Total Quality Management Overview
Total Quality Management Overview
MANAGEMENT
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INTRODUCTION : QUALITY DEFINITION
(CONT.)
The concept and vocabulary of quality are unlimited
Different people interpret quality differently.
When asked what differentiates their product or
service;
The banker will answer” service”
The healthcare worker will answer “quality health care”
The hotel employee will answer “customer satisfaction”
The manufacturer will simply answer “quality product”
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Q: HOW DO YOU DEFINE QUALITY
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THE IMPORTANCE OF QUALITY
WHY QUALITY?
Reasons for quality becoming a cardinal priority for
most organizations:
1. Competition – Today’s market demand high quality
products at low cost. Having `high quality’ reputation is
not enough! Internal cost of maintaining the reputation
should be less.
2. Changing customer – The new customer is not only
commanding priority based on volume but is more
demanding about the “quality system.”
3. Changing product mix – The shift from low volume,
high price to high volume, low price have resulted in a
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need to reduce the internal cost of poor quality.
WHY QUALITY?
4. Product complexity – As systems have become more
complex, the reliability requirements for suppliers of
components have become more stringent.
5. Higher levels of customer satisfaction – Higher
customers expectations are getting spawned by
increasing competition.
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DYNAMIC APPROACH OF THE
QUALITY
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CUSTOMER AND PRODUCT
What is a customer?
Anyone who is impacted by the product or process delivered
by an organization.
External customer: The end user as well as intermediate
processors. Other external customers may not be purchasers
but may have some connection with the product.
Internal customer: Other divisions of the company that receive
the processed product.
What is a product?
The output of the process carried out by the organization. It
may be goods (e.g. automobiles, missile), software (e.g. a
computer code, a report) or service (e.g. banking, insurance)
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How is customer satisfaction achieved?
Two dimensions: Product features and Freedom from
deficiencies.
Product features – Refers to quality of design.
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QUALITY PERSPECTIVES
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QUALITY LEVELS
At organizational level, we need to ask following
questions:
Which products and services meet your expectations?
Which products and services you need that you are not
currently receiving?
At process level, we need to ask:
What products and services are most important to the
external customer?
What processes produce those products and services?
competitiveness of an organization
through the continual improvement of
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THE CONCEPT OF TOTAL QUALITY
MANAGEMENT (CONT.)
Juran
Deming
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THE EVOLUTION OF TQM
[Link] Control.
[Link] Assurance.
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THE EVOLUTION OF TQM
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1. Inspection
In manufacturing incoming goods and output would be
measured and physically inspected for defaults or not
meeting required guidelines.
Services would be appraised at certain levels and inspected
in production and delivery, non conforming products being
sent back to be re-worked or result in lower graded
products that are produced in a rating system.
2. Quality Control
Quality control remains in the operation of detecting
mistakes, finding and fixing them.
everything is closely monitored, with detailed performance
and product specifications as well as control systems for
paperwork and procedures, product testing at raw material
and mid-production stages with reports being filed and
overall feedback on the processes involved to personnel
and suppliers. 31
3. Quality Assurance
Continual improvement in quality was needed a
targeting efforts towards planning and prevention of
problems occurring at the root source of the quality
problems.
By using quality systems advanced quality planning,
comprehensive quality manuals, involvement of non-
production operations. the organization should
experience a shift in emphasis from detection towards
prevention of noncompliant produce.
Example : quality planning
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COST OF APPRAISAL
Those costs incurred to identify poor quality products
after they occur but before shipment to customers.
Example : Inspection activity.
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COST OF INTERNAL FAILURE
Those incurred during the production process.
Example : Scrap, and Rework.
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COST OF EXTERNAL FAILURE
Those incurred after the product is shipped.
Example : Warranty costs,
Hidden costs of customer dissatisfaction
Lost market share.
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CHAPTER 2
HISTORY OF QUALITY
MANAGEMENT
…To know the future, know the past!
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HISTORY OF QUALITY
MANAGEMENT
Statistical approaches to quality control started at
Western Electric by Walter Shewhart.
After World War II, Japan rebuilding plan, Deming and
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HISTORY OF QUALITY
MANAGEMENT
Market started preferring Japanese products and
American companies suffered immensely.
