7QC Tools are the Problem Solving tools used in the various sectors especially in the automotive manufacturing industries. These are the graphical and statistical tools that used to analyze and solve product and process-related problems effectively. The 7 Quality Control tools are widely applied by quality engineers to solve quality issues and to avoid recurrence.

Statistical Process Control (SPC) is a quality control technique that monitors and regulates a process using statistical techniques. The primary objective is to make sure the process runs smoothly and generates more products that meet specifications while generating less waste (scrap or rework).

Key Objectives of Statistical Process Control

• Maintain and control process capability or stability.
• Detect and control process variations before they lead to defects.
• Identify areas of improvement for corrective actions.
• Control process variability.

8D Methodology is a structured and team based approach that uses 8 disciplines or principles of Problem Solving. The main purpose of the 8D technique is to identify and define the problem statement systematically for necessary corrective and preventive measures to prevent the recurrence of the quality problem especially in quality management and manufacturing.

An FMEA is a systemized study or set of activities designed to recognize and assess a possible failure in advance and its negative effects on product and process quality. FMEA is classified as: Design FMEA (DFMEA) and Process FMEA (PFMEA).

A Pareto chart helps in decision-making by narrow down or prioritize or highlight major quality problems.

It is based on the 80/20 Pareto principle or rule, which means that roughly 80% of quality problems are come from 20% of causes. Pareto principle is widely applied in problem solving, process improvement, decision-making, and quality management.

A Cause and Effect Diagram is an organized tool for determining and investigating all the potential causes (related to 4M or 6M factors) of a specific quality problem (Effect). Because of its fishbone-like shape, it is also known as the Fishbone Diagram.

• It is developed by Japanese quality control guru Kaoru Ishikawa.
• Commonly used for root cause analysis during problem solving using 8D or Six Sigma methodologies.

A PFC (Process Flow Chart) is a visual representation of the sequences of processes or steps or operations involved in manufacturing of a part/product. Process flow chart is widely used during new product development process, and quality problem-solving process. PFC ensures clarity, consistency, and efficiency throughout all manufacturing processes by assisting in the documentation, analysis, and improvement of production processes.

The Japanese word “Poka-Yoke” refers to mistake-proofing or error-proofing.

Poka-Yoke is a Lean manufacturing tool that is used to prevent mistakes before they happen, or to make them immediately evident so they can be fixed or corrected easily and quickly.

Shigeo Shingo, a major contributor to the Toyota Production System, created this concept.

Kaizen means small-small but continuous improvement in daily working life. Kaizen is a philosophy that encourages all employees-from top to bottom line or frontline workers to identify area/opportunity for improvement at workplace and suggest solutions.

Kaizen is a Japanese word made of two words:

Kaizen = Kai (change or Change) + Zen (Good or for better)

So, Kaizen is defined as the “change for the better”.

Six Sigma is a disciplined quality improvement methodology with a primary goal of improving business processes by reducing the process variation and eliminating defects. Six Sigma focuses on reducing process variability and improving quality using the DMAIC (Define, Measure, Analyze, Improve, Control) methodology.

There are two Six Sigma methodologies:

• DMAIC: For Improving Existing Processes
• DMADV: For Creating New Processes or Products

5S is an improvement process/technique that helps to maintain good housekeeping, improve visual management, improve product and process quality, and to eliminate the seven type of waste within the organization. It is the foundation stone of Lean manufacturing and TPM (Total Productive Maintenance). The organizations cannot succeed without the effective implementation of 5S at workplace.

Total Productive Maintenance consists of 8 supporting activities or 8 pillars.

TPM aims for:

• Zero Machine Breakdowns
• Zero Accidents
• Zero Defects

TPM is a maintenance philosophy that strives for continuously improving the effectiveness of the production equipment through the people’s involvement within the organization (from operators to top management).

Lean manufacturing is a systematic production methodology that focused on eliminating/minimizing waste or NVAs (non value added activities), and to maximize value (value means any useful activities for which a customer is willing to pay) to achieve perfection.

Lean manufacturing utilizes various Lean Manufacturing Tools to enhance quality, productivity, and operational efficiency by reducing waste/non-value-added activities within the manufacturing process or supply chain.

The Deming’s PDCA Cycle is a four step, iterative problem-solving method that is used for continuous improvement in products/processes or services. PDCA application areas include: Lean Manufacturing, Quality Management, Healthcare, Project Management, and Education etc.