Free quality &amp; process improvement tools

Fishbone Diagram (Ishikawa)

Brainstorm and organize possible causes by category (6M, 8P, 4S) on a live Ishikawa diagram.

5 Whys

Drill down from a symptom to its root cause by asking "why?" and track countermeasures.

Cause-and-Effect Matrix

Score process inputs against weighted customer outputs to prioritize the vital few.

Fault Tree Analysis

Model a top event with AND/OR gates, compute its probability and find minimal cut sets.

Root Cause Tree

Break a problem into causal factors and classified root causes on a tree diagram.

Is/Is Not Analysis

Define a problem precisely by what, where, when and extent, and test possible causes against it.

Barrier Analysis

Identify which barriers between a hazard and a target failed, were missing or were not used.

Change Analysis

Compare an incident with an incident-free situation to find the change that caused it.

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Process mapping

Visualize how work actually flows so you can see waste, hand-offs and risks.

Process Flowchart

Draw a flowchart with standard shapes: drag steps, connect them and label decisions.

Swimlane Diagram

Map who does what with a cross-functional flowchart organized in lanes.

SIPOC

Scope a process on one page: suppliers, inputs, process steps, outputs and customers.

Value Stream Mapping

Map material and information flow, calculate takt time, lead time and process cycle efficiency.

Turtle Diagram

Define a process with its inputs, outputs, resources, people, methods and KPIs (IATF 16949).

Spaghetti Diagram

Trace people and material movement on a floor plan and measure the distance travelled.

Workflow Map

Lay out workflow steps by owner, then see handoffs, wait time and value-added time.

Process Hierarchy Map

Break your process architecture into levels, from value chain to activities, with owners.

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Basic quality tools

The classic seven quality tools for collecting, organizing and reading data.

Check Sheet

Tally defects or events by type and time on a digital check sheet, then send totals to a Pareto chart.

Pareto Chart

Rank problems by count or cost and find the vital few with an 80/20 cumulative line.

Histogram

See the shape of your data against spec limits, with mean, standard deviation and Pp/Ppk.

Scatter Diagram

Test whether two variables are related with a trend line, correlation (r) and R².

Control Chart

Build I-MR, X̄-R, X̄-S, p, c and u charts with control limits and Nelson rule signals.

Stratification

Split data by machine, shift, supplier or operator to see where the problem really is.

Fishbone Diagram (Ishikawa)

Brainstorm and organize possible causes by category on a live Ishikawa diagram.

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Statistical analysis

Quantify variation, capability and the effect of changes with sound statistics.

Run Chart

Plot data over time with the median and detect shifts, trends and unusual numbers of runs.

Process Capability Analysis (Cp/Cpk, Pp/Ppk)

Calculate Cp, Cpk, Pp, Ppk and expected PPM with a capability histogram and a normality test.

Measurement System Analysis

Check gauge bias and repeatability (Cg, Cgk) and linearity across the measuring range.

Gage R&R

Run a crossed Gage R&R study by ANOVA: %Study Var, %Tolerance and number of distinct categories.

Hypothesis Testing

Run t-tests and proportion tests with p-values, confidence intervals and a plain-language conclusion.

Regression Analysis

Fit simple or multiple linear regression with p-values, residual plots and predictions.

ANOVA

Compare several group means with one-way ANOVA, Welch's test and Tukey comparisons.

Design of Experiments

Plan 2-level factorial experiments, then find the significant effects and the best settings.

Sampling Plans

Find AQL sampling plans (Z1.4 / ISO 2859-1) with OC curve, LTPD and AOQL.

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Risk analysis

Anticipate failures and hazards, rate them and plan controls before they happen.

FMEA

Rate failure modes by severity, occurrence and detection, with RPN and AIAG-VDA Action Priority.

FMECA

Add quantitative criticality (Cm = β·α·λp·t) and a criticality matrix to your failure analysis.

Risk Matrix

Build a customizable risk matrix and drag risks between cells to rate likelihood and impact.

Bowtie Analysis

Map threats, prevention and mitigation barriers and consequences around a top event.

Hazard Analysis

Analyse hazards, hazardous situations and harms, then plan and verify risk controls (ISO 14971).

Preliminary Hazard Analysis

Identify hazards early in design and rate them with the MIL-STD-882E risk matrix.

HAZOP

Run a HAZOP study with nodes, guidewords, deviations, safeguards and a coverage grid.

HACCP

Build a HACCP plan: flow diagram, hazard analysis, CCP decision tree and CCP plan.

What-If Analysis

Brainstorm "what if?" scenarios, rate their risk and track the recommendations.

Fault Tree Analysis

Model a top event with AND/OR gates, compute its probability and find minimal cut sets.

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Lean improvement

Remove waste, stabilize flow and build a culture of continuous improvement.

5S Audit

Score Sort, Set in order, Shine, Standardize and Sustain, see the 5S radar and track the findings.

Kaizen Report

Document quick improvements on before/after kaizen cards and total the annual savings.

Kaizen Event

Plan a kaizen blitz: charter, team, daily agenda, before/after metrics and the 30-day action list.

