Cause and Effect Diagram (Fishbone Diagram)

Identify and categorize potential causes of a problem. The fishbone diagram helps visualize the relationship between an effect and its possible causes across categories like Machines, Methods, Materials, Manpower, Measurement, and Environment.

Machines

Methods

Materials

Manpower

graph LR A[Increased product defects on Line 3] --> B[Machines] A --> C[Methods] A --> D[Materials] A --> E[Manpower] B --> B1[Aging equipment] B --> B2[Lack of maintenance] B --> B3[Calibration issues] C --> C1[Inconsistent procedures] C --> C2[Lack of training] C --> C3[Poor documentation] D --> D1[Supplier variations] D --> D2[Storage conditions] D --> D3[Material defects] E --> E1[Operator fatigue] E --> E2[Skill gaps] E --> E3[High turnover]

Check Sheet

A structured form for collecting and organizing quality data in real-time. Use this tool to track the frequency of different defect types over time.

Defect Check Sheet: Aluminum Casting - Line 3 (June 1-7, 2023)

Date Surface Scratches Dents Dimensional Inaccuracy Porosity Cracks Total Defects
June 1 |||| || | |||| || 13
June 2 ||| |||| || ||| | 13
June 3 ||||| ||| | |||| 13
June 4 |||| || |||| ||| | 14
June 5 ||||| || || |||| 13
June 6 ||| ||||| ||| || || 15
June 7 |||| ||| | ||||| | 14
Total 25 20 14 26 7 92

Control Chart (Shewhart Chart)

Monitor process stability over time by distinguishing between common cause and special cause variation. This chart helps identify when a process is out of control.

Histogram

Visualize the distribution of your process data. This tool helps you understand the central tendency, spread, and shape of your data.

Pareto Chart

Identify the most significant factors in your data set. Based on the Pareto principle, this chart shows that 80% of problems are caused by 20% of the causes.

Scatter Diagram

Explore relationships between two variables. This tool helps you identify correlations and patterns in your data.

Stratification Analysis

Break down your data into meaningful categories to identify patterns and sources of variation. This tool helps you analyze data by shift, operator, machine, or material batch.