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How to do data analysis by excel sheet? Step by step guides

15/03/2024 by TECHIEQUALITY

How to do data analysis by excel sheet? i| Step by step guides

Hi Readers! Today we will discuss an important topic i.e. How to do data analysis by excel sheet. Data analysis is very important and it helps to make the correct decision on fact basis. While data analysis we generally use many tools/ techniques like 7QC Tools (Pareto chart, fishbone diagram, histogram, scatter diagram, control chart, checklist, diagram & PFC) and Statistical tools, etc. Basically, we use several platforms to execute the test or plot the graph to know the interpretation of results. But with the help of a simple Excel sheet you can analyze your data by doing advanced tests like Regression analysis, Correlation, ANOVA, Z-test, etc. but you can’t get the option of those tests directly in your Excel sheet, for getting the option you have to install the data analysis tools in your excel sheet, so we will aid you through this article for easy installation of analysis tools.

DOWNLOAD:-Several Data Analysis Tools

Below are the step-by-step installation processes of Data Analysis Tools:

Step-1:

We cannot find the Data Analysis option in excel sheet because this tool is not pre-installed. You have to install it manually, so open your excel sheet and then click on the Office Button, and then follow the step-2 mentioned in the below figure.

Step-2:

Now select the Add-Ins” option as shown in the below figure, next select Analysis ToolPak, and then follow the step-5 of below figure to install the Analysis Tool Pack.

Step-3:

You have successfully installed the Data Analysis Tools Pack, and now you are ready to use the Data Analysis options. Just go to the Data section in excel sheet for usages of Analysis Tools.

For doing individual tests like correlation, regression analysis, ANOVA, Z-test, etc, open the data analysis option and select the data as per individual test instructions.

FAQ:

How to organize data in excel for analysis?

Ans.: it depends on which data analysis tools you are going to use, for example, if are going to do the ANOVA-single factor test then the selection criteria and data arrangement will be different than other tests like paired comparison, 2P test, etc.

What are the common data analysis tools used in manufacturing industries?

There are many common tools used in the manufacturing industry but some are 7QC tools, why-why analysis, 5 Core tools, hypothesis testing tools, etc. Directly you can also use the data analysis tool in excel which is given in the “Data” section in excel as Data Analysis. just you have to install the same by following the above process. so follow the above steps and use it for data analysis. you can also use the excel function for data analysis, it purely depends on the data type, nature of the test, etc.

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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Shanti Gopal Pradhan is an experienced professional in Quality Management Systems, QA, Operations, Business Excellence, and Process Improvement. He has strong expertise in international standards including IATF 16949, ISO 9001, ISO 14001, ISO 45001, and ISO 17025, along with methodologies such as TQM, TPM, and Six Sigma.

He holds a degree in Mechanical Engineering along with an MBA, combining strong technical acumen with strategic business insight, he is a Certified Internal Auditor, Lead Auditor, and Six Sigma Black Belt, with a proven track record in driving quality transformation and operational excellence.

Scatter Diagram Template | Industrial Example | Download Excel Format

07/04/202615/03/2024 by TECHIEQUALITY

Industrial Example of Scatter Diagram | Interpretation of result | Scatter Diagram Template:

Hi readers! Today we will discuss on Scatter diagram Example with the interpretation of its results. The scatter diagram is one of the popular tools of 7QC tools. It’s a type of diagram to displays the value for typically two continuous variables for a set of data. One variable can be positioned on the X-axis and another variable can be positioned on the Y-axis. This diagram will help you to find out the significant causes among the total collection of potential causes. When you have variable types of data collection of potential causes and you do not know the positive or negative relationship that time you can plot the scatter diagram to know the relationship among them. You can download our simple Excel Scatter Diagram Template from the below link.

DOWNLOAD– Sample Scatter Diagram Excel Template/ Format.

Example:

An organization has tried to know the significant causes for the high compressive strength of “X” quantity sand, so initially quality engineer drew the cause& effect diagram with the help of CFT team members and then he started the validation of each potential cause. The same C&F diagram is mentioned below.

Here, we have not mentioned the other potential causes like mixing time, water%, etc. because these are already validated but now we have to know the relationship among the two variables as additive quantity v/s compressive strength through a scatter diagram. To do so data has to be collected and then a scatter diagram needs to be drawn.

Data table:

Additives in Kg.	Compressive Strength (gm/cm²)
2.5	1245
3.5	1290
5	1330
6.5	1395
7.5	1435

Scatter Diagram:

Interpretation of result:

The above scatter diagram indicates us there is a perfect positive correlation between two variables i.e. Additives in Kg. vs. Compressive Strength (gm/cm²). So we can conclude that more the additive addition can result in high compressive strength.

