7QC Tools
(Essentials of lean Manufacturing )
7QC Tools Part-7
Cause & Effect Diagram
Cause and Effect Diagram
What is Cause and Effect Diagram ?
A tool that shows systematic relationship between an effect
and its causes .
A diagram which shows the relationship between quality
characteristics and the cause factor
An effective tool to systematically generate ideas about the
causes of problem
Cause and Effect diagrams (also called Ishikawa diagrams, or
herringbone diagrams , Fishbone diagrams)
Cause and Effect Diagram
Underlying principle of C & E Diagram
It enables team to identify ,explore and graphically display all
possible causes contributing to the problem
A Cause and effect diagram is good for looking the whole “casual
“ relationship of possible causes and its effect toward problem
It enables identification of root cause not symptoms
Cause and Effect Diagram
Dr. Kaoru Ishikawa developed
the first cause and effect
diagram in 1943 while working
with Kawasaki steel Works
Cause and Effect Diagram
Structure of Cause and Effect Diagram
Big Bone
Medium Size Bone
Back Bone Effect
Small Bone
Cause and Effect Diagram
FISHBONE DIAGRAM
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Text
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Category Category Category
Cause and Effect Diagram
Steps in constructing C & E diagram
Define the effect
Identify the main causes group
Identify causes and Sub causes
Identify potential root causes
Cause and Effect Diagram
1. Define the effect
Draw backbone and write the effect in box
Effect
Causes
Draw backbone write the effect
Cause and Effect Diagram
2. Identify the main causes group
Use 6 M as Main causes, such as Man, machine, Method,
Material, Measurement and Mother nature (Environment)
Material Machine Man
Effect
Causes
Write the effect
Environment Measurement Method
Cause and Effect Diagram
3. Identify the causes and Sub Causes
Do brainstorming by asking “why” question
Poor Material Machine Man
Handling
Rod bent Effect
High
Causes
Raw Write the effect
material Hardness
Environment Measurement Method
Cause and Effect Diagram
4. Identify the root causes
Check all possible cause and encircle the important cause
Poor Material Machine Man
Handling
Rod bent Effect
High
Causes
Raw Write the effect
material Hardness
Environment Measurement Method
Cause and Effect Diagram
Example :
Fishbone Diagram
Measurement Man Machines
Faulty testing equipment Poor supervision Out of adjustment
Incorrect specifications Lack of concentration Tooling problems
Improper methods Inadequate training Old / worn
Quality
Inaccurate Problem
temperature
control Defective from vendor Poor process design
Ineffective quality
Dust and Dirt Not to specifications management
Material-
handling problems
Deficiencies
in product design Why-Why Analysis
Environment Materials Method
Cause and Effect Diagram
Advantage of Cause and effect diagram :
Making the diagram is educational in itself
It demonstrates knowledge of problem solving team
It results in active searches for causes
It is a guide for data collection
Cause and Effect Diagram
Check few factors while constructing Cause and
effect diagram :
Identify all the relevant causes (factors) and the causes most strongly
influencing the effect (Characteristics)
Express the effect (characteristic) “negatively.
The “why” is the linkage between effect and its causes
Make the same no of C& E diagram as that of effects
TYPICAL CAUSES FOR NON
CONFORMANCE/ DEFECTS
MACHINE FACTORS
Inadequate process capability
Incorrectly designed tooling
Worn tools, jigs or dies
Poor maintenance
Equipment effected by environmental factors such as heat,
humidity etc.
TYPICAL CAUSES FOR NON
CONFORMANCE/ DEFECTS
MATERIAL FACTORS
Use of untested materials
Mix-up of materials
Substandard material accepted on concession because of non-availability of
correct material
Inconsistency in specifications on the part of vendors
TYPICAL CAUSES FOR NON
CONFORMANCE/ DEFECTS
MEN FACTORS
Incorrect knowledge of setting up machines
Careless operator and inadequate supervision
Undue rush by the operator to achieve quality targets
Lack of understanding of drawing instructions relating to a process
Operator does not possess requisite skill for operating machines
TYPICAL CAUSES FOR NON
CONFORMANCE/ DEFECTS
METHOD FACTORS
Inadequate process controls
Non availability of proper test equipment
Test equipment out of calibration
Vague inspection/ testing instructions
Inspectors do not possess the necessary skill
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