Chapter 5 Total Quality Management Operations Management by
Chapter 5 - Total Quality Management Operations Management by R. Dan Reid & Nada R. Sanders 4 th Edition © Wiley 2010 1
Learning Objectives n n n Explain the meaning and evolution of TQM Identify the costs of Quality Identify Quality leaders and their contributions Identify key features of the TQM philosophy Describe tools for identifying and solving quality problems Describe quality awards and quality certifications © Wiley 2010 2
Defining Quality – 5 Ways Conformance to specifications 1. § Does product/service meet targets and tolerances defined by designers? Fitness for use 2. § Evaluates performance for intended use Value for price paid 3. § Evaluation of usefulness vs. price paid Support services 4. § Quality of support after sale Psychological 5. § Ambiance, prestige, friendly staff © Wiley 2010 3
Manufactured Product Quality vs. Service Quality n Manufactured Product quality focuses on tangible features n n Conformance, performance, reliability, features Service organizations produce intangible products that must be experienced n Quality often defined by perceptional factors like courtesy, friendliness, promptness, waiting time, consistency © Wiley 2010 4
Cost of Quality n n Quality affects all aspects of the organization Quality has dramatic cost implications of: n Cost of achieving good quality (quality control costs) n n n Prevention costs Appraisal costs Cost of poor quality (quality failure costs) n n Internal failure costs External failure costs © Wiley 2010 5
Cost of Quality – 4 Categories Early detection/prevention is less costly n (Maybe by a factor of 10) © Wiley 2010 6
Evolution of TQM – New Focus © Wiley 2010 7
Quality Gurus © Wiley 2010 8
TQM Philosophy n n TQM Focuses on identifying quality problem root causes Encompasses the entire organization Involves the technical as well as people Relies on seven basic concepts of n Customer focus n Continuous improvement n Employee empowerment n Use of quality tools n Product design n Process management n Managing supplier quality © Wiley 2010 9
TQM Philosophy - concepts n Focus on Customer n n n Continuous Improvement n n Identify and meet customer needs Stay tuned to changing needs, e. g. fashion styles Continuous learning and problem solving, e. g. Kaizen, 6 sigma Plan-D-Study-Act (PDSA) Benchmarking Employee Empowerment n Empower all employees; external and internal customers © Wiley 2010 10
TQM Philosophy– Concepts con’t n Team Approach n n n Teams formed around processes – 8 to 10 people Meet weekly to analyze and solve problems Use of Quality Tools n n Ongoing training on analysis, assessment, and correction, & implementation tools Studying practices at “best in class” companies © Wiley 2010 11
Ways of Improving Quality n Plan-Do-Study-Act Cycle (PDSA) n n n Seven Tools of Quality Control n n Also called the Deming Wheel after originator Circular, never ending problem solving process Tools typically taught to problem solving teams Quality Function Deployment n Used to translate customer preferences to design © Wiley 2010 12
PDSA Details n Plan n n Do n n Implement the plan – trial basis Study n n Evaluate current process Collect procedures, data, identify problems Develop an improvement plan, performance objectives Collect data and evaluate against objectives Act n n Communicate the results from trial If successful, implement new process © Wiley 2010 13
PDSA con’t n Cycle is repeated n After act phase, start planning and repeat process © Wiley 2010 14
Seven Tools of Quality Control 1. 2. 3. 4. 5. 6. 7. Cause-and-Effect Diagrams Flowcharts Checklists Control Charts Scatter Diagrams Pareto Analysis Histograms © Wiley 2010 15
Cause-and-Effect Diagram Measurement Faulty testing equipment Lack of concentration Improper methods Inadequate training Environment Tooling problems Old / worn Quality Problem Defective from vendor Not to specifications Dust and Dirt Machines Out of adjustment Poor supervision Incorrect specifications Inaccurate temperature control Human Materialhandling problems Materials Poor process design Ineffective quality management Deficiencies in product design Process
Flow Chart Used to document the detailed steps in a process Often the first step in Process Re-Engineering Start/ Finish Operation Decision Operation Decision Start/ Finish
Checklist Simple data check-off sheet designed to identify type of quality problems at each work station; per shift, per machine, per operator © Wiley 2010 18
Control Charts n n Important tool used in Statistical Process Control – Chapter 6 The UCL and LCL are calculated limits used to show when process is in or out of control © Wiley 2010 19
Scatter Diagrams n n A graph that shows how two variables are related to one another Data can be used in a regression analysis to establish equation for the relationship © Wiley 2010 20
Pareto Analysis n n n Technique that displays the degree of importance for each element Named after the 19 th century Italian economist; often called the 80 -20 Rule Principle is that quality problems are the result of only a few problems e. g. 80% of the problems caused by 20% of causes © Wiley 2010 21
