Total Quality Management (TQM) emphasizes the continuous improvement of processes, products, and services to meet customer requirements. Various quality tools are used in TQM to collect, analyze, and interpret data to identify and resolve quality-related issues.
Key Facts
- The Seven Basic Quality Tools: The seven basic quality tools, also known as the 7 QC tools, were developed by Kaoru Ishikawa in the 1950s to simplify quality control measures and make them more accessible to workers with non-technical backgrounds. These tools are widely used in TQM and other process improvement methodologies. The seven tools are:
a. Stratification: Sorting data into separate groups to reveal patterns and meaning.
b. Histogram: Representing frequency distribution of data to identify areas of improvement.
c. Check sheet (or tally sheet): Collecting data using check or tally marks to identify defects or errors.
d. Cause-and-effect diagram (fishbone or Ishikawa diagram): Identifying root causes and sub-causes of a problem.
e. Pareto chart (80-20 rule): Prioritizing problems based on their frequency and impact.
f. Scatter diagram: Analyzing the relationship between two variables to identify cause and effect.
g. Control chart (Shewhart chart): Determining process stability and predictability by comparing historical and current data. - Other Quality Management Tools: In addition to the seven basic quality tools, there are other tools used in TQM to improve quality. Some of these tools include:
a. Checklists: Used to collect and organize data, identify problems, and track improvements.
b. Pareto Chart: Helps in identifying and prioritizing problems based on their frequency and impact.
c. Cause and Effect Diagram (Fishbone Diagram): Helps in identifying the root causes of a problem.
d. Histogram: Graphical representation of data distribution to analyze the intensity of a problem.
e. Scatter Diagram: Analyzes the relationship between two variables to identify correlations.
f. Graphs: Simplest and commonly used tools to identify deviations from standard specifications.
Seven Basic Quality Tools
The seven basic quality tools, also known as the 7 QC tools, were developed by Kaoru Ishikawa in the 1950s to simplify quality control measures and make them more accessible to workers with non-technical backgrounds. These tools are widely used in TQM and other process improvement methodologies.
Stratification
Stratification involves sorting data into separate groups or categories to reveal patterns and meaning that might not be apparent when the data is viewed as a whole. This technique helps identify the factors that contribute to variation and enables targeted analysis and improvement efforts.
Histogram
A histogram is a graphical representation of the frequency distribution of data. It helps visualize the distribution of data and identify patterns, such as central tendency, dispersion, and outliers. Histograms are useful for analyzing data related to process performance, product quality, and customer satisfaction.
Check Sheet (or Tally Sheet)
A check sheet is a simple data collection tool used to record the frequency of occurrence of specific events or defects. It helps identify the types and frequency of problems, allowing for targeted analysis and improvement efforts. Check sheets can be used to collect data on various aspects of a process, such as defects, errors, or customer complaints.
Cause-and-Effect Diagram (Fishbone or Ishikawa Diagram)
A cause-and-effect diagram, also known as a fishbone diagram or Ishikawa diagram, is a visual tool used to identify the root causes of a problem. It helps to organize and analyze the potential causes of a problem by categorizing them into major and minor factors. This tool facilitates a systematic approach to problem-solving and identifying the underlying causes that need to be addressed.
Pareto Chart (80-20 Rule)
A Pareto chart is a bar graph that helps prioritize problems based on their frequency and impact. It is based on the 80-20 rule, which states that approximately 80% of problems are caused by 20% of the factors. The Pareto chart enables organizations to focus their efforts on addressing the most significant problems that have the greatest impact on quality.
Scatter Diagram
A scatter diagram is a graphical representation of the relationship between two variables. It helps to identify the correlation between variables and determine whether there is a cause-and-effect relationship. Scatter diagrams are useful for analyzing the relationship between process inputs and outputs, product characteristics, and customer satisfaction.
