The Pioneers of TQM and their Philosophies

Name: VINEET KOHLI Roll No: 0921001479 Subject :IMT -55

Concept of Quality

Quality means conformance to specifications. Quality is determined by what a customer wants and willing to pay for. Quality means consistently producing products and services that give customers their moneys worth.

Concepts of Quality

Evolution of TQM

Quality Control:The approach of quality management that was product oriented and focused on correction of defects. Quality Assurance:It focused on process control which is meant for online correction and prevention of defects. TQM:It is a continuous improvement approach involving Customers,people,Process and leadership.

TQM

A people focused management system that aims to integrate all activities,functions and processes within an organization for achieving continuous improvement in quality,cost,value and delivery of goods and services for continual customer satisfaction. Four pillars of TQM are Customers,People,Process and Leadership

TQM-Objective

The objective of TQM is to do the right things,right the first time every time. TQM is concerned with continuous improvement in all work,from high level strategic planning and decision making,to detailed execution of work elements on the shop floor.

TQM Model

Principles of TQM

Quality can and must be managed Everyone has a customer and a supplier Processes,not people are the problem Every employee is responsible for quality Problem must be prevented,not just fixed Quality must be measured Quality improvements must be continuous

Principles of TQM(contd.)

The quality standard is defect free. Goals are based on requirements, not negotiated. Talk Life cycle costs,not front end costs. Management must be involved and must lead. Plan and organize for quality improvement.

Quality masters

Deming -known for statistical process control Juran -known for Juran Trilogy Crosby -known for four absolutes of quality Feignbaum - known for concept of TQM Ishikawa -known for QCC and Ishikawa diagram Taguchi -known for Taguchi loss Function Shigeo Shingo- known for JIT and Poka Yoke Masaaki Imai -known for Kaizen .

Philosophy of Deming

Deming emphasized the need for measurements and statistical analysis of data for determining the variations,and controlling the sources of errors. His overall approach focused on improvement of processes and systems,rather than workers,in the cause and control of process variations.

PDCA Model

Demings 14 points

1.Create consistency of purpose with plan 2.Adopt the new philosophy of quality 3.Stop the practice of mass inspection 4.Identify problems and work continuously for improving the system 5.Change the focus from quantity to quality 6.Stop asking for productivity improvement without identifying and providing methods to achieve them without any risk of quality

Demings 14 points(contd.)

7.Adopt the method of training on the job. 8.End the practice of choosing suppliers based purely on price. 9.Eliminate work standards that prescribe numerical quotas. 10. Drive out fear from the mind of the people 11.Remove barriers to pride of workmanship. 12. Break down the barriers between departments.

Demings 14 points(contd.)

13.Institute vigorous education and training 14.Create an appropriate management structure for implementation and follow up of foregoing points for quality management in the organization.

Philososphy of Juran

Juran emphasized the need for planning,control and improvement of quality by management actions and problem solving techniques. Unlike Deming,he focused on top-down approach to quality management and technical methods to solve problems rather than emphasizing on workers pride,motivation and satisfaction.

Juranss Quality Trilogy

Quality Planning:A process of pre-setting the quality goals and working out the preparations for meeting these goals. Quality Control:The process for ensuring that quality goals are being achieved during the operations. Quality Improvement:This is the process of solving the problems and for breaking through to higher levels of quality for superior performance.

Jurans 10 points

1.Build awareness of opportunities to improve. 2.Set goals for improvement. 3.Organize to reach goals. 4.Carry out improvement projects to solve problems. 5.Provide training to people.

Jurans 10 points

6.Give recognition to quality 7.Measure and report progress 8Communicate results 9.Keep the score 10.Maintain momentum

Philosophy of Crosby

Crosby contributed by popularizing the concept of aiming for zero-defect as a standard for quality improvement and by advocating the system of managing quality by prevention of defects rather than inspection,detection and correction. Crosby stresses on motivation and planning,and did not overemphasize on statistical techniques or problem-solving tools like Deming or Juran.

Crosby:Four absolutes for quality

1.Quality is conformance to requirements, not goodness. 2.The system of achieving quality is prevention,and not appraisal. 3.The performance standard is ZeroDefect, not a subjective close enough 4.The measurement of quality is the price of non-conformance,and not indexes.

Crosbys 14 points

1.Commitment of top management to quality. 2.Team approach to quality management 3.Measurement of quality to identify the areas for improvements 4.System for measuring cost of quality 5.Initiating corrective actions

Crosbys 14 points

6.Promoting quality awareness in the company 7.Planning Zero-defect programme 8. Setting goals for improvement by individuals and groups in the organization 9.Organizing supervisory training for employees

Crosbys 14 points

10.Promoting work systems for performing error free work. 11.Observe a Zero-defect day to stress upon the required quality standards. 12.Recognize those who meet their quality goals. 13. Constitute Quality Councils of quality professionals to share experiences,problems and solutions. 14.Do it all over again for further improvement.

