Quality Management

Lecture Outline

 Meaning of Quality
 Total Quality Management
 Quality Improvement and Role of
Employees
 Strategic Implications of TQM
 Six Sigma

3-2
 Lecture Outline (cont.)

 TQM in Service Companies

 Cost of Quality
 Quality Management and Productivity
 Identifying Quality Problems and Causes
 Quality Awards and Setting Quality
Standards
 ISO 9000
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 Meaning of Quality

 Webster’s Dictionary

degree of excellence of a thing
 American Society for Quality

totality of features and characteristics
that satisfy needs
 Consumer’s and producer’s
perspective

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 Meaning of Quality:
Consumer’s Perspective
 Fitness for use
 how well product or
service does what it is
supposed to
 Quality of design
 designing quality
characteristics into a
product or service
 A Mercedes and a Ford are
equally “fit for use,” but with
different design dimensions

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 Dimensions of Quality:
Manufactured Products
 Performance

basic operating characteristics of a product; how
well a car is handled or its gas mileage
 Features

“extra” items added to basic features, such as a
stereo CD or a leather interior in a car
 Reliability

probability that a product will operate properly
within an expected time frame; that is, a TV will
work without repair for about seven years

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 Dimensions of Quality:
Manufactured Products (cont.)
 Conformance

degree to which a product meets pre–established
standards
 Durability

how long product lasts before replacement?
 Serviceability

ease of getting repairs, speed of repairs, courtesy
and competence of repair person

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 Dimensions of Quality:
Manufactured Products (cont.)
 Aesthetics

how a product looks, feels, sounds,
smells, or tastes?
 Safety

assurance that customer will not suffer
injury or harm from a product; an
especially important consideration for
automobiles
 Perceptions

subjective perceptions based on brand
name, advertising, and like

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 Dimensions of Quality:
Service
 Time and timeliness
 how long must a customer wait for service,
and is it completed on time?
 is an overnight package delivered overnight?
 Completeness:
 is everything customer asked for provided?
 is a mail order from a catalogue company
complete when delivered?

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 Dimensions of Quality:
Service (cont.)
 Courtesy:
 how are customers treated by employees?
 are catalogue phone operators nice and are
their voices pleasant?
 Consistency
 is same level of service provided to each
customer each time?
 is your newspaper delivered on time every
morning?

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 Dimensions of Quality:
Service (cont.)
 Accessibility and convenience
 how easy is it to obtain service?
 does service representative answer you calls quickly?
 Accuracy
 is service performed right every time?
 is your bank or credit card statement correct every month?
 Responsiveness
 how well does company react to unusual situations?
 how well is a telephone operator at able to respond to a
customer’s questions?

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 Meaning of Quality:
Producer’s Perspective

 Quality of conformance
 Making sure product or service is produced
according to design
 if new tires do not conform to specifications, y
wobble
 if a hotel room is not clean when a guest checks
in, hotel is not functioning according to
specifications of its design

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 Meaning of Quality:
A Final Perspective

 Consumer’s and producer’s

perspectives depend on each other
 Consumer’s perspective: PRICE
 Producer’s perspective: COST
 Consumer’s view must dominate

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 Meaning of Quality
Meaning
Meaning of
of Quality
Quality

Producer’s
Producer’s Perspective
Perspective Consumer’s
Consumer’s Perspective
Perspective

Quality
Quality of
of Conformance
Conformance Quality
Quality of
of Design
Design

Production
Production • Conformance to • Quality characteristics Marketing
Marketing
specifications • Price
• Cost

Fitness
Fitness for
for
Consumer
Consumer UseUse

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 Total Quality Management

 Commitment to quality throughout organization

 Principles of TQM
 Customer-oriented
 Leadership
 Strategic planning
 Employee responsibility
 Continuous improvement
 Cooperation
 Statistical methods
 Training and education

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 Quality Gurus
 Walter Shewart

In 1920s, developed control charts

Introduced term “quality assurance”
 W. Edwards Deming

Developed courses during World War II to teach
statistical quality-control techniques to engineers and
executives of companies that were military suppliers

After war, began teaching statistical quality control to
Japanese companies
 Joseph M. Juran

Followed Deming to Japan in 1954

Focused on strategic quality planning

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 Quality Gurus (cont.)

 Armand V. Feigenbaum

In 1951, introduced concepts of total quality control
and continuous quality improvement
 Philip Crosby

In 1979, emphasized that costs of poor quality far
outweigh cost of preventing poor quality

In 1984, defined absolutes of quality management—
conformance to requirements, prevention, and “zero
defects”
 Kaoru Ishikawa

Promoted use of quality circles

Developed “fishbone” diagram

Emphasized importance of internal customer

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 Deming’s 14 Points

1. Create constancy of purpose

2. Adopt philosophy of prevention
3. Cease mass inspection
4. Select a few suppliers based on
quality
5. Constantly improve system and
workers
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 Deming’s 14 Points (cont.)

