphical 5. Graphs
Data Collection
Analysis

7
 Types of Data
Variable
 Any variable measured on
continuum or scale that can
be infinitely divided.
 It’s carry more information
and there are more powerful
statistical tools to interpret
continuous data.
 Time (sec.), any physical
dimensions or characteristics
such height (m), weight (kg),
temperature (C) etc.
8
Attribute
 Count or percentage :
Count of error or
percentage of reject
 Data that could have only two
values such pass / fail, go / no
go.
 The data are names or labels
such QA Dept., IT Dept. etc.
 Few categories include
binomial, nominal, count ect.
 Sources of Data

Historical Experimentation Data

 Data that we already have  Data gathered in an

and which may seem to be attempt to study a
relevant to a question or problem that has arisen or
problem that has arisen. is contemplated.
Such data are sometimes
also called existing data
sets.

9
 Benefits of QC Tools

 The QC tools are very simple and easy to understand.

They are useful in every quality levels, Re-action ~
Detection ~ Prevention.
 The Japanese have used these 7 simple non-high tech
weapon to make vast improvement.
 Through continuous improvement, customer satisfaction
and company’s profit have been increased.

10
 Deming’s Cycle

 The QC tools are to combined with the concept of Plan-Do-

Check-Action (PDCA) for an effective application.
 PDCA, Deming cycle represent a cycle for continuous
improvement (CI).

P D

Quality CI
QC Tools

A C

Deming Cycle for CI

11
 Data Collection Tools

2. Scatter Plot
3. Pareto chart
1. Check Sheet
4. Histogram
Graphical 5. Graphs
Data Collection
Analysis

12
 Key Learning

 Data Collection
 Point of Measures
 Stratification Factors
 Check Sheets

13
 Data Collection Planning

1. Decide what data to collect.

2. Decide the stratification factor.
3. Determine the needed sample size.
4. Identify the source or location of data.
5. Develop data collection check sheet.
6. Decide the data collector.
7. Train data collector.
8. Do ground work for analysis.
9. Execute data collection plan.

14
 Point of Measures

Xs Ys
Predictor measures Result measures
(Leading indicator) (Lagging indicators)

(X) (X) (Y)

Input Process Output

• Arrival time • Customer
• Accuracy satisfaction
• Spec. • Total Defects
• Cost • Lead time
• Profit

Cycle time, Labor hours, In-

How well we do this…
process errors, Exception …predict this.

15
 X & Y Measures

Input (X) Process (X) Output (Y)

Referred as Y data. Output

measures quantify the
overall performance of the
process, including;
• How well customer needs and
requirements were met?
(Quality & Speed)
• How well business needs and
requirement were met? (Cost
& Speed)
One type of X variables in
data. Referred to as X variables in
data.
Measure quality, speed and
cost at key points in the
process.

Measures quality, speed and

Output measures provide
the best overall barometer
of process performance.
Some process measures will
be subset of output
measures (Y). (e.g.:
Time/step (X) total up to
Total Process Lead Time (Y))
cost performance of
information or items
coming into the process.

16
 Stratification Factors

 Purpose of stratification factors is to collect descriptive

presentation that will help you identify important pattern
in the data.
 Help to focus data collection on the vital few.
 Speed up the search for real cause.
 Generates a deeper understanding of process factors.

17
 Stratification Factors (Tree Diagram)

2 3 4
Questions Stratification factors Measurements
about Output X variables
5
Do existing data
support these
measurements?
(Y/N)

Output (Y) 6
1 Will this
measurements help
to predict Y?
(Y/N)

18
 Stratification Factors - Procedure

1. Identify an output measure (Y), and enter it at the center point of the
diagram.
2. List the key questions you have about the output.
3. Identify stratification factors that define different subgroups of data you
suspect may be relevant to your questions.
4. Create specific measurement for each stratification factor.
5. Review Y and X measurements and determine whether or not current
data exists (historical data) for those measurements.
6. Review X measurements, whether or not its predict the output,Y. If not,
re-identify the stratification factors to define new measurements.

