Professional Documents
Culture Documents
Quality Awards
Quality awards have been established to generate improvement in
quality.
1. Malcom Baldrige Award
The purpose of this award competition is to stimulate efforts to
improve quality, to recognize quality achievement's and publicize
successful programs.
The award was first presented in 1988 and award categories included
manufacturing and small business. Later on categories of healthcare
and education were also added.
Quality Awards
Applicants are evaluated in seven main areas:
• Leadership
• Information and Analysis
• Strategic Planning
• Human Resource Management
• Customer and Market focus
• Process Management
• Business Results
Quality Awards
2 The European Quality Award
The European Quality Award is Europe’s most prestigious award for
organizational excellence.
The European Quality Award sits at the top of regional and national
quality awards and applicants have often won one or more of those
awards prior to applying for the European Quality Award.
Quality Awards
3. The Deming Prize
The Deming Prize named in honor of the late W. Edwards Deming. It is
Japan’s highly desirable award recognizing successful quality awards. It
is given annually to any company that meets the awards standards.
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DEFINITION – COST OF QUALITY
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QUALITY COSTS
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QUALITY COSTS
• Prevention Costs:
Prevention costs include those activities which remove and prevent defects from
occurring in the production process. Included are such activities as quality
planning, production reviews, training, and engineering analysis, which are
incurred to ensure that poor quality is not produced.
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QUALITY COSTS
• Appraisal Costs:
Appraisal costs are those costs incurred to identify poor quality products after they
occur but before shipment to the customers. Inspection activity is an example.
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QUALITY COSTS
Failure Costs:
Failure costs are those incurred either during the
production process (internal) or after the product
is shipped (external).
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QUALITY COSTS
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QUALITY COSTS
• This figure is an attempt to convey the idea of
an iceberg, where only 10% is visible and 90%
is hidden from view.
• The visible 10% comprises of such items as
scrap, rework, inspection and returns under
warranty
• For many companies these comprise what
they believe to be the total costs.
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QUALITY COSTS
• The principle is like the traditional medical axiom: “An ounce of prevention
is worth a pound of cure”.
• The relationship between these costs is reflected in the 1-10-100 rule
depicted in the following figure.
• One dollar spent on prevention will save $10 on appraisal and $100 on
failure costs.
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Prevention 1
10
$
Correction $
$ 100
$
Failure
$ $
$ $
$ $
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QUALITY COSTS
• “The earlier you detect and prevent a defect the more you can
save. If you catch a two cent resistor before you use it and throw
it away, you lose two cents. If you don’t find it until it has been
soldered into a computer component, it may cost $10 to repair
the part. If you don’t catch the component until it is in the
computer user’s hands, the repair will cost hundreds of dollars ”.
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Prevention Appraisal
Design review Vendor surveillance
Zero defects program Receiving inspection
Supplier training Product acceptance
Supplier evaluation Process control
Specification review Inspection
Quality audits Quality control
Preventive maintenance Testing
Engineering changes Equipment costs
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Internal Failure External Failure
Downtime Customer affairs
Engineering changes Purchase changes
Excess inventory Service after sales
Disposal costs Product liability
Reinspection Lost market share
Delivery delay
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BENEFITS OF COSTS OF QUALITY CONTROL
Reduced Items Improved Items
Inventory Finished goods Return on assets Economies of
levels scale
Lead-time Warehouse Return on Scheduling
space investment
Time-to- Order process Vendor relations Productivity
market time
Turnaround Design to Transportation
delivery time
Work in process Learning curve
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THE USE OF QUALITY COST
INFORMATION
Quality cost information can be used in a number of ways:
• To identify profit opportunities
• To make capital budgeting and other investment decisions (quality, as
opposed to payback, is the driver of decision to purchase new equipment
or dispose off unneeded ones; equipment for network is not needed if the
rework is eliminated or reduced).
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THE USE OF QUALITY COST
INFORMATION
• To improve purchasing and supplier-related costs.
• To identify waste in overhead caused by activities not required by the
customer.
• To identify redundant systems.
• To determine whether quality costs are properly distributed.
• To establish goals for budget and profit planning.
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THE USE OF QUALITY COST
INFORMATION
• To identify quality problems.
• As a management tool for comparative measure of input-output
relationships (e.g., the cost of a reliability effort versus warranty costs).
• As a tool of Pareto Analysis to distinguish between the “vital few” and the
“trivial many”.
• As a strategic management tool to allocate resources for strategy formulation and
implementation.
• As an objective performance appraisal measure.
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Process Improvement
Kaizen Cycle For Continuous Improvement
• Kaizen is a Japanese word for the philosophy that defines management role in
continuously encouraging and implementing small improvements involving everyone.
• It is the process of continuous improvement in small increments that make the process
more efficient, effective, adoptable and under control.
• Improvements are usually accomplished at little or no expense, without sophisticated
techniques or expensive equipment
• It focuses on simplification by breaking down complex processes into their sub processes
and than improving them.