Interpolation: you can guess the value from the set of data points. From the above graph, I would like to know the compressive strength if I will add 5.5 Kg additives in “X” Kg of Sand.

FAQ:

Q1: What are the common possibilities of correlation between two variables of the scatter diagram?

Ans.: There are so many possibilities but three common correlations are positive, negative, and no correlation. Positive and Negative correlations are further categorized into three types as.

Positive Correlation:

Low positive correlation
High positive correlation
Perfect positive correlation

Negative Correlation:

Low negative correlation
High negative correlation
Perfect negative correlation

Q2: What types of data are used to plot the scatter diagram?

Ans.: Continuous variable type data.

Useful Articles:

Types of Fishbone Diagram |Dispersion Analysis |Enumeration |Process Classification

7 QC Tools Template.

Repeatability vs Reproducibility | Discussion of Key difference.

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How to Plot Scatter Diagram in Excel? | Guides with example | Interpretation

15/03/2024 by TECHIEQUALITY

How to Plot Scatter Diagram in Excel |Guides with example | Interpretation:

Hi reader! Today we will discuss on How to Plot Scatter Diagram in Excel? The scatter diagram is a type of tool that is generally used to know the correlation between two variables. We have published a separate post on the concept of scatter diagrams with industrial examples and interpretation of results, if you are interested in knowing the concept before reading this article then you may read more, the link is provided below.

Scatter Diagram Template |Industrial Example |Download Excel Format.

How to Plot Scatter Diagram in Excel?

We would like to explain it with examples.

Example:

A class teacher tried to survey their top five students’ marks obtained in % v/s study hours. Details of the data are given below.

Variable-1	Variable-2
Study hours	Mark obtained in %
5	40
6	50
7	65
8	82
10	89

Now class teacher has drawn the scatter diagram to know the correlation between variables. Step by step guide is mentioned below;

Step-1:

Open the excel sheet and make a table.

Step-2:

Select the table to plot the diagram.

Step-3:

Choose the pattern of the Scatter diagram as you wish, To do so first go to the option “Insert” and then select the scatter diagram option with your preferred pattern. Details are mentioned in the below figure.

Step-4:

Now, your Scatter Diagram is ready.

Interpretation of the above scatter diagram:

All sample points are nearer to the trend line and in a positive direction. So the scatter diagram indicates us there is a perfect positive correlation between two variables. Read more…to know more about common possibilities of correlation.

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Types of Fishbone Diagram |Dispersion Analysis |Enumeration |Process Classification

15/03/2024 by TECHIEQUALITY

Different Types of Fishbone Diagram:

Hi readers! Today we will discuss on Types of Fishbone Diagram. Basically, the fishbone/ cause & Effect/Ishikawa diagram is one of the most popular tools among 7QC Tools. Due to the simplicity and easy understanding, almost all sectors (manufacturing, service sector, non-manufacturing) are using this tool for represent the potential cause of a Problem statement. It’s an effective tool for the diagnosis of the various causes of the problem and helping to solve the problem. You can download the all types of C&E Diagram Template/formats from the below links.

DOWNLOAD– Cause & Effect Diagram Template (DA, E & PC types).

Types of Fishbone Diagram/ Cause & Effect/ Ishikawa Diagram:

Three basic types of Fishbone Diagrams are [1] Dispersion Analysis [2] Process Classification [3] Enumeration. Dispersion analysis type of cause and effect diagram involves identifying and classifying possible causes for a specific quality problem. For example, 4Ps, 4Ms, 8Ms, and 4M1E are the most popular pattern of dispersion analysis fishbone diagrams. Some sample pattern templates are given below;

The Process classification fishbone diagram involves establishing causes related to the Process. But in Enumeration types, there a slight changes as compared to the above both types, simply list all the possible causes first and then draw the chart in order to relate the causes to each other.

Example of Dispersion analysis type of cause and effect diagram:

We have built the two popular C&E diagrams considering with two scenarios as [1] Electric fire [2] Product delivery issues. First of all, we have listed up the potential causes and then constructed the fishbone diagram.

Problem Statement: Electric Fire.

Potential Causes:

Loose connection,
Open wire,
Short circuit
Overload of power consumption.

Example of Process classification cause and effect diagram:

Problem Statement: Delayed Delivery.