19
 Check Sheet

 A Check Sheet is a data recording form that has been

designed to readily interpret results from the form itself.
It needs to be designed for the specific data it is to gather.
 Check sheet help us collect data in a more systematic and
standardized way.
 Capture essential information that otherwise might be
overlooked or forgotten.
 Ensure consistent data from different people.

20
 Check Sheet - Procedure

1. Select specific data and stratification factors to be included.

2. Determine time or period to be covered by the form.
 day, week, shift, quarter etc.
3. Construct the form
 Include space for identifying collector by name
 Use explanatory title
 Use full date (day, month, year)
 Decide how precise the measurement must be.

21
 Check Sheet – Procedure cont.~

4. Pilot test the form the from design and make changes as
needed.
 Ask data collectors for advice on the check sheet design.
 Have data collectors practice using data collection form
and resolve any conflicts and differences in use.
 If the “Other” column gets to many entries, you may
missing out important categories of in formation. See if
there are new categories you could add to check sheet.

22
 Types of Check Sheet

 Though there are many type check sheets available, only

3 types are discussed here as follows;
1. Basic Check Sheet
2. Frequency Plot Check Sheet
3. Location Check Sheet

23
 Basic Check Sheet

 Easy to make and use.

 Simply list the problem you are tracking and leave space to
allow marks whenever someone find that problem.
 Include the time element.

Typo Error In Employees Database

Inspector : Victor Month : February,05

Department : Data Entry

Week
Error Category 1 2 3 4 Total
Incorrect SSN II I I 4
Incorrect Address I I IIII 6
Incorrect Work History I I 2
Incorrect Salary History II I IIII I 9

24
 Frequency Plot Check Sheet

Easy to do by hand while a

Repair Shop Output Rate
 Operator : Julian Duration : Jan 1 ~ Jan 20

process is operating. Date

1
Completed Repair
X X X X X X X X

 Automatically shows 2
3
X X X X
X X X X X X
distribution of items or 4 X X
5 X
events along a scale. 6 X X X
7 X X X X X X X X
 Helps detect unusual 8 X X X X X X X X

patterns in a population. 9
10
X X X X X X
X X X X X

Give visual picture of

11 X X X X X
 12 X X X

maximum, minimum and 13

14
X X
X X X X X X X
range of the data without 15 X X X X

any further analysis.

16 X X X X X
17 X X
18 X X X X X
19 X
20 X X X X

25
 Location Check Sheet

 Data collection based on a

physical representation of
a product, workplace or X

form
 Data collectors enter X
X

marks where pre-defined X

defect occur
X X

 Allow you to pinpoint

area prone to defects or X
X X
X X
problem. X
X
X

26
 Graphical Analysis Tools

2. Scatter Plot
3. Pareto chart
1. Check Sheet
4. Histogram
Graphical 5. Graphs
Data Collection
Analysis

27
 Key Learning

 Graphical Analysis
 Scatter Plots
 Pareto Chart
 Histograms
 Graphs

28
 Graphical Analysis Tools - Definition

 A set of tools that produce a graphical representation of data

based on a chosen set of parameters for analysis purpose. The
tools discuss are as follows:

Tool Type of Data

Pareto Chart Attribute
Graphs Variable
- Run Chart
- Bar Chart
- Pie Chart
Histogram Variable
Scatter Plot Variable

29
 Advantages

 Visualization of data that allows quick information.

 Free from reading.
 Awakens Interest.
 Easy to prepare
 No complicated calculations
 No need for drawing capability

30
 Scatter Plots

 Scatter plots is a graph showing a relationship between

two factors or variables. X-axis is the mark unit for
suspected cause (input) and Y-axis is the mark unit for the
effect (output).
 Shows relationship patterns in data
 The width and tightness of scatter reflects the strength of
the relationship.
 Predicts effects under other circumstances.