6. Institute worker training

7. Instill leadership among
supervisors
8. Eliminate fear among employees
9. Eliminate barriers between
departments
10. Eliminate slogans
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 Deming’s 14 Points (cont.)

11. Remove numerical quotas

12. Enhance worker pride
13. Institute vigorous training and
education programs
14. Develop a commitment from top
management to implement
above 13 points
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Deming Wheel: PDCA
Cycle

4. Act 1. Plan
Institutionalize Identify
improvement; problem and
continue develop plan
cycle. for
improvement.

3. Study/Check 2. Do
Assess plan; is it Implement
working? plan on a test
basis.

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 TQM and…
 … Partnering

a relationship between a company and
its supplier based on mutual quality
standards
 … Customers

system must measure customer
satisfaction
 … Information Technology

infrastructure of hardware, networks,
and software necessary to support a
quality program

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 Quality Improvement
and Role of Employees

 Participative
problem solving
 employees involved in
quality management
 every employee has
undergone extensive
training to provide quality
service to Disney’s guests

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Quality Circle Organization
8-10 members
Same area
Supervisor/moderator

Training
Presentation Group processes
Implementation Data collection
Monitoring Problem analysis

Problem
Solution Identification
Problem results List alternatives
Consensus
Brainstorming
Problem
Analysis
Cause and effect
Data collection
and analysis

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 Strategic Implications of
TQM

 Strong leadership
 Goals, vision, or mission
 Operational plans and policies
 Mechanism for feedback

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 Six Sigma

 A process for developing and delivering

near perfect products and services
 Measure of how much a process
deviates from perfection
 3.4 defects per million opportunities
 Champion
 an executive responsible for project success

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 Black Belts and
Green Belts
 Black Belt
 project leader
 Master Black Belt
 a teacher and mentor
for Black Belts
 Green Belts
 project team
members

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 Six Sigma: DMAIC
DEFINE
DEFINE MEASURE
MEASURE ANALYZE
ANALYZE IMPROVE
IMPROVE CONTROL
CONTROL

67,000
67,000 DPMO
DPMO
cost
cost == 25%
25% of
of
sales
sales 3.4
3.4 DPMO
DPMO

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 TQM in Service
Companies
 Principles of TQM apply equally well to
services and manufacturing
 Services and manufacturing
companies have similar inputs but
different processes and outputs
 Services tend to be labor intensive
 Service defects are not always easy to
measure because service output is not
usually a tangible item

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 Quality Attributes in
Service
 Benchmark

“best” level of quality
achievement in one
company that or
companies seek to
achieve
 Timeliness

how quickly a service is “quickest, friendliest, most
provided? accurate service
available.”

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 Cost of Quality

 Cost of Achieving Good Quality


Prevention costs
 costs incurred during product design

Appraisal costs
 costs of measuring, testing, and analyzing
 Cost of Poor Quality

Internal failure costs
 include scrap, rework, process failure, downtime,
and price reductions

External failure costs
 include complaints, returns, warranty claims,
liability, and lost sales
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 Prevention Costs
 Quality planning costs  Training costs

costs of developing and  costs of developing and
implementing quality putting on quality training
management program programs for employees
 Product-design costs and management

costs of designing  Information costs
products with quality
characteristics  costs of acquiring and
 Process costs maintaining data related
to quality, and

costs expended to make development of reports on
sure productive process
conforms to quality quality performance
specifications

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 Appraisal Costs

 Inspection and testing


costs of testing and inspecting materials, parts, and
product at various stages and at end of process
 Test equipment costs

costs of maintaining equipment used in testing
quality characteristics of products
 Operator costs

costs of time spent by operators to gar data for
testing product quality, to make equipment
adjustments to maintain quality, and to stop work to
assess quality

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 Internal Failure Costs
 Scrap costs  Process downtime costs

costs of poor-quality
products that must be
 costs of shutting down
discarded, including labor, productive process to fix
material, and indirect costs problem
 Rework costs  Price-downgrading costs

costs of fixing defective
products to conform to
 costs of discounting poor-
quality specifications quality products—that is,
 Process failure costs selling products as

costs of determining why “seconds”
production process is
producing poor-quality
products

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 External Failure Costs
 Customer complaint costs  Product liability costs

costs of investigating and  litigation costs
satisfactorily responding to a resulting from product
customer complaint resulting liability and customer
from a poor-quality product
injury
 Product return costs
 Lost sales costs

costs of handling and
replacing poor-quality products  costs incurred
returned by customer because customers
 Warranty claims costs are dissatisfied with

costs of complying with poor quality products
product warranties and do not make
additional purchases

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 Measuring and
Reporting Quality Costs
 Index numbers

ratios that measure quality costs against a
base value

labor index
 ratio of quality cost to labor hours

cost index
 ratio of quality cost to manufacturing cost

sales index
 ratio of quality cost to sales

production index
 ratio of quality cost to units of final product

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 Quality–Cost Relationship

 Cost of quality
 Difference between price of
nonconformance and conformance
 Cost of doing things wrong
 20 to 35% of revenues
 Cost of doing things right
 3 to 4% of revenues
 Profitability
 In the long run, quality is free

