TOTAL QUALITY MANAGEMENT & SIX SIGMA

Submitted By :Group 6
Satyajeet Senapati
UM14220
Shankalp Mohanty
UM14285

ACKNOWLEDGEMENT
We would like to thank Professor Arun Kumar Paul for for his guidance and
teaching throughout our work. We also thank him for giving us the
opportunity to work on a project where we have had the opportunity to
understand the processes and the complete control processes and strategies
in play. We gained a lot of wonderful insights on the processes and how to
suggest the control methods for various applications and day-to-day
operations in every real life sector.

CONTROL CHARTS
Introduction
Control charts are used to understand the behavior of the process and to
examine if the process under surveillance is under statistical control. It is
called as Shewhart chart as well being named after Walter Shewhart. There
are seven basic tools of quality and control chart is one among them.
Shewharts work was then taken up by Edwards Deming who made the
widespread usage of control charts. These charts became very popular in
1950s and 60s in the manufacturing sector of Japan.

Sample Control Chart. The control limit (CL), upper control limit (UCL) and
lower control limit (LCL) have been mentioned.

Advantages of control charts

It alerts when the system needs attention in order to rectify possible

interference in the system
Helps us to identify the limits within which the system has to be
operated
Very useful to maintain product quality

Helps to determine sources of variation

Can be used to predict the future performance of the product
Helps to build organizations reputation and customers trust

Types of control charts

x-bar and R chart Quality characteristic measurement within a given

sample. (Variables)
p chart Proportion of non-conforming within a given sample.
(Attributes)
np chart number of non-conforming
within a given sample.
(Attributes)
c chart number of non-conformances within a given sample.
(Attributes)
u chart non-conformances per unit within a given sample (Attributes)

Other notable control chart

IMR chart Used to measure quality characteristic of a single

observation (variables)

Real Life Applications

In order to appreciate the usefulness and applicability of control charts, we
have considered some real life applications. We have tried to collect some
data from various internet sources and plot a control chart (whichever is
applicable) and then put inside our analysis into what might be the status of
the process involved in those scenarios. The uses of control charts is very
extensive and we have tried to point out some of these advantages.

P Chart
Problem Definition

For the purpose of analysis, we took two types of data from the internet. The
first set of data is the number of errors in internet connectivity in a
university.
This is a highly unstable data as the kind of connection can be vary a lot by
its very nature.
The data set is given as under:
Day
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19

Attem
pts
41267
0
39573
6
40176
5
39542
2
42222
3
43323
4
39678
8
41138
3
42334
8
47405
3
44682
3
43166
1
43435
3
40623
2
40245
4
40331
2
38778
2
35550
0
37244

Errors
42104
40286
35399
97981
45346
43699
24752
45391
39179
48680
40405
44198
36047
39455
48292
47720
53173
49474
45222

20
21
22
23
24
25

1
41581
3
43389
6
36749
6
38752
8
40668
9
37936
8

40583
41396
39527
40865
39047
36579

Now, for analysis, we followed the p chart analysis with variable sample size.
We have shown both the normal method and standardized method here.

Methodologies Adopted
Normal Method
The probability and upper and lower control limits for each and every sample
is calculated and then depicted in a plot.
Here, we find p-bar= Errors/Attempts
Standard deviation= sqrt(p-bar*(1-p-bar)/ni)
LCL= p-bar 3*sd
UCL= p-bar + 3*sd

Attemp
ts

Day

Errors

412670

42104

395736

40286

401765

35399

395422

97981

p
0.1020
28
0.1018
0.0881
09
0.2477
88

sd
0.0004
84
0.0004
94
0.0004
9
0.0004
94

LCL
0.1068
84
0.1068
53
0.1068
64
0.1068
53

UCL
0.1097
87
0.1098
17
0.1098
06
0.1098
18

422223

45346

433234

43699

396788

24752

411383

45391

423348

39179

10

474053

48680

11

446823

40405

12

431661

44198

13

434353

36047

14

406232

39455

15

402454

48292

16

403312

47720

17

387782

53173

18

355500

49474

19

372441

45222

20

415813

40583

21

433896

41396

22

367496

39527

23

387528

40865

24

406689

39047

25

379368

36579

The corresponding chart is:

0.1073
98
0.1008
67
0.0623
81
0.1103
38
0.0925
46
0.1026
89
0.0904
27
0.1023
91
0.0829
9
0.0971
24
0.1199
94
0.1183
2
0.1371
21
0.1391
67
0.1214
21
0.0975
99
0.0954
05
0.1075
58
0.1054
5
0.0960
12
0.0964
21

0.0004
78
0.0004
72
0.0004
93
0.0004
85
0.0004
78
0.0004
51
0.0004
65
0.0004
73
0.0004
72
0.0004
88
0.0004
9
0.0004
89
0.0004
99
0.0005
21
0.0005
09
0.0004
82
0.0004
72
0.0005
13
0.0004
99
0.0004
87
0.0005
05

0.1069
0.1069
19
0.1068
55
0.1068
82
0.1069
02
0.1069
81
0.1069
4
0.1069
16
0.1069
21
0.1068
72
0.1068
66
0.1068
67
0.1068
38
0.1067
71
0.1068
07
0.1068
89
0.1069
2
0.1067
97
0.1068
37
0.1068
73
0.1068
21

0.1097
7
0.1097
52
0.1098
16
0.1097
89
0.1097
68
0.1096
9
0.1097
3
0.1097
54
0.1097
5
0.1097
98
0.1098
05
0.1098
03
0.1098
33
0.1098
99
0.1098
63
0.1097
81
0.1097
51
0.1098
73
0.1098
33
0.1097
97
0.1098
49