Control Chart (Shewhart Chart)
A control chart is a statistical tool used to monitor and evaluate the stability of a process. It helps to identify whether a process is in control or if there is significant variation. Control charts are used to track process performance over time and identify special causes of variation that require investigation and corrective action.
Other Quality Management Tools
In addition to the seven basic quality tools, there are other tools used in TQM to improve quality. Some of these tools include:
Checklists
Checklists are used to collect and organize data, identify problems, and track improvements. They help ensure that all necessary steps are followed and that nothing is overlooked. Checklists can be used in various areas, such as process audits, product inspections, and customer surveys.
Process Flowcharts
Process flowcharts are visual representations of the steps involved in a process. They help to identify bottlenecks, inefficiencies, and opportunities for improvement. Process flowcharts can be used to analyze and redesign processes to make them more efficient and effective.
Failure Mode and Effects Analysis (FMEA)
FMEA is a systematic approach to identifying and evaluating potential failure modes in a product or process. It helps to prioritize risks and develop strategies to mitigate or eliminate potential failures. FMEA is widely used in product design, process development, and risk management.
Design of Experiments (DOE)
DOE is a statistical method used to investigate the relationship between input variables and output responses in a process or system. It helps to identify the optimal settings of input variables to achieve desired outcomes. DOE is used in product development, process optimization, and quality engineering.
Quality Function Deployment (QFD)
QFD is a customer-focused quality improvement tool that translates customer requirements into product or service characteristics. It helps to ensure that products and services are designed to meet customer needs and expectations. QFD is used in product development, service design, and marketing.
Conclusion
Quality tools are essential for organizations seeking to improve the quality of their products, processes, and services. The seven basic quality tools, along with other quality management tools, provide a structured approach to identifying, analyzing, and resolving quality-related issues. By using these tools effectively, organizations can enhance their overall quality performance, reduce costs, and increase customer satisfaction.
References
- What Are the 7 Basic Quality Tools? | Lucidchart Blog. (n.d.). Lucidchart. https://www.lucidchart.com/blog/what-are-the-7-basic-quality-tools
- Quality Management Tools. (n.d.). Management Study Guide. https://managementstudyguide.com/quality-management-tools.htm
- TQM tools – Total Quality Management. (n.d.). Total Quality Management. https://totalqualitymanagement.weebly.com/tqm-tools.html
FAQs
1. What are the seven basic quality tools in TQM?
The seven basic quality tools in TQM are stratification, histogram, check sheet, cause-and-effect diagram, Pareto chart, scatter diagram, and control chart.
2. What is the purpose of stratification in TQM?
Stratification helps to identify patterns and meaning in data by sorting it into separate groups or categories. This technique allows for targeted analysis and improvement efforts.
3. How does a histogram help in TQM?
A histogram is a graphical representation of the frequency distribution of data. It helps to visualize the distribution of data and identify patterns, such as central tendency, dispersion, and outliers.
4. What is the use of a check sheet in TQM?
A check sheet is a simple data collection tool used to record the frequency of occurrence of specific events or defects. It helps to identify the types and frequency of problems, enabling targeted analysis and improvement efforts.
5. What is the purpose of a cause-and-effect diagram in TQM?
A cause-and-effect diagram, also known as a fishbone diagram, helps to identify the root causes of a problem. It organizes and analyzes the potential causes of a problem by categorizing them into major and minor factors.
6. How does a Pareto chart help in TQM?
A Pareto chart is a bar graph that helps to prioritize problems based on their frequency and impact. It is based on the 80-20 rule, which states that approximately 80% of problems are caused by 20% of the factors.
7. What is the purpose of a scatter diagram in TQM?
A scatter diagram is a graphical representation of the relationship between two variables. It helps to identify the correlation between variables and determine whether there is a cause-and-effect relationship.
8. How does a control chart help in TQM?
A control chart is a statistical tool used to monitor and evaluate the stability of a process. It helps to identify whether a process is in control or if there is significant variation. Control charts are used to track process performance over time and identify special causes of variation that require investigation and corrective action.