Potential Cause:

Process-1:

Plan not executed timely.
Shortage of Raw material.

Process-2:

M/C B/D.

Process-3:

More process defects
Operators absenteeism

Process-4:

Shortage of packaging material.

FAQ:

What are the 3 types of cause and effect diagrams?

Ans. The common three types of fishbone or cause & effect diagrams are 1-Dispersion Analysis, 2- Process Classification, and 3-Enumeration.

4M Checklist Template | Free Download Format

07/04/202606/03/2024 by TECHIEQUALITY

4M Checklist Template |Free Download Format:

Hi Readers! Today we will discuss here on 4M Checklist Template. Generally, the 4M concept is used in several methodologies, In the Cause and effect diagram it represents the potential causes and similarly, it is also used as a checklist for Kaizen. In the kaizen approach, there are some checklists used as [1] 5MUs checklist [2] 5W1H checklist [3] 4M Checklist. But here we will only explain on the 4M checklist. We have prepared the 4M checklist for your ready reference. You can easily download this checklist/check sheet from the below link.

DOWNLOAD-4M Checklist/Check-sheet / 4m analysis template excel

Sample 4M Checklist Copy:

4M Checklist Template:

4M i.e. Men, Machines, Materials & Methods are the common aspects and important for quality improvement and KAIZEN. Questions to be asked related to 4M to implement kaizen activities effectively are;

Man (Workforce)

Is he responsible?

Is he accountable?

Is he qualified?

Is he experienced?

Is he assigned to the right job?

Is everything in a good working order?

Does he follow standards?

Is his work efficiency acceptable?

Is he willing to improve?

Machine

Does it meet process capabilities?

Is the oiling/greasing adequate?

Does it meet production requirements?

Does it meet precision requirements?

Does it make any unusual noise?

Is the layout adequate?

Are there enough resources available?

Are there any mistakes in the material grade?

Is PM done as per plan?

Material

Is there any issue with material flow?

Are there any impurities mixed in?

Are there any mistakes in quantity?

Is the inventory level adequate?

Is there any wastage of materials?

Is the material quality standard adequate?

IS it a method that ensures a good product?

Method

Is the SOP adequate?

Is the SOP available on the shop floor?

Is the SOP upgraded?

Is it a safe method?

Is the setup adequate?

Is it a safe method?

Is it an efficient method?

Is the sequence of work adequate?

Are there any mistakes in the material grade?

Are the process characteristics set as per standard?

Are the product characteristics meeting the standard requirement?

Template

Example: We had audited the manufacturing process and got the below observations;

During the process audit through the 4M checklist, we have observed so many improvement points, these are mentioned in the above checklist remark column. In this way, you can easily find out the process improvement points. Download the above 4M Checklist and try to customize it according to your manufacturing process.

How to Implement the 4M checklist /Check sheet in Manufacturing Industries?

I always try to share my own industrial experience so that my readers can easily understand, learn, and implement the skill-based concept in their operational process.

Posts/articles on this website are skilled base, you can read our articles for your personal learning, for training purposes, and for practical implementation in the industry as well.

Generally, we use the 4M, and 6M check sheets to audit /investigate and to check the condition and lacking points of 4M factors (Men, Machine, Method, and Material). Some industries plan the checking schedule on a weekly and some on a monthly basis as per the production plan. By doing so we can easily maintain the machine condition, reduce the B/D, Increase the machine run time, we can identify the on-job training of operators /workers, maintain the material inventory, monitor the effectiveness of the Method, we can further improve our process, etc.

Below are the steps for implementation of 4M checklist/ check sheet:

Prepare the 4M checklist /Check sheet as per your Process in detail considering with past 6 months’ quality defect causes, B/D nature causes, customer complaints, etc.
Define the Checking plan (e.g. weekly, monthly, etc.)
Check 4M factors by using the 4M check sheet as per your plan,
Write the observations.
Discuss with the concerned department and formulate the Action plan / CAPA.
Implement the CAPA /Action Plan.
Monitor the implementation of the action plan (For example, verify it in the next checking).

4M Change Management:

After doing the 4M Audit you can easily identify the 4M-related changes. the above 4m checklists is mentioned for your reference but the checking points are not limited. you can customize the above checklist as per your manufacturing process.

You can identify and monitor the 4M changes in the 4M change Record sheet as per below.

Sl. No.	Process	Type of Change	Nature of Change	Details of Change	Action Taken	Set-up Approval	Retroactive check	Containment Action

4M Change record

Example:

Type of Change: Man, Machine, Method, and Material.

