1. Chapter 5 - Total Quality Management
Operations Management by
R. Dan Reid & Nada R. Sanders
3rd Edition © Wiley 2007
PowerPoint Presentation by R.B. Clough – UNH
M. E. Henrie - UAA
© Wiley 2007

2. Learning Objectives Explain the meaning of TQM
Identify the costs of Quality
Describe the evolution of TQM
Identify Quality leaders and their contributions
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3. Learning Objectives Identify key features of the TQM philosophy
Describe tools identifying and solving quality problems
Describe quality awards and quality certifications
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4. Defining Quality
Definition of quality is dependent on the people defining it
There is a lack of a single, universal definition of quality
5 common definitions include
Conformance to specifications
Fitness for use
Value for price paid
Support services
Psychological criteria
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5. Defining Quality – 5 Ways
Conformance to specifications
Does product/service meet targets and tolerances defined by designers?
Fitness for use
Evaluates performance for intended use
Value for price paid
Evaluation of usefulness vs. price paid
Support services
Quality of support after sale
Psychological
e.g. Ambiance, prestige, friendly staff
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6. Manufacturing Quality vs. Service Quality
Manufacturing quality focuses on tangible product features
Conformance, performance, reliability, features
Service organizations produce intangible products that must be experienced
Quality often defined by perceptional factors like courtesy, friendliness, promptness, waiting time, consistency
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7. Cost of Quality Quality affects all aspects of the organization
Quality has dramatic cost implications of;
Quality control costs
Prevention costs
Appraisal costs
Quality failure costs
Internal failure costs
External failure costs
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8. Cost of Quality – 4 Categories
Early detection/prevention is less costly
May be less by a factor of 10
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9. Evolution of TQM – New Focus
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10. Quality Gurus
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11. TQM Philosophy 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
Customer focus
Continuous improvement
Employee empowerment
Use of quality tools
Product design
Process management
Managing supplier quality
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12. TQM Philosophy - concepts
Focus on Customer
Identify and meet customer needs
Stay tuned to changing needs, e.g. fashion styles
Continuous Improvement
Continuous learning and problem solving, e.g. Kaizen, 6 sigma
Benchmarking
Employee Empowerment
Empower all employees; external and internal customers
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13. TQM Philosophy– Concepts (continued)
Team Approach
Teams formed around processes – 8 to 10 people
Meet weekly to analyze and solve problems
Understanding Quality Tools
Ongoing training on analysis, assessment, and correction, & implementation tools
Studying practices at “best in class” companies
Plan-Do-Study-Act
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14. Ways of Improving Quality
Plan-Do-Study-Act Cycle (PDSA)
Also called the Deming Wheel after originator
Circular, never ending problem solving process
Seven Tools of Quality Control
Tools typically taught to problem solving teams
Quality Function Deployment
Used to translate customer preferences to design
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15. PDSA Details Plan Do Study Act Evaluate current process
Collect procedures, data, identify problems
Develop an improvement plan, performance objectives Do
Implement the plan – trial basis
Study
Collect data and evaluate against objectives
Act
Communicate the results from trial
If successful, implement new process
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16. PDSA (continued) Cycle is repeated
After act phase, start planning and repeat process
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17. Seven Tools of Quality Control
Cause-and-Effect Diagrams
Flowcharts
Checklists
Control Charts
Scatter Diagrams
Pareto Analysis
Histograms
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18. Cause-and-Effect Diagrams
Called Fishbone Diagram
Focused on solving identified quality problem
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19. Flowcharts Used to document the detailed steps in a process
Often the first step in Process Re-Engineering
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20. Checklist
Simple data check-off sheet designed to identify type of quality problems at each work station; per shift, per machine, per operator
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21. Control Charts
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
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22. Scatter Diagrams
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
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23. Pareto Analysis
Technique that displays the degree of importance for each element
Named after the 19th century Italian economist
Often called the 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
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24. Histograms
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
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25. Product Design - Quality Function Deployment
Critical to ensure product design meets customer expectations
Useful tool for translating customer specifications into technical requirements is Quality Function Deployment (QFD)
QFD encompasses
Customer requirements
Competitive evaluation
Product characteristics
Relationship matrix
Trade-off matrix
Setting Targets
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26. 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
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27. QFD - House of Quality
Adding trade-offs, targets & developing product specifications
Trade-offs
Technical
Benchmarks
Targets
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28. Reliability – critical to quality
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
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29. Reliability – critical to quality
Reliability of a system is the product of component reliabilities
RS = (R1) (R2) (R3) (Rn)
RS = reliability of the product or system
R1 = reliability of the components
Increase reliability by placing components in parallel
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30. Reliability – critical to quality
Increase reliability by placing components in parallel
Parallel components allow system to operate if one or the other fails
RS = R1 + (R2* Probability of needing 2nd component)
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31. Process Management 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
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32. Quality Awards and Standards
Malcolm Baldrige National Quality Award (MBNQA)
The Deming Prize
ISO 9000 Certification
ISO Standards
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33. MBNQA- What Is It?
Award named after the former Secretary of Commerce – Regan 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, FedEx, 3M, IBM, Ritz-Carlton
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34. The Deming Prize
Given by the Union of Japanese Scientists and Engineers since 1951
Named after W. Edwards Deming who worked to improve Japanese quality after WWII
Not open to foreign companies until 1984
Florida P & L was first US company winner
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35. ISO Standards ISO 9000 Standards: ISO 14000:
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:
Focuses on a company’s environmental responsibility
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36. Why TQM Efforts Fail Lack of a genuine quality culture
Lack of top management support and commitment
Over- and under-reliance on SPC methods
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37. TQM Within OM TQM is broad sweeping organizational change TQM impacts
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
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38. Chapter 5 Highlights
TQM is different from the old concept of quality as it focus is on serving customers, identifying the causes of quality problems, and building quality into the production process
Four categories of quality cost of prevention, appraisal, internal and external costs
Seven TQM notable individuals include Walter A. Shewhart, W. Edwards Demings, Joseph M. Juran, Armand V. Feigenbaum, Philip B. Crosby, Kaoru Ishikawa, and Genichi Taguchi
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39. Chapter 5 Highlights - Continued
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.
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40. The End
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