America woke up to the quality revolution in early
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HISTORY OF QUALITY
MANAGEMENT
Managers started to realize that “quality of management”
is more important than “management of quality.” Birth
of the term Total Quality Management (TQM).
TQM – Integration of quality principles into
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THE DEMING PHILOSOPHY
14 points for management:
1. Create and publish to all employees a statement of the
aims and purposes of the company. The management
must demonstrate their commitment to this statement.
2. Learn the new philosophy.
3. Understand the purpose of inspection – to reduce the
cost and improve the processes.
4. End the practice of awarding business on the basis of
price tag alone.
5. Improve constantly and forever the system of
production and service. 46
THE DEMING PHILOSOPHY
6. Institute training
7. Teach and institute leadership.
8. Drive out fear. Create an environment of innovation.
9. Optimize the team efforts towards the aims and
purposes of the company.
10. Eliminate exhortations for the workforce.
11. Eliminate numerical quotas for production.
12. Remove the barriers that rob pride of workmanship.
13. Encourage learning and self-improvement.
14. Take action to accomplish the transformation.
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THE DEMING PHILOSOPHY
“A System of Profound Knowledge”
1. Appreciation for a system - A system is a set of
functions or activities within an organization that
work together to achieve organizational goals.
Management’s job is to optimize the system. (not parts
of system, but the whole!). System requires co-
operation.
2. Psychology – The designers and implementers of
decisions are people. Hence understanding their
psychology is important.
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THE DEMING PHILOSOPHY
3. Understanding process variation – A production
process contains many sources of variation. Reduction
in variation improves quality. Two types of variations-
common causes and special causes. Focus on the
special causes. Common causes can be reduced only
by change of technology.
4. Theory of knowledge – Management decisions should
be driven by facts, data and justifiable theories. Don’t
follow the managements fads!
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THE JURAN PHILOSOPHY
Joseph Moses Juran (December 24, 1904 –
February 28, 2008) was a 20th century
management consultant who is principally
remembered as an evangelist for quality and
quality management, writing several
influential books on these subjects.
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THE JURAN PHILOSOPHY
Pursue quality on two levels:
1. The mission of the firm as a whole is to achieve high
product quality.
2. The mission of each individual department is to
achieve high production quality.
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PROCESS CONTROL
Control is the activity of ensuring the conformance to
the requirements and taking corrective action when
necessary.
Two reasons for controlling the process
1. Process control methods are the basis of effective
daily management of processes.
2. Long-term improvements can not be made to a process
unless the process is first brought under control.
Short-term corrective action should be taken by the
process owners. Long-term remedial action should be
the responsibility of the management.
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PROCESS CONTROL
Effective quality control systems include
1. Documented procedures for all key processes
2. A clear understanding of the appropriate equipment
and working environment
3. Methods of monitoring and controlling critical quality
characteristics
4. Approval processes for equipment
5. Criteria for workmanship: written standards, samples
etc.
6. Maintenance activities
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PROCESS IMPROVEMENT
Customer loyalty is driven by delivered value.
Delivered value is created by business processes.
Sustained success in competitive markets require a business to
continuously improve delivered value.
To continuously improve value creation ability, a business must
continuously improve its value creation processes.
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PROCESS IMPROVEMENT:
KAIZEN
Every employee strives for improvement. Top
management views improvement as part of strategy and
supports it. Middle management can implement top
management’s improvement goals by establishing,
maintaining, and upgrading operating standards. Workers
can engage through suggestions, small group activity.
Middle management can help create conducive
environment for improvement by improving cooperation
amongst departments, and by making employees
conscious of their responsibilities for improvement.
Supervisors can direct their attention more on
improvement than supervision, which will facilitate
communication. 64
KAIZEN: IMPLEMENTATION
The Deming cycle: Originally developed by Walter Shewart,
but renamed in 1950s because Deming promoted it extensively.
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KAIZEN: IMPLEMENTATION
Plan – Study the current system; identifying problems;
testing theories of causes; and developing solutions.
Do – Plan is implemented on a trial basis. Data collected
and documented.
Study – Determine whether the trial plan is working
correctly by evaluating the results.
Act – Improvements are standardized and final plan is
implemented.