31
 Strength of Relationship

Strong Weak

The width and tightness of scatter reflects the strength of the

relationship.

32
 Interpreting Scatter Plots

No pattern. Data points are Negative correlation. Larger

scattered randomly in the values of one variable (input)
chart. associated with smaller
values of other variable
(effect).

Positive correlation. Larger Complex pattern. This often

values of one variable occur when there is come
(cause) associated with other factor at work that
larger values of other variable interact one of the factors.
(effect).

33
 Scatter Plot - Procedure

1. Collect paired data

To create scatter plot, you must have two measurements for each observation
point. e.g : Table below shows data from a study to understand the relation
between call length and broker’s experiences.

Table : Call Length vs. Experiences

No Call Length (min) Experiences (yr) No Call Length (min) Experiences (yr)
1 58 1 11 35 11
2 61 2 12 31 12
3 53 3 13 30 13
4 50 4 14 32 14
5 52 5 15 28 15
6 47 6 16 26 16
7 42 7 17 25 17
8 42 8 18 27 18
9 39 9 19 24 19
10 35 10 20 22 20

34
 Scatter Plot – Procedure cont~

2. Determine the appropriate measures and increments for the

axes on the plot.
 Mark units for the suspected cause (input) on the horizontal X-axis
 Mark units for the effect (output) on the vertical Y-axis
3. Plot the points on the chart.

35
 Scatter Plot

Scatter Plot of Call Length (min) vs. Broker's Experience

60

50
Call Length (min)

40

30

20
0 5 10 15 20
Experiences (yr)

36
 Pareto Chart

 Pareto chart is the tool use to ranking opportunities to determine

which of the many potential opportunities should be pursued first. It
is also known as “separating the vital few to trivial many”.
Pareto Chart Components
1. Pareto chart are a type of bar chart in which the horizontal axis
represents categories rather than continuous scale.
2. The height of the bars can represent a count or percent of error
or defect.
3. By arranging the bars form largest to smallest, a Pareto chart can
help you determine which categories will yield the biggest gains if
addressed, and which are only minor contributors to the problem.

37
 Pareto Chart

(Count) (%)
300 Cumulative
100 3 percentage

250 80

200
60
2
150

40
100

50 20

0
A B C D E F
1 (Category)

38
 Pareto Chart - Procedure

1. Collect data on different categories of problem.

Recommended to use stratification factors.
2. Tabulate the scores. Determined the count for each category.
3. Arrange the data in order of decreasing size.
4. Calculate total number of occurrence
5. Calculate the percentage and the cumulative percentage for
each category.

39
 Pareto Chart – Procedure cont~

6. Sort the problem by frequency. Highest to the most left of

the chart except for “Other” to the most right.
7. Draw vertical axis and divided into increments equal to total
number of problem observed.
8. Draw bar for each category , starting with the largest and
working down.
9. Add the cumulative percentage line if necessary.

40
 Pareto Table – Raw Data

Table : Data on Incomplete Filing of Slips

1 2
Item Number of Defects

Account numer 52

Transaction number 23

Spelling of names 38

Post code 18

Address 9

Telephone number 11

Date 87

Basic data 4

Other 6

41
 Pareto Table - Result

Table : Data on Incomplete Filing of Slips

3 Number of Defects Cummulative
Item Percentage
(Decending order) Percentage
5 6
Date 87 35.1% 35.1%

Account number 52 21.0% 56.0%

Spelling of names 38 15.3% 71.4%

Transaction number 23 9.3% 80.6%

Post code 18 7.3% 87.9%

Telephone number 11 4.4% 92.3%

Address 9 3.6% 96.0%

Basic data 4 1.6% 97.6%

Other 6 2.4% 100.0%

4
Total 248

42
 Pareto Chart - Result

7 Pareto Chart : Incomplete Filing Slips

250 100.0%

90.0%
9
200 80.0%

70.0%

150 60.0%

50.0%

100 40.0%

30.0%

8
50 20.0%

10.0%

0 0.0%
Date Account Spelling of Transaction Post code Telephone Address Basic data Other
number names number number
6
43
 Pareto Principle – 80/20 Rule