Histograms n n A chart that shows the frequency distribution of observed values of a variable like service time at a bank drive-up window Displays whether the distribution is symmetrical (normal) or skewed © Wiley 2010 22
Product Design - Quality Function Deployment n n n Critical to ensure product design meets customer expectations Useful tool for translating customer specifications into technical requirements is Quality Function Deployment (QFD) QFD encompasses n n n Customer requirements Competitive evaluation Product characteristics Relationship matrix Trade-off matrix Setting Targets © Wiley 2010 23
Quality Function Deployment (QFD) Details Process used to ensure that the product meets customer specifications Voice of the engineer Customer-based benchmarks Voice of the customer © Wiley 2010 24
QFD - House of Quality Technical Benchmarks Trade-offs Targets Adding trade-offs, targets & developing product specifications © Wiley 2010 25
Reliability – critical to quality n n n Reliability is the probability that the product, service or part will function as expected No product is 100% certain to function properly Reliability is a probability function dependent on sub-parts or components © Wiley 2010 26
Reliability – critical to quality Reliability of a system is the product of component reliabilities RS = (R 1) (R 2) (R 3). . . (Rn) RS = reliability of the product or system R 1 = reliability of the components n Increase reliability by placing components in parallel n © Wiley 2010 27
Example 1: Computing Reliability Components in series 0. 90 x 0. 90 = 0. 81
Reliability – critical to quality n n Increase reliability by placing components in parallel Parallel components allow system to operate if one or the other fails RS = R 1 + (R 2* Probability of needing 2 nd component) © Wiley 2010 29
Example 2: Computing Reliability Components in parallel 0. 90 R 2 0. 95 + 0. 90(1 -0. 95) = 0. 995 0. 95 R 1
Example 3: Computing Reliability 0. 90 0. 98 0. 92+(1 -0. 92)(0. 90)=0. 99 0. 98 x 0. 99 x 0. 98 = 0. 951 0. 98
Quality Awards and Standards n Malcolm Baldrige National Quality Award (MBNQA) n The Deming Prize n ISO 9000 Certification n ISO 14000 Standards
Process Management & Managing Supplier Quality n n Quality products come from quality sources Quality must be built into the process Quality at the source is belief that it is better to uncover source of quality problems and correct it TQM extends to quality of product from company’s suppliers © Wiley 2010 33
Quality Awards and Standards n Malcolm Baldrige National Quality Award (MBNQA) n The Deming Prize n ISO 9000 Certification n ISO 14000 Standards © Wiley 2010 34
MBNQA- What Is It? n n Award named after the former Secretary of Commerce – Reagan Administration Intended to reward and stimulate quality initiatives Given to no more that two companies in each of three categories; manufacturing, service, and small business Past winners; Motorola Corp. , Xerox, Fed. Ex, 3 M, IBM, Ritz-Carlton © Wiley 2010 35
The Deming Prize n Given by the Union of Japanese Scientists and Engineers since 1951 n Named after W. Edwards Deming who worked to improve Japanese quality after WWII n Not open to foreign companies until 1984 n Florida P & L was first US company winner © Wiley 2010 36
ISO Standards n ISO 9000 Standards: n n n n Certification developed by International Organization for Standardization Set of internationally recognized quality standards Companies are periodically audited & certified ISO 9000: 2000 QMS – Fundamentals and Standards ISO 9001: 2000 QMS – Requirements ISO 9004: 2000 QMS - Guidelines for Performance More than 40, 000 companies have been certified ISO 14000: n Focuses on a company’s environmental responsibility © Wiley 2010 37
Why TQM Efforts Fail Lack of a genuine quality culture n Lack of top management support and commitment n Over- and under-reliance on SPC methods n © Wiley 2010 38
TQM Within OM n n TQM is broad sweeping organizational change TQM impacts n n n n Marketing – providing key inputs of customer information Finance – evaluating and monitoring financial impact Accounting – provides exact costing Engineering – translate customer requirements into specific engineering terms Purchasing – acquiring materials to support product development Human Resources – hire employees with skills necessary Information systems – increased need for accessible information © Wiley 2010 39
Chapter 5 Highlights n n n TQM’s focus is on serving customers, identifying the causes of quality problems, and building quality into the production process Four categories of quality costs are prevention, appraisal, internal and external costs Seven features of TQM combine to create TQM philosophy: customer focus, continuous improvement, employee empowerment, use of quality tools, product design, process management, and managing supplier quality QFD is a tool used to translate customer needs into specific engineering requirements Reliability is the probability that the product will functions as expected The Malcom Baldridge Award is given to companies to recognize excellence in quality management. © Wiley 2010 40
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