12

10

LCL
UCL

0
0

10

12

Standard Method
Here, we normalize the data and plot the points. We check that the points lie
between +/-3 for being under 3-sigma limit.
Standard pi =( pi p-bar ) / sqrt ( p-bar*(1-p-bar)/ni)

The data is as follows:

Day

Attempt
s

Errors

sd

Standar
d

LCL

UCL

0.10202
8

412670

42104

395736

40286

401765

35399

395422

97981

422223

45346

433234

43699

396788

24752

411383

45391

423348

39179

10

474053

48680

11

446823

40405

12

431661

44198

13

434353

36047

14

406232

39455

15

402454

48292

16

403312

47720

17

387782

53173

18

355500

49474

19

372441

45222

20

415813

40583

21

433896

41396

22

367496

39527

0.11832
0.13712
1
0.13916
7
0.12142
1
0.09759
9
0.09540
5
0.10755
8

23
24

387528
406689

40865
39047

0.10545
0.09601

0.1018
0.08810
9
0.24778
8
0.10739
8
0.10086
7
0.06238
1
0.11033
8
0.09254
6
0.10268
9
0.09042
7
0.10239
1
0.08299
0.09712
4
0.11999
4

0.00048
4
0.00049
4
0.00049
0.00049
4
0.00047
8
0.00047
2
0.00049
3
0.00048
5
0.00047
8
0.00045
1
0.00046
5
0.00047
3
0.00047
2
0.00048
8
0.00049
0.00048
9
0.00049
9
0.00052
1
0.00050
9
0.00048
2
0.00047
2
0.00051
3
0.00049
9
0.00048

13.0359
13.2272
41.2499
282.145
4
1.95909
15.8161
93.1366
4.13202
3
33.0549
12.5082
38.5149
12.5666
53.7441
22.9903
23.7967
1
20.4025
2
57.6743
8
59.1475
7
25.6936
8
22.2746
27.4033
1.51679
5.77814
-

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3

-3
-3

3
3

25

379368

2
0.09642
1

36579

7
0.00050
5

25.2856
23.6111

-3

The corresponding graph is:

12

10

0
0

10

12

Inference
We see that the variations are pretty huge as compared to the 3-sigma
limits. This proves the theory that the variations in an internet connection
are pretty huge by nature.

Np-chart
Problem Definition
For np chart, we found data for whistle production. The sample size was a
constant 120.
Mean is calculated as n*p-bar.
And sd is sqrt(n*p-bar(1-p-bar)).
The data is as follows
Subgrou
p
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

Subgroup
Size

np
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120
120

7
4
9
10
3
6
12
5
9
9
3
8
11
0
5
1
0
2
8
1
4

22
23
24
25
26
27
28
29
30
31
32
33
34
35

120
120
120
120
120
120
120
120
120
120
120
120
120
120

3
8
8
4
1
12
2
8
7
8
10
11
8
7

Methodologies Adopted
For further analysis, mean and standard deviation were calculated. After this,
the LSL and USL were calculated as
LSL = mean - 3 * sd
USL = mean + 3* sd

After this step, plotting was done on a graph to check if all the points were
with limit.
Subgrou
p

Subgroup
Size

np

p
0.05833
3
0.03333
3

120

120

120

120

10

0.075
0.08333
3

120

0.025

120

0.05

7
8

120
120

12
5

0.1
0.04166

sd
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888

LCL
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238

UCL
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409

7
9

120

0.075

10

120

0.075

11

120

12

120

13

120

11

0.025
0.06666
7
0.09166
7

14

120

15

120

16

120

17

120

18

120

19

120

20

120

21

120

22

120

23

120

24

120

25

120

26

120

27

120

12

28

120

29

120

30

120

31

120

0
0.04166
7
0.00833
3
0
0.01666
7
0.06666
7
0.00833
3
0.03333
3
0.025
0.06666
7
0.06666
7
0.03333
3
0.00833
3
0.1
0.01666
7
0.06666
7
0.05833
3
0.06666
7

9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9
2.40888
9

-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238
-1.11238

5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5
13.3409
5

32

120

10

33

120

11

34

120

35

120

0.08333
3
0.09166
7
0.06666
7
0.05833
3

2.40888
9
2.40888
9
2.40888
9
2.40888
9

-1.11238
-1.11238
-1.11238
-1.11238

13.3409
5
13.3409
5
13.3409
5
13.3409
5

Mean = 6.114286

The corresponding graph:

12

10

8
LCL

UCL

0
0

10

12

Inference
Thus, we see that for this manufacturing process, all the points are within
LSL and USL.
The excel has been embedded herewith.

TQM_Assignment.xls
x

Conclusion
From the data we have taken for our analysis, we conclude that while some
processes can be in statistical control while some others can seldom be in
control. This uncontrollability of those processes is in-built and it will be
pretty tough to bring them within control unless and until the management
takes some steps or try to increase the control limits so that the process can
be shown to be in statistical control. This can both be a costly and lengthy
procedure and hence companies or firms which are into this task must
handle this situation effectively and must not lose their patience during the
procedure.
In our case, we saw that the variation in internet connection is out of
control by huge bounds while the manufacturing process involving whistles is
perfectly in control. Now, internet connectivity is such a pertaining issue and
to bring it in control the government and the service providers have to take
some major steps to provide an equal level of connection throughout to all
people and only then that process can be somewhat brought into control. In
case of the whistles, the company or firm should now think about how to
improvise the process and reduce the common causes of errors.
Finally, we would like to appreciate the usefulness of control charts in
helping us draw our conclusions about the real life applications we
considered above.