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 Quality Management
and Productivity
 Productivity
 ratio of output to input
 Yield: a measure of productivity

Yield=(total
Yield=(total input)(%
input)(% good
good units)
units) ++ (total
(total input)(1-%good
input)(1-%good units)(%
units)(% reworked)
reworked)

or
or
Y=(I)(%G)+(I)(1-%G)(%R)
Y=(I)(%G)+(I)(1-%G)(%R)

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Product Cost

( K d )( I )  ( K r )( R)
Product Cost 
Y
where:
Kd = direct manufacturing cost per unit
I = input
Kr = rework cost per unit
R = reworked units
Y = yield

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Computing Product
Yield for Multistage Processes

Y = (I)(%g1)(%g2) … (%gn)

where:
I = input of items to the production process that will
result in finished products
gi = good-quality, work-in-process products at stage i

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 Quality–Productivity Ratio

QPR
 productivity index that includes productivity and
quality costs

(non-defective units)
QPR =
(input) (processing cost) + (defective units) (reworked cost)

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 Seven Quality Control Tools

 Pareto Analysis  Scatter Diagram

 Flow Chart  SPC Chart
 Check Sheet  Cause-and-Effect
 Histogram Diagram

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 Pareto Analysis

NUMBER OF
CAUSE DEFECTS PERCENTAGE

Poor design 80 64 %
Wrong part dimensions 16 13
Defective parts 12 10
Incorrect machine calibration 7 6
Operator errors 4 3
Defective material 3 2
Surface abrasions 3 2
125 100 %

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 Percent from each cause

10
20
30
40
50
60
70

0
Po
W or
ro De
ng si
di gn
(64)

m
De en
fe si
ct on
iv s

(13)
M e
ac pa
hi rts
ne
c
O p al i b (10)
er ra
at t
(6)
or i on
er s
De ro
fe rs
ct
iv
(3)

e
Su m

Causes of poor quality

rfa at
er
ce ia
(2)

ab ls
ra
si
Pareto Chart

on
s
(2)

3-44
 Flow Chart
Start/
Finish Operation Operation Decision Operation

Operation Operation

Decision Start/
Finish

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Check Sheet
COMPONENTS REPLACED BY LAB
TIME PERIOD: 22 Feb to 27 Feb 2002
REPAIR TECHNICIAN: Bob

TV SET MODEL 1013

Integrated Circuits ||||
Capacitors |||| |||| |||| |||| |||| ||
Resistors ||
Transformers ||||
Commands
CRT |

3-46
Histogram

20

15

10

0
1 2 6 13 10 16 19 17 12 16 2017 13 5 6 2 1

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 Scatter Diagram
Y

X
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 Control Chart
24
UCL = 23.35
21
Number of defects

18 c = 12.67

15

12

6
LCL = 1.99
3
2 4 6 8 10 12 14 16
Sample number
3-49
 Cause-and-Effect Diagram
Measurement
Measurement Human
Human Machines
Machines
Faulty
testing equipment Poor supervision Out of adjustment

Incorrect specifications Lack of concentration Tooling problems

Improper methods Inadequate training Old / worn

Quality
Quality
Inaccurate Problem
Problem
temperature
control Defective from vendor Poor process design
Ineffective quality
Not to specifications management
Dust and Dirt Material- Deficiencies
handling problems in product design

Environment
Environment Materials
Materials Process
Process

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 Baldrige Award

 Created in 1987 to stimulate growth of

quality management in United States
 Categories

Leadership

Information and analysis

Strategic planning

Human resource

Focus

Process management

Business results

Customer and market focus
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 Other Awards for Quality

 National individual  International awards

awards  European Quality Award
 Armand V. Feigenbaum  Canadian Quality Award
Medal  Australian Business
 Deming Medal Excellence Award
 E. Jack Lancaster Medal  Deming Prize from
 Edwards Medal Japans
 Shewart Medal
 Ishikawa Medal

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 American Customer
Satisfaction Index (ACSI)
 Measures customer satisfaction
 Established in 1994
 Web site: www.acsi.org
 Examples (in 2003)
 Amazon.com scored 88 (highest in service)
 Dell scored of 78 (highest in computer industry)

 Cadillac scored 87 (highest in car industry)

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 ISO 9000
 A set of procedures and  ISO 9001:2000
policies for international 
Quality Management Systems
quality certification of —Requirements
suppliers 
standard to assess ability to
 Standards achieve customer satisfaction

ISO 9000:2000  ISO 9004:2000
 Quality Management

Quality Management Systems
Systems—Fundamentals —Guidelines for Performance
and Vocabulary Improvements
 defines fundamental 
guidance to a company for
terms and definitions continual improvement of its
used in ISO 9000 family quality-management system

3-54
 Implications of ISO 9000 for U.S.
Companies

 Many overseas companies

will not do business with a
supplier unless it has ISO
9000 certification
 ISO 9000 accreditation
 ISO registrars
 A total commitment to quality
is required throughout an
organization

3-55