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KAIZEN, CONCEPT AND
TECHNIQUES
The characteristics of Kaizen are as follows:
•Improvement efforts are people oriented.
•Process and efforts for better results.
•Improvement efforts are based on accumulation of small steps.
•Effect is long term and long lasting.
•Timeframe of improvement is continuous and incremental.
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KAIZEN, CONCEPT AND
TECHNIQUES
• Change is gradual and constant.
• The improvement effort is focused on total employee involvement.
• The approach for improvement is that of group efforts/team work.
• Requires little investment but great effort to maintain it.
• The advantage of Kaizen is that it works well/better suited to slow
growth economies.
KAIZEN AND INNOVATION
• Kaizen is different from innovation.
• Innovation generally represents the focus of western management,
which results in large, short-term, radical changes in product or
process.
• Often innovation is the result of substantial investment in equipment
or technology to the major re-building of entire plant.
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Focus of Kaizen Improvement
The kaizen improvement also focuses on the use of following:
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The 5S Principles
5S is a disciplined step-by-step approach to keeping the
workplace clean and well organized. The five S’s come from
Japanese words starting with S as follows:
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WORD MEANING
1st S SEIRI Sort out unnecessary items in the
workplace and discard them.
2nd S SEITON Arrange necessary items in good order.
WORD MEANING
3rd S SEISO Clean the workplace thoroughly to
eliminate waste and dust on the floor,
machinery and equipment.
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QUALITY CONTROL CIRCLE
• Introduction of Quality Circle Concept
• Quality circles are small groups comprising 6-8 volunteer
workers who come from the same work unit or who do
similar work.
• Meet regularly to identify problems and improvements
within their area of responsibility.
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DEFINITION OF QUALITY CIRCLE
• Quality circles is a small group that performs
voluntarily for improvement activities within the same
area.
• This small group carries on continuously as a part of
company wide improvement activities with the focus
on self and mutual developments and improvements
within the workplace, utilizing quality control
techniques with the participation of all members.
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Quality Improvement
Approaches:
Lean Operations System
LEAN OPERATIONS SYSTEM
A lean operation is a flexible system of operation that uses considerably
fewer resources (i.e., activities, people, inventory, and floor space) than
a traditional system. Moreover, lean systems tend to achieve greater
productivity, lower costs, shorter cycle times, and higher quality than
nonlean systems.
The ultimate goal of lean is a balanced system, that is, one that achieves a smooth,
rapid flow of materials and/or work through the system. The idea is to make the
process time as short as possible by using resources in the best possible way. The
degree to which the overall goal is achieved depends on how well certain
supporting goals are achieved.
Those goals are to
1. Eliminate disruptions.
2. Make the system flexible.
3. Eliminate waste, especially excess inventory.
SUPPORTING GOALS
5. Kaizen is built on a cheap strategy, and it does not require spending great
sums on technology or consultants
6. It can be applied anywhere.
7. It is supported by a visual system: a total transparency of procedures,
processes, and values, making problems and wastes visible to all.
8. It focuses attention where value is created.
9. It is process oriented.
10. It stresses that the main effort of improvement should come from new
thinking and a new work style.
11. The essence of organizational learning is to learn while doing.
Building Blocks
As shown in above figure, following are the building blocks:
1. Product design.
2. Process design.
3. Personnel/organizational elements.
4. Manufacturing planning and control.
Product Design
There are four elements of product design:
1. Standard parts: It means that workers have to deal with fewer parts
2. Modular design: Modules are clusters of part treated as single unit
and therefore, it reduces the number of parts which are to be dealt with.
3. Highly capable production systems with quality built in: this is the
requirement of lean operations, therefore quality must be developed in
goods and processes
4. Concurrent engineering: engineering changes which can be disruptive
to smooth operations can be reduced
Process Design
Following are various aspects of process design:
1. Small lot sizes: lot sizes are to be reduced as much as possible, which is one of the
requirements of a lean system
Some of the benefits are :
• Reduced inventory, lower carrying costs
• Less space required to store inventory
• Less rework if defects occur Less inventory to “work off” before implementing
product improvements
• Increased visibility of problems Increased production flexibility Increased ease of
balancing operations
Process Design
2. Setup time reduction: the lean systems require short setup times
3. Manufacturing cells: the cells contain the machine and tools needed
to process parts having similar processing requirements. Therefore,
multiple manufacturing cells are required in lean production
systems.
4. Quality improvement: avoiding the occurrence of quality defects
during the process is required.
Process Design
• Use many small units of capacity; many small cells make it easier
to shift capacity temporarily and to add or subtract capacity than
a few units of large capacity.
• Use offline buffers. Store infrequently used safety stock away
from the production area to decrease congestion and to avoid
continually turning it over.
• Reserve capacity for important customers.
Personnel/organizational elements
Following are the 5 important elements of lean systems:
5. Close vendor relationships: lean systems require a close relationship with the
vendors who were expected to provide small frequent deliveries of high
quality goods.