Standard Work

Build a standard work combination sheet with manual, machine and walk time against takt.

Takt Time Calculator

Calculate takt time from available time and demand, then compare every step and size the crew.

Cycle Time Analysis

Run a time study: element statistics, sample size check, rating and allowances to standard time.

Line Balancing

Balance tasks across stations with precedence, see the Yamazumi chart and balance efficiency.

Kanban Calculator

Size kanban loops from demand, lead time and safety stock, then print the kanban cards.

Poka-Yoke

Mistake-proof a process: rate each error, design a device and move it up the control hierarchy.

SMED

Cut changeover time: split internal and external work, convert and streamline, compare before/after.

Heijunka

Level the production mix: build a heijunka box, a mixed-model sequence and check interval load.

Visual Management Board

Run a daily SQDCP tier board with letter calendars, KPI status and an action list.

Gemba Walk

Walk the floor with a structured checklist, log observations and follow up on the actions.

Waste Analysis

Find and cost the 8 wastes (TIMWOODS) and rank where the time and money go.

OEE Calculator

Calculate availability, performance, quality and OEE with a six big losses waterfall.

Value Stream Mapping

Map material and information flow, calculate takt time, lead time and process cycle efficiency.

Spaghetti Diagram

Trace people and material movement on a floor plan and measure the distance travelled.

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Structured problem solving

Proven step-by-step methods that take a team from problem to verified solution.

PDCA Cycle

Plan, Do, Check, Act on one page, with a target metric, action plan and a live PDCA wheel.

PDSA Cycle

Use the Model for Improvement and run linked PDSA cycles with predictions up the ramp.

DMAIC

Run a Six Sigma project: charter, tollgate checklists, CTQ metric and sigma level, phase by phase.

A3 Problem Solving

Write a Toyota-style A3 report on one editable page, from background to follow-up.

8D Report

Complete the eight disciplines (D0–D8) with team, containment, root causes and verified actions.

CAPA

Manage a corrective and preventive action from risk rating to effectiveness check and closure.

QC Story

Tell a quality improvement story in seven steps, with the before, target and after results.

5 Whys

Drill down from a symptom to its root cause by asking "why?" and track countermeasures.

Is/Is Not Analysis

Define a problem precisely by what, where, when and extent, and test possible causes against it.

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Planning and prioritization

Organize ideas and decide what to work on first, as a team.

Affinity Diagram

Sort a brainstorm into natural groups: drag sticky notes between columns and name the themes.

Interrelationship Diagram

Map cause-and-effect links between issues and find the key drivers and key outcomes.

Tree Diagram

Break a goal down into the means and actions needed to reach it, level by level.

Matrix Diagram

Show the strength of relationships between two lists with ◎ ○ △ symbols and weighted totals.

Prioritization Matrix

Weight criteria by pairwise comparison, score the options and rank them.

Impact/Effort Matrix

Plot ideas by impact and effort to find the quick wins; drag to re-rate.

Decision Matrix

Score options against weighted criteria and see what drives the winner.

Pugh Matrix

Compare concepts against a baseline with +, S and − to find the best design.

Multivoting

Narrow a long list with dot voting rounds, using the N/3 rule for votes per person.

Nominal Group Technique

Rank ideas individually, then combine the rankings into a team priority list.

Cause-and-Effect Matrix

Score process inputs against weighted customer outputs to prioritize the vital few.

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Project and action planning

Turn improvement decisions into owned, scheduled and tracked actions.

Gantt Chart

Plan tasks, dependencies and milestones on a timeline; drag bars to reschedule.

Action Plan

List actions with owners, dates and status on a board, and see what is late.

RACI Matrix

Assign Responsible, Accountable, Consulted and Informed roles and check the gaps.

Arrow Diagram

Draw an activity-on-arrow network with events, dummies and the critical path.

Critical Path Method

Calculate early and late dates, float and the critical path on a network diagram.

PERT Chart

Use three-point estimates to get the expected duration and the chance of meeting a deadline.

Process Decision Program Chart

Anticipate what could go wrong with a plan and prepare countermeasures (PDPC).

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Customer needs and product design

Translate the voice of the customer into measurable design requirements.

Voice of the Customer

Collect what customers say, group it into needs and translate each need into a measurable requirement.

CTQ Tree

Break a customer need into drivers and measurable CTQs with specification limits and current status.

Quality Function Deployment

Cascade customer needs through four QFD phases down to the production controls that protect them.

House of Quality

Build the full house: needs, characteristics, relationships, roof, competitor ratings and technical priorities.

Kano Model

Classify features as must-be, performance, attractive or indifferent from survey answers.

Quality by Design

Go from QTPP to CQAs, a parameter risk assessment, design space ranges and the control strategy.

Design for Six Sigma

Run a DMADV project and predict the capability of every CTQ with a design scorecard.

Benchmarking

Compare your metrics with partners and the best in class, size the gaps and plan what to adapt.

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Performance and effectiveness

Measure whether quality efforts are paying off.