Nature of Change: Plan change, Unplan change, Abnormal change

QA/QC/TQM/Lean/6-Sigma Template or Format:

DMAIC Tools | DMAIC Template | Six Sigma Methodologies | 30+ Free Tools

Six Sigma Project Charter Template

DPMO Calculation, Formula, Template & Manufacturing Example

Process Flow Diagram Template | Examples |Symbols |PFD

P Chart Excel Template | Formula |Example | Control Chart | Calculation

C Chart Excel Template | Formula | Example | Calculation

SIPOC Template | SIPOC Diagram Example of Manufacturing & Service Industry

Scatter Diagram Template | Industrial Example | Download Excel Format

4M Checklist Template | Free Download Format

3MU Check sheet | Details of MURA, MURI & MUDA | Download

Dispersion Analysis Cause & Effect Diagram Template |Download Excel Format

5W1H Analysis Example |Download Template

5W2H Analysis Example |Download 5W2H Format

Fault tree analysis template | Download format free…

Process Performance (Pp) & Ppk Excel Template |DOWNLOAD

Histogram Template with example | Download

SWOT Analysis Word Template

Process Capability Analysis | Cp & Cpk Calculation Excel Sheet with Example

Run Chart Example | Concept & Interpretation of Result with Case Study | Industrial Example:

Risk Register | Download Risk Register Template:

Control Chart Excel Template | How to Plot Control Chart in Excel | Download Template

MTBF and MTTR Template, Format, Calculation | Manufacturing Example

OEE Means | Full Form | Download OEE Template

8D Report | Free Download of 8D Template or Format

Pareto Chart Excel Template | Download format

Fishbone Diagram Template With Example

How to calculate z-score in excel with manufacturing example

Corrective and Preventive Action Format, capa format, capa format in word, capa format in excel

Corrective and Preventive Action Format | CAPA with Example

Implementation of KAIZEN in Industry

5 Whys Excel Template , Download why why analysis excel format

FAQ (Frequently Asked Question):

What is 4M in Manufacturing Industries?

Ans.: In Industries the term 4M is generally used as [1] Man [2] Machine [3] Material & [4] Method.

What is 4M method?

Ans.: The 4M method is generally used in manufacturing industries for problem-solving /analysis. These terms are generally represented in 4M change management and also in the Cause and effect diagram or Fishbone diagram. The potential causes are basically represented under the category of 4M- Cause and effect diagram for further processing like causes/problem analysis and validation of causes, etc.

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3MU Check sheet | Details of MURA, MURI & MUDA | Download

07/04/202606/03/2024 by TECHIEQUALITY

3MU Check sheet | Details of MURA, MURI & MUDA:

Hi Readers! Today we will discuss here details on MURA, MURI & MUDA. you can download our free template of the 3MU check sheet from the below links. The 3MU’s are MURA (Discrepancy), MURI (Strain), MUDA Waste).

DOWNLOAD-3MU Check Sheet. (MUDA).

The 3MU can be applied in the below fields;

Method of operation.
Manpower.
Process involved.
Technique.
Facilities.
Time.
Jigs & Tools.
Materials.
Inventory.
Production Volume.
Place.
Way of thinking.

Details of MURA, MURI & MUDA:

MURA	MURI	MUDA
Unevenness, Discrepancy, Irregular	Unreasonableness, Strain, Overdoing, Overburdened	Unusefulness, Waste.
Any variation leading to unbalanced situations.	A system, facility, or process designed beyond the physical capacities of equipment/ workforce	Activities which does not add value.

MUDA: Waste, Unusefulness;

An any activities that do not add value w.r.t the customer perspective, presently in industry; elimination of waste (MUDA) is the big challenge. Many lean tools are there that you can implement it to deduce the MUDA. Value stream mapping is the one of the popular tools that basically used in many industries. But the identification of waste is a big job. The common 7 wastes are;

Defects: The Defective product is total waste.
Overproduction: Production more than demand or less than demand is a loss.
Over Processing: Rework, Repair, Rechecking is a waste of time and money.
Waiting: Waste of time, and money.
Moving: The movement of goods within or outside is waste.
Inventory: Unfinished goods, R/M, BOP add no value.
Transportation: Unnecessary transfer of goods is waste.

Considering with above points we have prepared a sample MUDA Checklist for your ready reference. DOWNLOAD the MUDA Check sheet.

MURA: Unevenness, Discrepancy, Irregular;

MURA can exist when the workflow is out of balance.