Variation of PDSA cycle: FADE – Focus, Analyze,
Develop, Execute cycle!
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KAIZEN: IMPLEMENTATION
Juran’s breakthrough sequence:
1. Proof of the need
2. Project identification
3. Organization for breakthrough – two paths identified:
symptom to cause (diagnostic) and cause to remedy
(remedial) paths.
4. Diagnostic journey
5. Remedial journey
6. Holding the gains.
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PROCESS IMPROVEMENT
TOOLS
Seven QC Tools
1. Flow charts
2. Check sheets
3. Histograms
4. Pareto diagrams
5. Cause-and-effect diagrams
6. Scatter diagrams
7. Control charts
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FLOW CHARTS
Process map identifies the sequence of activities or the
flow in a process.
Objectively provides a picture of the steps needed to
accomplish a task.
Helps all employees understand how they fit into the
process and who are their suppliers and customers.
Can also pinpoint places where quality-related
measurements should be taken.
Also called process mapping and analysis.
Very successfully implemented in various organizations.
e.g. Motorola reduced manufacturing time for pagers
using flow charts.
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CHECK SHEETS
Special types of data collection forms in which the
results may be interpreted on the form directly without
additional processing.
Data sheets use simple columnar or tabular forms to
record data. However, to generate useful information
from raw data, further processing generally is necessary.
Additionally, including information such as specification
limits makes the number of nonconforming items easily
observable and provides an immediate indication of the
quality of the process.
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PARETO DIAGRAMS
Based on the 85-15
Pareto distribution.
Helpful in identifying
the quality focus areas.
Popularized by Juran.
It is a histogram of the
data from the largest
frequency to the
smallest.
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CAUSE-EFFECT DIAGRAMS
Also called fishbone diagrams (because of their shape)
or Ishikawa diagrams.
Helps in identifying root causes of the quality failure.
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SCATTER DIAGRAMS
Graphical components of the regression analysis.
Often used to point out relationship between variables.
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RUN CHARTS AND CONTROL
CHARTS
Run chart: Measurement against progression of time.
Control chart: Add Upper Control Limit and Lower
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CH. 4
TQM FOR THE
WORKFORCE
Quality Circles
Kaizen teams
QUALITY CIRCLES
Teams of workers and supervisors that meet regularly to
address work-related problems involving quality and
productivity.
Developed by Kaoru Ishikawa at University of Tokyo.
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CH. 5
QUALITY MANAGEMENT
AWARDS AND
FRAMEWORK
ISO 9000: 2000
Malcolm Baldrige National Quality Award
Deming Prize
Six Sigma
ISO 9000: 2000
Created by International Organization for
Standardization (IOS) which was created in 1946 to
standardize quality requirement within the European
market.
IOS initially composed of representatives from 91
countries: probably most wide base for quality standards.
Adopted a series of written quality standards in 1987
(first revised in 1994, and more recently (and
significantly) in 2000).
Prefix “ISO” in the name refers to the scientific term
“iso” for equal. Thus, certified organizations are assured
to have quality equal to their peers.
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ISO 9000: 2000
Defines quality systems standards based on the premise
that certain generic characteristics of management
principles can be standardized.
And that a well-designed, well-implemented and well
managed quality system provides confidence that outputs
will meet customer expectations and requirements.
Standards are recognized by 100 countries including
Japan and USA.
Intended to apply to all types of businesses. (Recently,
B2B firm [Link] became the first e-commerce
company to get ISO certification.)
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ISO 9000: 2000
Created to meet five objectives:
1. Achieve, maintain, and seek to continuously improve
product quality in relation to the requirements.
2. Improve the quality of operations to continually meet
customers’ and stakeholders’ needs.
3. Provide confidence to internal management that
quality requirements are being met.
4. Provide confidence to the customers that quality
requirements are being met.
5. Provide confidence that quality system requirements
are fulfilled.
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ISO 9000: 2000 STRUCTURE
Consists of three documents
1. ISO 9000 – Fundamentals and vocabulary.
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ISO 9000 REGISTRATION
Originally intended to be a two-party process where the
supplier is audited by its customers, the ISO 9000
process became a third-party accreditation process.
Independent laboratory or a certification agency
conducts the audit.
Recertification is required every three years.
