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A flow chart is used to

Define

and analyze processes; Build a step-by-step picture of the process for analysis, discussion, or communication; and Define, standardize or find areas for improvement in a process

How to make a flow chart

Most

flow charts are made up of three main types of symbol: Elongated circles, which signify the start or end of a process;

Rectangles,

which show instructions or actions; and

Diamonds,

which show decisions that must be made

Within

each symbol, write down what the symbol represents. This could be the start or finish of the process, the action to be taken, or the decision to be made. Symbols are connected one to the other by arrows, showing the flow of the process.

Points to note
Flow

charts are simple diagrams that map out a process so that it can easily be communicated to other people. To draw a flowchart, brainstorm the tasks and decisions made during a process, and write them down in order. Then map these out in flow chart format using appropriate symbols for the start and end of a process, for actions to be taken and for decisions

Finally,

challenge your flow chart to make sure that its an accurate representation of the process, and that that it represents the most efficient way of doing the job

3. Check sheets
The

intent and purpose of collecting data is to either control the production process, to see the relationship between cause-and-effect, or for the continuous improvement of those processes that produce any type of defect or nonconforming product. A Check Sheet is used for the purpose of collecting data to compile in such a way as to be easily used, understood and analyzed automatically.

The

Check Sheet, as it is being completed, actually becomes a graphical representation of the data you are collecting, thus you do NOT need any computer software, or spreadsheet to record the data. It can be simply done with pencil and paper

The main functions Checks

Production

process distribution checks where the distribution lies. Defective item checks - to determine what kind of defects exist in the process. Defect location checks - to determine where the common defects on a part are located.

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Defective

cause checks - type of defect and thus validate the cause thereof. Check-up confirmation checks - final phase of assembly to check the finished product or work.

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4. Histograms
The

common person believes that if a part is made in mass production from a machine, all of the parts will be exactly alike.
The truth is that even with the best of machines and processes, no two parts are exactly the same. The product will have a main or "mean" specification limit, with plus/minus tolerance that states that as long as the part is produced within this range, to that range, it is an acceptable part.

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The

object is to hit the target specification, however, that is not always totally possible. The purpose of a Histogram is to take the data that is collected from a process and then display it graphically to view how the distribution of the data, centers itself around the mean, or main specification.

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The histogram will graphically show

The

center of the data. The spread of the data. Any data skewness (slant, bias or run at an angle). The presence of outliers (product outside the specification range). The presence of multiple modes (or peaks) within the data.

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5. Scatter diagrams
The

Scatter Diagram is another Quality Tool that can be used to show the relationship between "paired data", and can provide more useful information about a production process. What is meant by "paired data"? The term "cause-and-effect" relationship between two kinds of data may also refer to a relationship between one cause and another, or between one cause and several

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For

example, you could consider the relationship between an ingredient and the product hardness; between the cutting speed of a blade and the variations observed in length of parts; or the relationship between the illumination levels on the production floor and the mistakes made in quality inspection of product produced.

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6. Control charts
Control

charts are generally used in a production or manufacturing environment and are used to control, monitor and IMPROVE a process. Common causes are always present and generally attributed to machines, material and time vs. temperature.

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This

normally takes a minor adjustment to the process to make the correction and return the process to a normal output.
However, when making a change to the process, it should always be a MINOR change.

If

a plot is observed that shows a slight deviation trend upward or downward, the "tweaking" adjustment should be a slight change, and then another

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Too

often people will over-correct by making too big of an adjustment which then causes the process to dramatically shift in the other direction. For that reason, all changes to the process should be SLIGHT and GRADUAL!

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Control Lines
A

control chart is a graph or chart with limit lines, called control lines. There are basically three kinds of control lines: the upper control limit (UCL), the central line (actual nominal size of product), the lower control limit (LCL).

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The Xbar & R Control Chart

An

Xbar & R Control Chart is one that shows both the mean value ( X ), and the range ( R ). The Xbar portion of the chart mainly shows any changes in the mean value of the process, while the R portion shows any changes in the dispersion of the process.

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This

chart is particularly useful in that it shows changes in mean value and dispersion of the process at the same time, making it a very effective method for checking abnormalities within the process; and if charted while in progress, also points out a problem in the production flow in real time mode.

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7. Fishbone diagram
Cause

& Effect Diagrams Identifying the Likely Causes of Problems Also called Fish or Fishbone Diagram and Ishikawa Diagrams

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Cause

and Effect analysis helps you to think through causes of a problem thoroughly. Their major benefit is that they push you to consider all possible causes of the problem, rather than just the ones that are most obvious

Conclusion.
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