MURI: Unreasonableness, Strain, Overdoing, Overburdened;

A system, facility, or process designed beyond the physical capacities of equipment/ workforces.

How to eliminate 3MUs?

The MURA (Unbalanced Process) can lead to an overburden on the workforce or equipment which may cause later on all kinds of non-value-added activities (MUDA). So to eliminate the 3MUs you have to give more focus on Value stream mapping, Process layout design, and 5’S, Visual standard, Kaizen, Process feasibility analysis, and Process variation.

Example:

You can audit your respective area by using our 3MU-MUDA Check Sheet, Similarly, we have done this in the manufacturing unit and found some observations, same mentioned in below for your easy understanding.

We have taken some initiatives against the above findings (Observation) to eliminate the MUDA in the process as;

Observations	Management Initiative
Producing defective product	TQM, QA
The Nonsmooth flow of materials	KANBAN, JIT, PPC
Rework-0.5%	TQM, QA
Excessive B/D	TPM
Excess Production	Pull Production, PPC
FG Stock-High	Inventory Management, World class Supply chain Management

Useful Articles:

4M Checklist Template |Free Download Format

SPC Format |DOWNLOAD Excel Template of SPC Study

why why analysis methodology | 5-why analysis step by step guide

How to measure process capability (Cp & Cpk)? Download Excel Template

Error Proofing Understanding & Implementation of IATF 16949 Clauses 10.2.4

Pareto Chart Example of Manufacturing Units

Thank you for reading…keep visiting Techiequality.Com

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Strategies for Manufacturing Process Improvement |11+ Strategies

05/03/2024 by TECHIEQUALITY

Strategies for Manufacturing Process Improvement |11+ Strategies:

Process improvement is the challenging work in manufacturing industries for continuous Improvement. For continuous improvement, many organizations are following arbitrarily several strategies to improve the process. But they can’t achieve it. As we know the manufacturing unit has many different processes, so they can’t follow a single strategy in all processes. So here we are going to discuss some common standard strategies that will help you to improve the manufacturing process. Following are the Strategies for Manufacturing Process Improvement.

Strategies:

Details of Process:

Team members who are involved in process improvement should have details knowledge of the process. You have to first prepare the PFD (Process flow diagram) or SIPOC (Supplier, Input, Process, Output, Customer) to know the depth idea in the process. Study the Work procedure and verify the work going on in the process. If any obvious problem is identified then immediately correct it.

Tools/Methods/Approaches used in this Strategy are PFD, SIPOC, WP, and Process verification with standard Procedure.

Process Standardization:

Operators involved in operation should follow the standardized procedure, which is the most efficient, effective, and best. So process owner should take the initiative to standardize the check sheet, operational procedure, control plan, etc. To do so process owner is supposed to create a CFT team to validate process characteristics and standardize the validated parameters. Monitoring of record to be executed. And time to time all relevant documents need to be revised.

Tools/Methods/Approaches used in this Strategy are WP, CFT, Check sheet, SOP, Process validation, and Standardization of operation.

Process Streamline:

Streamlining of the process can be done by removing unnecessary activities and reducing the cycle time, inventory, etc. During the streamlining of the process, all the team members should eliminate the extra activities that do not provide the desired result and value to the organization and customer. Strong brain-storming is needed to identify the non-value-added activities.

Tools/Methods/Approaches used in this Strategy are VSM, Brain-storming, JIT, World class supply management, etc.

Elimination of Errors:

In this activity, CFT team members need to study the process including 4M (Man, Machine, Material, and Method) factors as a potential source of error. Following are the methods or approaches that CFT team members need to follow to identify the source of error and need to react immediately to improve.

Tools/Methods/Approach used in this Strategy are:

Man	On-job Training, Visual Standard, 5’S, MSA, WP, Operators skills, etc.
Machine	Calibration, Test report, Validation, Error proofing device, Machine maintenance, etc.
Material	JIT, KANBAN, Testing, 5’S, etc.
Method	SOP, Skill of operator, Testing, equipment calibration, etc.

Statistical Process Control:

Process Inspectors have to collect the data and prepare the control chart according to data types. If a special cause exists there then they have to plan for continual improvement.

Tools/Methods/Approaches used in this Strategy are Process Capability analysis, Control Chart, etc.

Process design improvement:

The CFT team needs to decide first which factors are going to be measured for improvement by experiment (DOE, DSS, etc.) methods. Before starting the experiment project, CFT members should represent the theoretical benefits and technical logic behind the improvement project. Then they have to set up, conduct an experiment project, and collect the data for analysis. If found positive result then the action of the experiment needs to be implemented in the process.