Individual sites – not entire company – must achieve
registration individually.
All costs are to be borne by the applicant.
A registration audit may cost anywhere from $10,000 to
$40,000.
(more information at [Link]
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SIX SIGMA
Business improvement approach that seeks to find and
eliminate causes of defects and errors in processes by
focusing on outputs that are critical to customers.
The term Six Sigma is based on a statistical measure that
it. 87
SIX SIGMA
Core philosophy based on key concepts:
Think in terms of key business processes and customer
requirements with focus on strategic objectives.
Focus on corporate sponsors responsible for
championing projects.
Emphasize quantifiable measures such as defects per
million opportunities (dpmo).
Ensure appropriate metrics is identified to maintain
accountability.
Provide extensive training.
Create highly qualified process improvement experts
-“belts”.
Set stretch objectives for improvement.
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SIX SIGMA
Contrasts between traditional TQM and Six Sigma (SS) -
TQM is based largely on worker empowerment and
teams; SS is owned by business leader champions.
TQM is process based; SS projects are truly cross-
functional.
TQM training is generally limited to simple
improvements tools and concepts; SS is more rigorous
with advanced statistical methods.
TQM has little emphasis on financial accountability; SS
requires verifiable return on investment and focus on
bottom line.
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CH. 6
TQM FOR TOP
MANAGEMENT
Strategic Quality
Management (SQM)
Competitive Advantage
SQM: HOSHIN PLANNING
Hoshin kanri: Japanese for management cycle build
around Plan, Do, Check, Act. Elements of this cycle
include –
Quality policies
Quality goals
Deployment of goals
Plans to meet goals
Organizational structure
Resources
Measurement feedback
Review of progress
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Training
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SQM: VISION/MISSION
STATEMENT
Developed by taking everyone in confidence. Guide for the
Quality journey. Ties quality to overall business goals.
Vision Statement: Collection of quality policies. A vision
statement outlines what a company wants to be. It focuses on
tomorrow; it is inspirational; it provides clear decision-
making criteria; and it is timeless. A vision needs to address
three areas: people, culture (or values) and product or service.
Mission statement: A mission statement outlines what the
company is now. It focuses on today; it identifies the
customers; it identifies the critical processes; and it states the
level of performance.
It has been said that a vision is something to be pursued, while
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a mission is something to be accomplished.
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CHARACTERISTICS OF TQM
LEADER
Visible,Committed and Knowledgeable
A Missionary Zeal
Aggressive Targets
Strong Drivers
Communication of Values
Organization
Customers Contact
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SQM: QUALITY POLICIES
Prepared to provide guidelines for planning the overall
quality program; and defining the action to be taken in
situation for which personnel had requested guidelines.
Policies state: a) a principle to be followed; b) what is to
be done.
Examples of quality policy – For a computer
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SQM: QUALITY GOALS
A goal (or objective) is a statement of the desired result to be
achieved within a specified period – an aimed-at target.
These goals then become basis for detailed planning of
activities.
Tactical goals are short range (up to 1 year), whereas strategic
company, the quality goals over the next year could be: “The
average leakage rate for …. product shall be reduced to …”
Note that quality goal statements include quantified data.
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SQM: CAVEATS
Reasons of failure of SQM could be
Lack of leadership by upper management.
Lack of infrastructure for quality.
Failure to understand the skepticism about the “new
quality program.”
Management assumption that the exhortation approach
will work.
Failure to start small and learn from pilot programs.
Reliance on specific techniques as the primary means.
Underestimating the time and resource required.
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AFTER STUDYING THIS HANDOUT YOU
SHOULD BE ABLE TO :
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THANK YOU FOR READING
Graeme Knowles , 2012, Managing Quality in The 21st Century, ,
[Link].
D. Helmi1, M. Radouani2, B. El fahime3, S.A. Kamel kaya4 , 2014,
Maintenance model based on multi agent system improving the performance
to a total quality management, International Journal of Management &
Information Technology, Vol. 9, No. 2.
[Link]/college/sc/reid/[Link]., CHAPTER 5 Total Quality
Management - John Wiley & Sons.
Graeme Knowles , 2012, Managing Quality in The 21st Century, ,
[Link].
[Link]
949360.
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