(Count) (%) • 80/20 rule is used to

300 100
show critical factors
that significantly
250 80 contribute to a
Less than 20% of the problem.
200 categories account 80% of the
count 60 • This Pareto chart
150 shows that only a few
40 categories (A) of the
100 problem account for
the most occurrences.
50 20

• Focus your
0 improvement effort
A B C D E F
on those categories.
44
 Pareto Principle Does Not Hold

(%)  Pareto chart shows that no

100
(Count) cause you have identified is
300
80
more important than any
It takes more than 20% of
other.
250
the categories to account
60  Think and use other
for 80% of the count.
200
stratification factors you may
150 40
not have considered, collect
data if necessary and create
100
another Pareto based on
20
50 new stratification factors.
0
A B C D E F

45
 Histogram - Definition

 A histogram is a graph in which the continuous variable is clustered into

categories and the value of each cluster is plotted to give a series of bars.

22 points of data
22 points of data (Half of the distribution)

Median

Mode

46 5 6 7 8
Mean (8.16)
9 10 11 12 13 14
 Histogram - Procedure

1. Collect the data and enter into table. The number of data
required generally between 50 and 200.
2. Get the minimum and maximum values from the data.
3. Calculate the number of classes
 No. of classes =  No. of data
 (Round up to the nearest integer)
4. Decide the class interval.
 Class interval = (max. value – min value) / No. of classes

47
 Histogram Sample Data

Table : Histograms Data

Time Time
0900hr 1100hr 1400hr 1600hr 0900hr 1100hr 1400hr 1600hr
Date Date
1 77.84 78.04 78.08 77.90 14 78.00 78.36 78.12 78.02
2 78.18 78.16 78.12 78.10 15 78.16 78.06 78.18 78.14
3 78.10 78.28 78.14 78.04 16 78.12 78.22 78.10 78.02
4 78.16 78.12 77.98 78.12 17 78.14 78.00 77.86 78.08
5 78.30 78.20 78.08 78.18 18 77.94 77.96 78.04 78.10
6 78.08 78.00 77.88 78.04 19 78.06 78.16 78.08 78.14
7 78.26 78.20 78.14 78.16 20 78.26 78.28 78.22 78.56
8 77.96 78.00 77.92 78.06 21 78.06 78.18 78.02 78.06
9 78.24 78.14 78.04 78.12 22 78.02 78.16 78.10 78.12
10 78.10 78.48 78.10 78.46 23 78.42 78.38 78.04 78.12
11 78.32 77.96 78.20 77.98 24 78.24 78.08 78.14 78.18
12 78.08 77.98 77.98 78.18 25 78.10 78.14 78.12 78.08
13 78.44 78.12 78.20 78.06

48
 Histogram – Procedure Cont~

5. Calculate class boundary values.

 Lover boundary value of first class =
 min. value – smallest unit of measurement / 2
 Upper boundary value of first class =
 Lower boundary + class interval
 Keep adding the “class interval” to obtain the boundaries for the
other classes until the class containing the maximum data value is
reached.
6. Calculate the middle value for each classes.

49
 Histogram – Procedure Cont~

7. Count number of observations in each interval.

8. Create bars whose height (y-axis) represent the count of
each interval. The class boundaries and mid values become
the category for x-axis. the

50
 Histograms Sorted Table

Table : Class Boundaries and Mid Value

No Class Boundary Mid value Frequency

1 77.83 ~ 77.91 77.87 4

2 77.91 ~ 77.99 77.95 9

3 77.99 ~ 78.07 78.03 20

4 78.07 ~ 78.15 78.11 34

5 78.15 ~ 78.23 78.19 18

6 78.23 ~ 78.31 78.27 7

7 78.31 ~ 78.39 78.35 3

8 78.39 ~ 78.47 78.43 3

9 78.47 ~ 78.55 78.51 1

10 78.55 ~ 78.63 78.59 1

51
 Histogram Interpretations

The shape has a bell shape. The shape has two humps. The shape has a long tail.
It is symmetric. It is bimodal. It is not symmetric.

