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Total Quality Management: in American Industry
Total Quality Management: in American Industry
Management
IN AMERICAN INDUSTRY
312 AAOHNJOURNAL
The Deming Cycle Juran's
"Journey from Symptom to Cause"
.: .. Assign prioritytoprojects
Pareto analysis ofsymptoms
Theorize oncauses Of symptoms
Testtheories: collect, analyze data
Narrow listoftheories
Journey
from symptom
to cause
Design experiment(s)
Approve design: provide authority
Check Do Conduct experiment: establish proofofcause
Propose remedies Journey
from cause
Test remedies to remedy
Action toinstitute remedy: control atnew level
proving the systems that deliver and guarantee ure 1). This cycle is used to design a work process
quality. Deming's 14 points for total quality man- and provide ongoing analysis, feedback, or evalu-
agement are: ation so that continuous improvements can be
1. Create constancy of purpose for improvement made.
of product and service. Juran views quality as a competitive bottom
2. Adopt the new philosophy of refusing to allow line issue. He created the "Juran Trilogy" of
defects. quality planning, quality control, and quality
3. Cease dependence on mass inspection and improvement (Juran, 1988). He also developed a
rely on statistical control. method to measure the costs of waste, mistakes,
4. Require suppliers to provide statistical evi- and defective products and services, which ap-
dence of quality. peals to senior managers and significantly affects
5. Constantly and forever improve production their understanding of quality as a competitive
and service. bottom line issue. Juran views quality as a com-
6. Train all employees. petitive bottom line issue.
7. Give all employees the proper tools to do the Juran, like Deming, believes the majority of
job right. quality problems (80%) are systems related, and
8. Encourage communication and productivity. therefore by nature rcmplex and elusive. He
9. Encourage different departments to work to- advocates a "journey of discovery from symptom
gether on problem solving. to cause." This involves managers and individual
10. Eliminate posters and slogans that do not contributors in steering groups who set priorities
teach specific improvement methods. and identify opportunities, and diagnostic groups
11. Use statistical methods to continuously im- who use statistical and other problem solving
prove quality and productivity. methods to define root causes and recommend
12. Eliminate all barriers to pride in workman- solutions and actions. Based on this journey of
ship. discovery, Juran says an organization can then go
13. Provide ongoing retraining to keep pace with on to create breakthroughs in serving customers
changing products, methods, etc. (Figure 2).
14. Clearly define top management's permanent At a more tactical level, Juran believes that to
commitment to quality (Deming, 1986). improve quality, an organization must prioritize
In addition, Deming also has articulated a clear its issues and "separate the significant few from
tactical approach to TQM-the Deming cycle (Fig- the trivial many" to do the right things the right
314 AAOHNJOURNAL
ment skills, empowerment skills, and group facili-
tation skills are needed.
Force Field Analysis Example
Process Capability and Process Control
PROBLEM: HOW TO STOP SMOKING GOAL
Whether it is delivering bread to the store,
delivering packages overnight, delivering the eve-
ning news, or delivering a baby, a satisfactory
outcome is the result of the right things done right
DRIVING FORCES
the first time at the right time. Examining what POOR HEALTH HABIT
must happen when, by whom, and in what se-
BURNS INCLOTHING
quence is the nature of process. Processes produce
outcomes. Focusing on process leads to questions
like:
EXPENSE
/FURNITURE
•• ..
+--TASTE
DEPENDENCY
REDUCED SENSE OF
• Does this matter to the customer? ..to the next
person down the line?
TASTE
• ..
~STUBBOR
ST RESS
NNESS
• Is this particular process or step even capable of
producing the outcomes we need?
• Which steps, actions, or operations are crucial
to successful outcomes and which ones are most
Figure 3: Force field analysis example.
vulnerable to mistakes?
• How can we measure and control these crucial
operations so we can prevent problems before their jobs. Deming talks about driving out fear
something goes wrong rather than trying to fix (Deming, 1986). Juran asks, "Who is your cus-
things after they have gone wrong? tomer, and how do you serve them?" (Juran,
1988). Crosby poses the value of "pass on no
Quality Improvement Tools defects" (Crosby, 1979). All are calling for a return
Measurement is essential to knowing what is of the old fashioned value of craftsmanship, and
important to customers and how one is doing, in suggest management's value added contribution
real time, against what is important. Measure- is to serve and support the people doing the work
ment also provides answers for anticipating and by creating and communicating a compelling vi-
preventing problems, as well as preparing for sion of the future. According to Donald J. Basch,
future changes and opportunities. Common tools director of quality for Honeywell Residential/
for process control, problem solving, and problem Building Controls Division, "Maybe a clear vision
prevention are statistical process control, cause- is the only boss you need."
effect diagrams, histograms, pareto diagrams,
process flow diagrams, scatter diagrams, check STEPS IN IMPLEMENTATION
sheets, and force field diagrams. Some of these Deming's 14 points, Juran's Journey of Discov-
measurement tools are more quantifiable and ery, and Crosby's Absolutes of Quality and 14
objective than others. steps form an infrastructure of vision, values,
An example of a quality improvement tool is a priorities, processes, tools, and techniques. Imple-
force field analysis. According to Lewin, the pur- menting these concepts helps to actually get on
pose of a force field analysis is to identify those with the business of creating a customer driven,
forces that aid change and those that oppose value added, process focused, statistically meas-
change (Kettner, 1985). The procedure in apply- ured, empowered enterprise. In answer to the
ing the tool is to: identify a problem, list driving question, "Where do we actually start, and what
and restraining forces, evaluate force (for ease do we do?", consider the following action steps:
and impact of change), and develop strategies and 1. Identify a problem, based on customer input,
plans for reviewing or reducing restraining focus. employee perceptions, and cost of quality anal-
Figure 3 shows a force field analysis example ysis. Identify the work process to be analyzed.