Tools/Methods/Approaches used in this Strategy are DOE, DSS, Experiment Projects, etc.

Flow Production:

Machines should be set up in such a way that productions will run smoothly and steadily without interruption. Process layout needs to be standardized according to workflow.

Tools/Methods/Approach used in this Strategy is: Standardizing of Work Layout.

Level Production:

This involves breaking the large lots into smaller lots and producing them at a constant level. All manufacturing industries should prepare the production plan accordingly so that a constant quantity of daily production will run without storing the whole period of raw material as inventory.

Tools/Methods/Approaches used in this Strategy are JIT, PPC, Inventory Management, etc.

Visual Control:

Visual control is one of the best methodologies for process improvement, in this process, you can visualize the Q-component level and decision-making component level in the shop floor process, activities, and machine to know the deviation in the process. You can easily act on it online.

For example, leveling of lubricant oil at the machine, during daily machine inspection you can easily check the oil level, which may allow you to prevent the machine break-down caused by the low level of lubricant oil in the machine.

Tools/Methods/Approach used in this Strategy is Match-mark, sign, level, Photos, 5’S, etc.

Jidoka:

Example-Andon system, read more…

Process Control:

This involves identifying the process variation (special cause, common cause, wastage, defects, yield, scrap, etc.). Process owners need to analyze it and take the necessary action on it.

Tools/Methods/Approach used in this Strategy are Control chart, run chart, 7QC tools, MSA, SPC, etc.

TPM (Total Productive Maintenance):

By actively doing the TPM activities may lead to some benefits like zero breakdown, zero defects, etc. and the machine’s basic condition will be maintained.

Note that all the above strategies are not applicable to all sectors/ units and it depends on the nature of the Manufacturing process and suitability.

Useful Articles:

3MU Check sheet | Details of MURA, MURI & MUDA|Download

4M Checklist Template |Free Download Format

How to enhance production in manufacturing unit?

5W2H Analysis Example |Download 5W2H Format

Process Performance (Pp) & Ppk Excel Template |DOWNLOAD

How to measure process capability (Cp & Cpk)? Download Excel Template

Thanks for reading…keeps visiting Techiequality.Com

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Dispersion Analysis Cause & Effect Diagram Template |Download Excel Format

07/04/202605/03/2024 by TECHIEQUALITY

Dispersion Analysis & Process Classification Cause & Effect Diagram Template

Hi readers! Today we will discuss on types of Cause & Effect Diagram/Fishbone diagram. The cause and effect diagram is the most popular and frequently used tool among the seven QC tools. Basically Fishbone diagram is classified into mainly two types as [1] Dispersion Analysis Cause and Effect diagram, and [2] Process Classification Fishbone diagram. The Dispersion analysis fishbone diagram involves identifying the potential cause for a specific quality problem. However, a Process classification cause & effect diagram involves establishing causes related to the Process. In the manufacturing industry, both types of diagrams are used but Dispersion types are most frequently used to identify the potential causes of the quality-related problems. If you are interested in downloading the Dispersion Analysis Cause & Effect Diagram Template & Process Classification fishbone diagram, then click on the given below links.

DOWNLOAD– Dispersion analysis cause & effect diagram template. (4Ms).

Dispersion analysis Fishbone Diagram Excel Template. (4Ps)-DOWNLOAD.

DOWNLOAD– Dispersion analysis cause & effect diagram format. (8Ms).

Process Classification cause & effect diagram excel format-DOWNLOAD.

Steps for construction of Cause & Effect Diagram:

Form a CFT- Team with a multifunctional experienced workforce.
The facilitator will listen carefully to the member’s potential causes to represent it in a diagram.
Draw a backbone line from left to right, terminating at the Head, and write the Problem statement.
Draw the small bone and write the potential cause.

Advantages:

It helps to identify the potential cause to improve the process.
Helps in the root cause identification of the problem.
C&E diagram is easily constructed & understood.
It is an effective tool for the diagnosis of the various causes of the problem and helping to solve the problem.

Disadvantages:

Waste of time to identify the other causes that are not critical to the Problem.
It’s a time-consuming methodology.