The shape is flat. There are one or more

outliers.

52
 Interpreting Pattern, Bell Shape

 Bell shape is what a normal

distribution would look like,
with data more-or-less
symmetric about a central
mean.
The shape has a bell shape.
It is symmetric.

53
 Interpreting pattern, Bi-modal

 A histogram with two peaks is

called bi-modal.
 This usually indicates that there
two distinct pathways through
the process.
 You need to define customer
requirements for this process,
investigate what account for The shape has two humps.
the systematic differences and It is bimodal.

improve pathways to shift both

paths toward the
requirements.

54
 Interpreting pattern, Skewed

 There are number of

distributions that are
skewed - meaning data
values pile up towards one
end and tail off towards
the other end. The pattern
is common with data such
as time measurements.

The shape has a long tail.

It is not symmetric.

55
 Interpreting patterns, Outlier and Flat

There are one or more

outliers. The shape is flat.

56
 Graphical Analysis Tools

2. Scatter Plot
3. Pareto chart
1. Check Sheet
4. Histogram
Graphical 5. Graphs
Data Collection
Analysis

57
 Graphs

 Graphs are the results of statistical data presented in a

diagrammatic form in order to allow understanding with a
single look.
 There many types of graphs available. The common
types that we will discuss are as follows;
1. Run Chart (a.k.a Line graph) – To show changes in data
within time
2. Bar Graph – To compare big and small values in data
3. Pie Graph – To show the relative proportion of the different
quantities

58
 Types of Graphs

 There many types of graphs available.

 However, the common types that we will discuss are as
follows;
1. Run Chart (a.k.a Line graph) – To show changes in data
within time
2. Bar Graph – To compare big and small values in data
3. Pie Graph – To show the relative proportion of the different
quantities

59
 Run Chart - Purpose

“Run chart is a time series plot”

Purpose
 It shows data point in which they occurred.
 It shows whether the process is changing over-time.
Advantages
 Easy to construct, even by hand, and require fewer data points.
 Easy to detect trend using some basic guidelines, so used to
detect trends and significant changes in the underlying process
generating the data.

60
 Run Chart

Transports time in day

4.5

4.0
Transport Days

3.5
Data Scale
3.0

2.5

2.0

12/3 12/6 12/9 12/12 12/15 12/18 12/21 12/24 12/27 12/30
Date

Time Series
The run chart shows the transport time for fresh fish from wholesaler to
sushi restaurant for month of December 2005.
61
 Run Chart -Procedure

1. Collect data and be sure to track the order in which the

data generated by the process.
2. Mark off the data units on the vertical axis (Y) and the
sequence (1, 2, 3…) or time unit (11 Mar, 12 Mar …) on the
horizontal axis (X).
3. Plot the data on the chart and draw a line connecting them
in sequence.

62
 Run Chart – Procedure cont~

4. Determine the median and draw line at that value on the

chart.
Run Chart for Parts Length

29

27

25
Median = 23.5

23
Length (cm)

21

19

17

15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Sequence

63
 Run Chart – Procedure cont~

5. Count the number of points not on the median.

6. Circle then count the number of runs.
 A “run” is defined as series of consecutive points that do not cross
the median.
 Point on the median is not counted toward the total points.
 Points on the median do not interrupt the run if the median is not
crossed.

64
 Run Chart for Parts Length

29

27

25
Median = 23.5

23
Length (cm)

21

19

17

15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Sequence
# of points not on the median = 20
# of runs below the median = 10 The data is RANDOM
# of runs above the median = 10

65
 Run Chart – Procedure cont~

7. Use the run chart table to interpret the result.

 The table gives you a range of runs you can accept to see if the data
random.
 If the number of counted runs is smaller or bigger that expected for
above median or below median, you may have trends in the data or
process. In other words, the data are not random.

