This document provides an overview of tools and methods for quality improvement teams using the PDCA cycle. It discusses selecting a theme to improve, planning the schedule, grasping the current status through data collection, setting targets, analyzing causes and determining corrective actions, implementing and evaluating results, and standardizing successful processes. Specific quality tools covered include checksheets, cause and effect diagrams, Pareto diagrams, histograms, control charts, scatter diagrams, and stratification.

1. PRACTICAL HANDBOOKPRACTICAL HANDBOOK
for
Quality Improvement Team
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2. COMPETENCY IMPROVEMENT TEAM
USING PDCA CYCLEUSING PDCA CYCLE
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3. THE PDCA CYCLE
PLAN
CHECK
DO
ACTION
PDCA
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4. SELECT THE THEME
From:-
• Customer
complaints.
• Department’s
objectives.
• The big ‘Q’
• The small ‘q”PLAN
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5. PLAN THE SCHEDULE
• List all the 8 steps
in the PDCA cycle.
• Indicate the
expected time
frame.
• Use the milestone
chart.
PLAN
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6. GRASP THE CURRENT STATUS
Obtain and review
data using
checksheet.
Study the effects of
the problem from
various perspectives.
Present available data
in graphs, and Pareto
charts.PLAN
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7. SET THE TARGET
• Indicate clearly the
statement of result
to be achieved.
• Target must be
reasonable and
realistic.
• Use SMART
concept.
PLAN
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8. ANALYSE THE CAUSE &
DETERMINE CORRECTIVE ACTION
• Prepare cause and
effect diagram.
• Prepare hypothesis
and verify most
probable causes.
• Determine
corrective action.
PLAN
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9. IMPLEMENT CORRECTIVE
ACTION
• Take immediate action
by following exactly as
planned.
• Collect data on results
and record any
deviations.
• Provide adequate
training.
DO
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10. EVALUATE THE RESULT
• Check the effect of
the corrective
action.
• Compare results
with target
• Use paired Pareto
Chart.
CHECK
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11. STANDARDISE THE PROCESS
• Document as
standard operating
procedure (SOP).
• Set parameters to
monitor and control
the successful
process.
• Ensure appropriate
training on the new
methods.
ACTION
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12. QUALITY TOOLS
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13. CHECKSHEET
• A Checksheet is used
to gather relevant data
in a simple,
standardised format.
The use of checksheet
makes the collection of
data easier and more
systematic.
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14. CHECKSHEET
Description 1 2 3 4 5 6 7 8 9 T
1 Poor coordination and
communication
25
2 No review on test run 22
3 Insufficient
information
28
4 Errors in report 39
5 Inaccuracy of report 37
Total 34 17 19 10 12 29 7 13 10 151
Observed by:
Frequency: Daily
Checksheet on: Generation of Final Report Date: 13TH
JAN 09
Location: IKRAM PAVES (Case study)
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15. CAUSE AND EFFECT DIAGRAM
• The Cause and Effect
diagram helps us to
find out all possible
causes, to sort them
out, and to organise
their inter-relationship.
Typically, the causes
are brainstormed in a
free-flowing session.
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16. CAUSE AND EFFECT DIAGRAM
MAN
METHODMACHINE
MATERIAL
Lack
Manpower
Error in
Report
Generation
Lack of training
Tight Dateline
Time wasted
Data entry
error
Insufficient
skill
Paper wastage
(Cost)
Graphics
module not on
line
No reference
materials
(Guide book)
Unable to
cater complex
reports
No proper
evaluation of
equipment
(vendor)
Take over of
vendor
No user
requirement
No proper
planning
No review during testing
Redundant work
Two individuals
processing same data
Manual to computer
format
Shipping delay
Holiday season
No inter dept
communication
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17. PARETO DIAGRAM
• A Pareto diagram is
constructed to show the
relative importance of
different categories in a
process. The vital few is
separated from the
trivial many. This will
ensure that focus is
made on the what is
important.
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18. PARETO DIAGRAM
Observed by:
Frequency: Daily
100151Total
100.014.622No review on test run5
85.416.625Poor communication & coordination
4
68.818.528Insufficient information3
50.324.537Inaccuracy in report2
25.825.839Errors in report1
Cum
%
%TOTDescription
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19. PARETO DIAGRAMPARETO DIAGRAM
0
20
40
60
80
100
120
140
160
Errors in report Inaccuracyin report Insufficient
Information
Poor communoation No Review
100%
0
50%
25.8%
75%
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20. HISTOGRAM
• A histogram is used to
summarise the
frequency of
occurrence of
something from a
sample of data. The
shape of distribution is
displayed and
descriptive statistics
can be calculated.
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21. HISTOGRAM
0
10
20
30
40
50
60
70
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22. CONTROL CHART
• A control chart has a
center line
corresponding to the
average quality at
which the process
should perform. An out
of control situation and
other unnatural
patterns can be
detected from the
chart
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23. CONTROL CHART
0
5
10
15
20
25
30
35
40
45
50
UCL
LCL
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24. SCATTER DIAGRAM
• A scatter diagram is a
special type of graph
which shows the
relationship between
two variables. If there
is an empirical
relationship between
the two variables it can
be easily seen.
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25. SCATTER DIAGRAM
0
5
10
15
20
25
0 2 4 6 8 10 12 14 16
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26. STRATIFICATION
• Stratification is the
technique of analysing
data by separating it
into several groups
with similar
characteristics. The
data must be stratified
by group to better
understand the
differences
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27. STRATIFICATION
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