Dispersion Analysis Cause & Effect diagram V/S Process Classification Fishbone diagram:

Useful Links:

Strategies for Manufacturing Process Improvement |11+ Strategies

7QC Tools for Problem Solving | What are 7 QC Tools

Fishbone Diagram Template With Example

Root Cause Analysis | 8 Steps of RCA

5W1H Analysis Example |Download Template

16/11/202402/03/2024 by TECHIEQUALITY

5W1H Analysis Example |Download Template:

Hi Readers! Today we will discuss here 5W1H Analysis with a manufacturing example. 5W1H is a methodology consisting of six questions as What? Where? When? Who? Why? How? Needs to ask a lot of questions to collect all the necessary data to draw up a report of the existing situation with the aim of identifying the phenomenon of the problem. Go through the below details of the 5W1H Analysis Example (Manufacturing Example).

DOWNLOAD-5W1H Template/ Format.

5W1H Analysis:

5W1H Analysis will help you broadly to know the nature of the problem like What is the Problem? Where did the problem occur? When did the problem happen? Who do you need to get involved? Why is it happening? How can you overcome the Problem?

The above pattern may be subject to change if it does not fit with the scenario/ nature of the problem. We can use “how much” additionally as and when applicable regarding the nature of the problem. And then it’s namely called 5W2H. Here, we will illustrate only 5W1H.

Description of 5W1H:

Phenomenon of Problem:	Explanation:
What is the Problem?	Where did the problem occur?
When did the problem happen?	Describe the location, place, and m/c involved.
Who do you need to get involved?	Find out the time when a situation took place.
Involvement of people, external providers, etc.	Why is it happening?
How can you overcome the problem?	To know the reason behind of facts
Method of implementation, deployment, etc.	Method of implementation, deployment, etc.

[5W1H Description Table]

Benefits of 5W1H Method:

It can apply to all types of industries.
One can use it to address all kinds of problems to ask questions from every angle.
It’s a simple method, that everyone can understand, no need for training to ask these types of questions.

You could also like to read the below Articles:

The Process Approach to QMS (ISO 9001, IATF 16949).

7 principles of QMS | Quality Management Principles.

SPC Format |DOWNLOAD Excel Template of SPC Study

7QC Tools Excel Template |DOWNLOAD Format.

How to measure process capability (Cp & Cpk)? Download Excel Template.

How to measure process performance (Pp & Ppk)?

How to apply 5W1H method in Industries?

From my past experience, I’m trying to share how I was involved with Gemba’s investigation of the line rejection problem. I often use the 5W1H and 5W2H methodology to collect the information on line rejection, before doing the brainstorming, our team members collect the information about the problem with details like which machine, which place, who is responsible, etc. so that we can get the complete data and information for root cause analysis. One day during the line product checking, we found 5 products were rejected. so next I collected the whole data and informed to our CFT team for analysis, Thereafter I realized that how this (5W1H methodology) is helpful. Below is the step-by-step approach described for the deployment of the 5W1H method in industries.

In Manufacturing Industries, this 5W1H format is generally used for problem-solving and It’s widely used during shop floor red bin analysis and also, it’s utilized for analysis of different types of problems like machine breakdown, process-related issue, man-related issues, material related issues, utility breakdown, tools related issue, mechanical & electrical related breakdown, etc.

Step by step approach:

The 5W1H method is applicable to address all kinds of Problems, so go to the real place where the problem occurred. Understand and write in the first “W” that, what is the problem, e.g. Ingate shrinkage, write the technical definition and details of the problem with the defective product picture.
The second process is to cover the question related to “W-2” i.e (Where), Now we have to mention the process area, the machine no, defect location in the product, here we have to cover the defect’s generation area/ process, where it actually generated.

The third “W” is When, here you have to investigate the shop floor workforce and to check the relevant data to know the time/ period/ date/ shift, etc. that when the problem occurred.
Now we will discuss “Why” This is an important process where we have to analyze the root cause of the problem by using a why-why methodology.
In the step “HOW” we have to take an action plan against the root cause.
This is the last step i.e. “Who”: who is the responsible person to implement the action plan.

5W1H Analysis Example-1:

We have taken the same example here, which is already explained in previous articles. If you have not yet read then kindly go through it-previous article.

5W1H Analysis Example template — **5W1H Analysis Template / Format**

According to previous article the problem found in the process was Ingate Shrinkage. And same we are going to explain it through the 5W1H template.

5W1H Analysis Example template format — **DOWNLOAD** **filled up Format** **|Manufacturing Example**]

EXAMPLE-2:

The cross-functional team has investigated the fire incident, which was happened in the office at 1.00PM. They have recorded the information in 5W1H format, the same as we have mentioned in below.