66
 Median - Review

Sequence Length (cm) Acsending  The median is the

1 25 20
2 20 20 midpoint of ranked
3 22 20 order set of data.
4 21 21
5 24 22  Arrange the data in
ascending or
6 25 22
7 23 22
8 20 22 descending order.
9 26 23
10 22 23  The median is the value
11
12
25
24
24
24
at the center or
13 20 24 average of two middle
14
15
23
26
25
25
values.
16 27 25
17 24 25
18 22 26 Median = (23 + 24) / 2 = 23.5 cm
19 22 26
20 25 27
67
 Run Chart Analysis Table

# of pts not on lower limit of upper limit of # of pts not on lower limit of upper limit of # of pts not on lower limit of upper limit of
median runs runs median runs runs median runs runs
10 3 8 31 11 21 70 28 43
11 3 9 32 11 22 80 33 48
12 3 10 33 11 22 90 37 54
13 4 10 34 12 23 100 42 59
14 4 11 35 19 23 110 46 65
15 4 12 36 13 23 120 48 70
16 6 12 37 13 25
17 5 13 38 14 25
18 6 13 39 14 26
19 6 14 40 15 26
20 6 14 41 16 26
21 7 15 42 16 27
22 7 16 43 17 27
23 8 16 44 17 28
24 8 17 45 17 29
25 9 17 46 17 30
26 9 18 47 18 30
27 9 19 48 18 31
28 10 19 49 19 31
29 10 20 50 19 32
30 11 20 60 24 37

68
 Trends

Median

Upward
Median

Median
Shift

Downward

69
 Bar Graph - Procedure

1. Collect and arrange the data.

 Recommendation : If the is no order of the relationship
between the items, then arrange the data in descending
order of the quantity. “Others” are placed at the bottom.
2. List the items on the horizontal axis.
3. List the number on the vertical axis. Scale and label the axes.
4. Draw the bars for each item.
 Recommendation : It is better that the width of the bar is
apply two times the space between the bar.

70
 Bar Graph Table

Table : Themes for Improvement Activities 1

Theme No. of Project

Quality improvement 160

Cost reduction 214

Safety 17

Morale improvement 5

Equipment improvement 33

Pollution prevention 5

Upgrading control 25

71
 Bar Graph

Themes for Improvement Activities

250

200

3
150

4
Quantity

100

50

0
Quality improvement Cost reduction Safety Morale improvement Equipment Pollution prevention Upgrading control
improvement
2

72
 Bar Graph – Quick Notes

 The base line should be set at zero for the vertical line. Where
the quantities are large and the difference to be compared is
small, draw a wavy line at the bottom.
 The scales of the horizontal axis and vertical axis should be
such that the shape of the graph is balanced.
 Combine the small quantity item under “Others”.

73
 Pie Graph - Procedure

1. Collect data.
2. Calculate the percentage for each item.
 % for an item = individual quantity / total quantity X 100
3. Calculate angle for each item.
 Angle = individual ratio X 360
4. Draw the circle and the base line as a line vertically upward
from the center of the circle. Divide the circle
proportionately according to the calculated degree of each
item.

74
 Pie Graph Table

1 Table : Number of Workers in Different Occupation

2 3
Occupation Data Ratio (%) Angle (Degree)

Managerial 2,279 4.3% 16

Profesionals 4,034 7.6% 27

Clerical 8,841 16.7% 60

Sales 7,042 13.3% 48

Service 3,729 7.1% 25

Blue collar 19,750 37.3% 134

Agriculture 7,210 13.6% 49

Total 52,885

75
 Pie Graph

Ratio of Workers in Various Occupation

4%
14% 8%

Managerial
17%
Profesionals
Clerical
Sales
Service
Blue collar
Agriculture
37%

13%

7%

76