Zero-Defect

Philososphy of Feignbaum

Feignbaum consolidated the pioneering works and thoughts,and evolved the concept of total quality control by aiming at customer satisfaction as a means for success in an organization.

Philosophy of Feignbaum

He put forward his concept of Total quality Control in the early 1960s and developed the principle that quality is everyones job in the organization. Unlike Deming and Juran, Feignbaum recommended the need for systems for integrating efforts to develop,maintain and improve quality by various groups in the company.

Philosophy of Feignbaum

Like Juran ,he also emphasized planning quality in order to build it into the process at early stages of production as a key to successful quality management.

Philosophy of Feignbaum

Complete satisfaction can only be achieved by offering essentially perfect goods and services whose quality is determined by the customers. Quality would be the epicenter of competitive advantage. Quality reduction failure is the way for accelerated growth in earnings and profit.

Philososphy of Feignbaum

Employee involvement and teamwork should be encouraged for quality improvement. Effective supplier partnership is essential for creating a seamless value chain among customers ,producers and suppliers.

TQM Model

Philosophy of Ishikawa

Ishikawa was the pioneer in popularizing company-wide quality control by introducing group activities in managing the quality ,which was later called Quality Control Circle where workers play a greater role than the quality specialists or supervisors.

Philosophy of Ishikawa

Quality Circle was defined as: a small group of working people who,under the leadership of their own foreman or supervisor,are trained to identify,analyze and solve quality related problems on a voluntary basis and present their solutions to their managers.

Philosophy of Ishikawa

Ishikawa also came up with the famous contribution of Ishikawa diagram also known as Cause and Effect diagram. He also introduced the concept that the next process is your customer.

Ishikawa Cause-Effect diagram

Philosophy of Taguchi

Taguchi was the first one to challenge the concept that if manufacturers or process operators can keep the dimension between the defined limits(e.g upper and lower specifications),then the component is okay and quality related costs are zero. He showed that quality costs follow a quadratic function which increase as variability increases from the target dimension, irrespective of process parameters

Philosophy of Taguchi Taguchis theorem came to be known as Taguchis Quality Loss Function(QLF) analysis. Taguchis quality loss function is a graph in which the lowest point represents the minimum loss to the customers i.e. society. Any deviation either way causes the cost axis to rise, i.e. larger variation cost to customer goes up.

Taguchi Loss Function

Philosophy of Taguchi

Taguchi defined quality as the loss a product causes to the society after being shipped, other than any losses caused by intrinsic functions. He suggested that QLF should be used during the early stages of design so that changes can be made as early as possible to reduce costs due to poor quality.

Philosophy of Taguchi

Taguchis philosophy is based on the premise that cost can be reduced by reducing variability and that quality automatically improves due to reduced variations. Taguchis philosophy closely followed the principles of Deming and Juran.

Philosophy of Shiego Shingo

Shiego Shingo is famous for Just-in-Time manufacturing. Shingo introduced the revolutionary concept of managing production by pull process that ensures the right part at the right time, at the right place i.e just in time. This is known as Kanban in Japan or JIT in general

JIT Concept

JIT can also be defined as an operations management philosophy.Its dual objectives are, To reduce waste To increase productivity JIT is also known as lean production or stockless production.

JIT model

JIT improves profit and return on investment by reducing inventory levels,reducing variability,improving product quality,reducing production and delivery lead times and reducing other costs such as those associated with machine setup and equipment breakdown.

JIT concept

JIT is a method of producing what is needed when needed and no more. It is based on two tenets: Elimination of waste and respect for humans. It is applied to repetitive manufacturing processes in which the same products and components are produced over and over again.

JIT Model

Philosophy of Shiego Shingo

His other evolutionary concept is PokaYoke (mistake proofing) which focuses on: 1. Prediction or recognition that a defect is about to occur, and then providing signals or warning. 2.Detection or recognition that a defect has occurred and the stopping the process so that no further defect can be produced.

Philosophy of Shiego Shingo

Poka Yoke is a simple mistake proofing in manufacturing by using automatic or manual signals or methods to help avoid human errors and loss of value. Poka Yoke techniques are often very simple like flashing of a light signal when the automatic or manual sensor detects the signal of malfunctioning or generation of defects.

Philosophy of Masaaki Imai

Masaki Imai is the father of Kaizen-the continuous improvement the technique practiced by the Japanese. He emphasized the participation of people associated with the job or process for successful Kaizen application and called for Kaizen teams in the organization.

Philososphy of Masaaki Imai

Imai defined 5 elements of Kaizen team.They are : Personal discipline Improved morale Participation in suggestion for improvement Working through quality Circle Teamwork

Philosophy of Masaaki Imai

Kaizen is not a process that looks at radical measures to create drastic changes and immediate improvement ;it is a process of continuous long term approach to improvements with the help of people involved with the jobs. Accordingly,he further developed the philosophy of Kaizen gemba for a complete solution of manufacturing problems combining Kaizen, Gemba, Muda and JIT.

Bibliography

Total quality managementIMT CDL Production and operation management-IMT CDL http://csqa.info Online tutorials. Various websites.

Thank You