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FAQ:

What is the difference between 5W1H and 5W2H?

the main difference is the absence of 2H i.e. “How much” in the 5W1H methodology, otherwise all terms are the same in both 5W1H and 5W2H. but sometimes we use “how much” in place of “How” as per the nature of the problem in the 5W1H template

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5W2H Analysis Example |Download 5W2H Format

16/11/202402/03/2024 by TECHIEQUALITY

5W2H Analysis Example |Download 5W2H Format:

Hi Readers! Today we will discuss on 5W2H Analysis Example with industrial/manufacturing practices and also in this post, you can download our approved template for deployment in your workplace. We have already posted our previous article 5W1H analysis with examples. If you have not yet read that article then first go through it. Our 5W2H template/format is ready to use just download it from given below link.

DOWNLOAD-5W2H Template.

How to use the 5W2H Method in Manufacturing Industries?

In Industry, both the 5W2H and 5W1H are frequently used methods to Understand, collect, and analyze the Problem. The application of the 5W2H method depends on the nature of the problem. The full form of 5W2H is What, Where, When, Who, Why, How, and How much. Information and Data on any problem are always required for analysis and to find out the root cause. So 5W2H Format will help you to get the collective data and information in one place for problem analysis. From my past experience, I’m sharing the approach and steps for the usage and implementation of the 5W2H methodology.

Daily we find some problem in our production process/line, to overcome such problem we have to resolve these as soon as possible. The problems may be maintenance-related (like Breakdown, equipment failure, utility problems, quality issues, etc.). To understand and solve the problem, we need info. and data. In my point of view, always problem-solving team should always visit the Gemba ( Actual place) to clearly understand and investigate the problem. Below are the steps that we generally were being followed;

Visit to the Gemba (E.g.-Shop floor)
Ask the question to the operator /shop floor person and collect the information and data.
Investigate the 4M or 6M (Men, M/C, Material, Method, Mother Nature, and Measurement) factors and see if any clues are present or not.
Do Brainstorming and find out the Root Cause.

The Manufacturing Example is mentioned below covering all the above steps.

5W2H Analysis:

5W2H Analysis will help you broadly to know the nature of the problem like What is the Problem? Where did the problem occur? When did the problem happen? Who do you need to get involved with? Why is it happening? How can you overcome the Problem? How much quantity?

The above pattern may be subject to change if it does not fit with the scenario/ nature of the problem. We can use only “how” as and when applicable regarding the nature of the problem. And then it’s namely called 5W1H. Here. Today in this article we will discuss only 5W2H Analysis with examples.

Explanation of 5W2H:

5W2H terms	The Phenomenon of the Problem:	Explanation:
What	What is the Problem?	Goal or Objectives (To describe the problem, activity, task, or project purpose)
Where	Where did the problem occur?	Location (Describe the location, place, and m/c involved)
When	When did the problem happen?	Time (Find out the time, date, and schedule when the situation took place)
Who	Who do you need to get involved with?	Responsible Person or Team (Involvement of people, external provider, etc.)
Why	Why is it happening?	Root Cause (To know the reason behind facts, popular tools used for root cause finding are, e.g. RCA, why-why analysis, etc.)
How	How can you overcome the problem?	Activities or Process (Method of implementation, deployment, etc.), e.g. CAPA.
How Much	How much quantity?	Cost, Quantity, etc.

Explanation Table [5W2H]

The above phenomenon of question is not always common for all scenarios; the question patterns will be changed according to the nature of issues/problems/risks/opportunities.

EXAMPLE-1:

During shop floor rejection analysis at the rejection yard, we found 5 nos casting were rejected due to a blow-hole on the top surface. Same we have explained through the 5W2H format as;

EXAMPLE-2:

Unfortunately, one day at 1.00 PM, a Fire incident happened at the office. The organization had taken the necessary immediate action during the incident but later the CFT team investigated the area to collect the data for root cause analysis. They have recorded the data and analysis report in 5W2H Format, the same format is given below.

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FAQ:

What is the difference between 5W2H and 5W1H?

What is the meaning of 5W2H?

The methodology itself indicates that there are 5 Ws and two Hs. This means, what, where, when, who, why, how, and how much. it’s a questioning method and very easy to implement in any organization. we have already given multiple examples for your better understanding. and also defined each term of 5W2H in the above table. just think of one more example of a machine breakdown issue on the shop floor. and you are trying to solve it in a systematic way by applying the 5W2H methodology. Once you applied it and resolved the problem then simultaneously, you did both jobs i.e. one is a record of b/d CAPA and solved the actual problem. It’s a very useful record and you can refer to it when there is the same problem occurs on the same machine.

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