6. Reduced transaction processing: in lean systems it is required that transaction
costs are reduced by reducing the number and frequency of transactions which
do not add value.
7. Preventive maintenance and housekeeping: maintaining the equipment in
good operating condition and replacing parts which have a tendency to fail
before failure is also required in a lean system. Housekeeping, a part of 5S
methodology which aims at maintaining a work place clean and free from
unnecessary materials is also useful in lean systems.
Source: “Operations Management” by William J Stevenson, Mc Graw Hill Education (11 th Edition)
Business Process
Reengineering
Introduction
• BPR is the fundamental rethinking and radical redesign of business
processes to achieve dramatic improvements in critical measures of
performance.
• More recently it has emerged as the concept which enables an
organization to take a radical and revolutionary look at the way in
which it operates, and the way work is done.
• It has become popular in a short period of time, promising amazing
results very quickly in relation to corporate and technological change,
transformation and competitive pressures.
Introduction
• While TQM is based, in general, on continuous improvements in processes
over a relatively long period of time, BPR emphasizes structural process
redesign, process reengineering and fundamental rethinking of the business
leading to producing faster returns in a relatively short period of time.
• The organizations which start with TQM will have a better understanding of
the processes which are crucial to both TQM and BPR. Therefore, they are
more prepared to deal with the more radical designing of the new
processes that is demanded by BPR.
• In general, it has been service industries and public sector organizations
which have adopted the BPR approach rather than manufacturing
industries.
Approaches used in BPR
• The two main approaches employed in BPR are process redesign and
process reengineering.
• These approaches are based on taking into consideration the core processes
that are needed to accomplish specific business objectives without being
constrained by what already exists.
• BPR covers a range of activities that result in radical change, to either
individual processes or the total organization.
• The main differences between the two approaches are that the later
involves greater structural change and risk while the former is quicker and
less costly to implement but with potentially fewer benefits and
improvements.
BPR Methodology
There are four main phases of a BPR project that are given as follows:
1. Preparation
2. Innovation and design
3. Implementation
4. Assessment
Preparation
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BENCHMARKING
In benchmarking practice, following points may prove useful:
• Too much information is as bad as too little.
• Only that information maybe obtained which is needed to make a
direct comparison of performance.
• If the benchmark is clearly defined in the first place, one will be
dealing with manageable and useful data.
• Before one starts comparing with other companies, benchmarking
within the own organization needs to be tested.
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BENCHMARKING
• When a higher level of performance is achieved in a certain activity,
one should:
Quantify it, as closely as possible.
Seek opinion of other managers in order to learn from the other companies’
experiences.
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BENCHMARKING
Remember that the most important issues may change with time.
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BENCHMARKING
Plan for Benchmarking:
• It is perhaps possible to benchmark almost any activity that can be
measured.
• In practice’ however, one would want to start with those things, an
organization is really good at to be successful in the benchmarking
processes or activities.
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BENCHMARKING FEATURES
Change
Measurement Review
BENCHMARKING FEATURES
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FOCUSING BENCHMARKING
Mission
BENCHMARKING
Critical
Processes
Critical Success
Factors
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THE MAIN CHARACTERISTICS OF
BENCHMARKING
The main characteristics of benchmarking are:
• It is a corporate wide applicable tool.
• It is process-driven and not individually focused.
• It comes in various forms and can focus on “what, where, how”
(practices) and “how much, how big, how small” (metrics).
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THE MAIN CHARACTERISTICS OF
BENCHMARKING
• It is based on continuous improvement and therefore is an integral
component of total quality management.
• It is a useful practice for bringing about a positive change in an
organization.
• It is knowledge based and brings in state of the art thinking all the
time.
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SELECTING BENCHMARKING
PARTNERS
Benchmarking
Benchmarking
Potential benchmarking partners
Type
Type
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FOUR MAIN TYPES OF BENCHMARKING
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FOUR MAIN TYPES OF BENCHMARKING
2) Competitive Benchmarking:
a) It aims at comparing specific models or junctions with
main competitors.
b) It is also described as reverse engineering since the
starting point in most cases has been the product and
looking at its characteristics and functionality.
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FOUR MAIN TYPES OF BENCHMARKING
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FOUR MAIN TYPES OF BENCHMARKING
3) Functional Benchmarking:
a) This type of benchmarking compares specific functions
with best in industry and best in class.
b) It is a positive approach in benchmarking because it is
only related to specific functions.
c) It may not be of benefit to other operations in the
business organizations concerned.
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FOUR MAIN TYPES OF BENCHMARKING
3) Generic Benchmarking:
a) This is the ultimate in terms of benchmarking
applications.
b) This approach applies to all functions of business
operations and encourages the continued effort of
comparing functions and processes with those of best in
class.
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DEFINITIONS OF BENCHMARKING
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DEFINITIONS OF BENCHMARKING
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DEFINITIONS OF BENCHMARKING
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