(Honeywell SSEC, 1990). 2. Define/understand existing process to deter-
mine flaws and opportunities.
Create an Environment of Empowerment 3. Design a new process.
The essence of TQM is showing people the 4. Implement remedy (corrective action) and new
vision; telling them the requirements; providing process.
them with tools, resources, and feedback; then 5. Measure and hold the gain (Crosby, 1979;
getting out of their way and letting them own Deming, 1986; Juran, 1988).
316 AAOHNJOURNAL
gether on Friday night, brought in some pizzas, IN SUMMARY
and asked for opinions about these late, incom-
plete shipments. Using a process flow analysis of
how an order gets entered, picked, packed, and Total Quality Management
shipped, they began to see that most of the new in American Industry.
employees were getting "on the job training" up
front where the orders were initially filled. They Widtfeldt, AX, & Widtfeldt, J.R.
had always started out up front until they learned AAOHNJournal 1992; 40(7):311-318.
their way around the warehouse. If they had
trouble finding something, they would put the
order aside until the supervisor came by, or until
they could ask one of the more experienced work- 1. The definition of total quality management
is conformance to customer requirements
and specifications, fitness for use, buyer
ers. Obviously, a lot of orders were not getting
satisfaction, and value at an affordable
picked completely. price.
As a result ofthis analysis, they decided to try
a "buddy system," teaming an experienced worker
with a new employee. After about 90 days of this
new orientation system, partials and lates were
2. The three individuals who have developed
the total quality management concepts in
the United States are W.E. Deming, J.M.
down a full 75%, and customers were beginning to Juran, and Philip Crosby.
report greater levels of satisfaction. In 6 months,
receivables were significantly improved as was
cash flow due to being able to start taking more
discounts for prompt or early payment. Employee
3. The universal principles of total quality
management are (a) a customer focus, (b)
management commitment, (c) training, (d)
turnover was also reduced by nearly 65%. process capability and control, and (e)
The wholesaler is currently investigating the measurement through quality improvement
idea of a "remote warehouse" location where tools.
certain select customers would have their own
keys and could help themselves. They would then
fax their invoice to the main office for billing and
4. Results from the National Demonstration
Project on Quality Improvement in Health
Care showed the principles of total quality
action by inventory control for restocking the management could be applied to
"self-service store." This idea came from one of the healthcare.
new employees who had been doing some cus-
tomer satisfaction surveying as part of his train-
ing.
health nurse then formed a quality improvement
CONTINUOUS QUALITY IMPROVEMENT team with the company benefits administration
IN HEALTHCARE and medical director, customer services and the
In 1985, the John Hartford Foundation funded business department at the clinic, and the com-
the National Demonstration Project on Quality pany. During several meetings, work processes
Improvement in Health Care to see if industrial were analyzed for access, billing, and the stan-
TQM could be applied to health care. Twenty-one dards of care for back injuries. The group ana-
health care organizations applied TQM principles lyzed the processes for delivering these outcomes
to service problems and quality of care issues step by step using quality improvement tools.
identified in their work processes. Results from They found that employees and dependents did
all participants showed that TQM worked. This not know how to access services at the multispe-
was the beginning of TQM or continuous quality cialty clinic and there were access problems to
improvement (CQI) in health care (Berwick, some specialty physicians. The billing system was
1991). set up to double bill, and/or protocols of care for
back injuries were not uniformly practiced by
Application in Healthcare physicians in various departments.
One health service noted problems with its As a result of these efforts a communication
managed care multi-specialty clinic provider in package for employees and dependents was devel-
the areas of access, billing errors, and unneces- oped to teach them how to access the system
sary and inappropriate care for work related back through their physician and how and when to
injuries. Further, the health service discovered access urgent care. It also announced the expan-
that employees often had to wait 48 hours for sion of medical staff in specialty shortage areas
urgent appointments, and employees were double such as OB/GYN. The billing department con-
billed or bills were delayed. The occupational verted to computerized billing and developed ex-
In the November 1992 issue of AAOHN JOURNAL, AAOHN will publish an occupational health
nurse consultant listing. The publication of this list will be accompanied by a disclaimer stating
that the list does not constitute an endorsement by AAOHN of the consultants listed.
The listing is an advertisement, and an opportunity for consultants to reach an audience of
businesses which may desire specialized assistance in the course of their work in occupational
health.
Listings will be accepted from AAOHN members only, and bills will be issued after publication.
The cost ofthe listing is $50 for up to six lines, and $10 per additional line. One person's name must
be printed with every listing, whether the consultant is individual or part of an organization. If
more than one name is to be listed, separate paid listings must be ordered.
Sample listing is as follows:
Jane A. Doe, MS, RN, COHN
Occupational Health Clinic, Inc.
1500 Main Street
Anywhere, USA 00000
(555) 555-1212
All listings must be ordered by October 1, 1992. To place an order, or for further information,
contact Donna Rosenstock, SLACK Incorporated, 6900 Grove Road, Thorofare, NJ 08086; (800)
257-8290 or (609) 848-1000; FAX (609) 853-5991.
318 AAOHNJOURNAL