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TQM Assignment PDF
TQM Assignment PDF
TQM Assignment PDF
"What Methods of TQM can be done, what can't be done, how can
we overcome barriers to Change Quality Standards in Sudan?"
October 2014
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Introduction:
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However, since most of customers are large multinational companies, many of
ZYTEC power supplies are exported around the world. ZYTEC competes from Far
East and European companies as well as 400 US companies.
ZYTEC is currently the fifth largest multiple output power supply company in the
US. The fastest growing US electronic power supply company, and the largest
power supply repair company in North America.
ZYTEC started in January 1984 the new company focus; Quality, Service and Value.
Therefore, ZYTEC managed to commit its overall performance to achieve quality,
service and value Provided that the company has required extensive knowledge
of TQM principles and implementation practices and standards, skills, expertise,
ambition, commitment, required infrastructure as well as tremendous desire to
achieve organization's objective of becoming a world class industrial leader. For
decades, ZYTEC has been recognized by its customers with nine awards for
supplier's excellence, and also ZYTEC remains the sole source supplier for 18 of its
20 new build customers, and this is not an easy task.
A ZYTEC has able to produce more with its existing resources through an
improved customer focus and streamlined work processes. With its increased
awareness of its internal and external customers, there is a greater focuses on
what really needs to be accomplished in order to meet (Exceed) their customers’
needs and expectations, therefore increasing their profitability through increased
customer retention. Being able to meet customer expectations the first time and
every time will enable the organization to increase its market share as new
customers seek them out. Since ZYTEC has focused and streamlined its work
processes they will benefit from lower costs because of reduced waste and
rework.
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One of the major savings that occurs is fewer customer complaints and warranty
claims. More satisfied customers’ results in greater market share, Because of
improved communication, teamwork, and good management-employee relations.
ZYTEC focus on the key processes that provide the organization’s customers with
products or services. An organization is a compilation of a wide variety of
activities. An organization needs to be looked at from all perspectives;
manufacturing, marketing, information technology, research and development
must work well together in an effective organization. The ZYTEC adhere to a
customer-centered philosophy that includes paying attention to organizational,
strategic, environmental, and people factors.
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Implementation of Total Quality Management
A clear and sound TQM framework have been created and adopted which should
be communicated to all the members, at all levels in the ZYTEC business, adopts
this in the right way; it would make the procedures in the organization more
comprehensive, controlled and time managed. This framework discusses the
factors that are important for any institute to successfully implement TQM within
the organization and enjoy the returns.
1. Leadership:
The top management has implement TQM through leadership by using two
elementary ways, first, integrating the TQM philosophy and principles in the
organization operations in every department. Second, delivering long-term
training and development that would be necessary for the development of the
company. As result of this trip, Zytec initiate process called Management by
Planning (MBP). The process involves employees in establishing long-range plans
and short-term objectives.
1. Involvement:
ZYTEC has representatives from all groups who would lead the
departments. The company identified group leaders and their
responsibilities from the affected departments.
2. Interest:
The senior management of the company led and make sure every individual
understands the urgency and importance of implementing TQM in the
company.
3. Monitoring:
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TQM is a procedure and not a process. Goals were monitored and altered
during implementation. Senior managers were analyzing the procedure and
make the right implementation to generate results that would favor TQM.
4. Phasing:
TQM is done in phases and the managers use their leadership skills and see
that before they start any phase, the previous phase is completed.
2. Information Analysis:
In every department and at every level, ZYTEC is data driven. ZYTEC systematically
collects and process reliable, timely, and accurate data and information, of board
scope and significant depth.
The purpose of QMS is similar to that of ISO 9000, which is, Customer
requirements need to be fulfilled. Achieve efficiency in terms of all factors of
production like manpower, technology and finance, both externally and
internally.
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ZYTEC is designed in order to assist the employees improve the quality and
reliability of the products. Reliability can be described as the trouble-free time
that a process gives before it fails, so as to:
Benchmarking
• Planning
• Collection of information
• Analysis of data
• Implementation
• Monitoring
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Benchmarking has been practiced by ZYTEC so as to achieve the best in the
market, which made with several leading firms, such as IBM, Wal-Mart, Sony,
P&G, HP, FEdex, etc.
ZYTEC’s planning process takes the quality and service needs of customers and
drives them through the organization and its suppliers. Strategic quality planning
includes vision, mission, and values of the firms. They are formed by taking into
account the quality concept. With effective strategic quality planning efforts
employees are taken as an input in developing the vision, mission, strategies, and
objectives. This facilitates acceptance and support of strategic quality plans by the
employees. Successful strategic quality planning efforts also take into account the
possible side effects of the plan to the environment prior to the production.
Strategic quality planning is positively associated with operational performance,
inventory management performance, society results, customer results, and
market performance. However, strategic quality planning is not statistically
related to perceived performance in the company, Thus Strategic quality planning
is positively related to performance.
ZYTEC involves its human resources in setting and achieving the company’s quality
objectives. Employee involvement refers to the regular participation of
employees in the work process, suggestions for improvement, setting goals and
monitoring the performance. So the organization makes a positive work
environment that is based on trust, good customer service, teamwork and
operational excellence, the ZYTEC leadership team has understand and invest in
the needs of the most important stakeholders of the organization, and the
employees.
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Employee empowerment
Teamwork
Reward and recognition
Education and training
Suggestion schemes
Commitment to quality deals with the leadership aspect, being the basic step of
the TQM implementation in the organization where all members are well
committed to the goal.
People/teams are the members who are responsible for the processes and by
working in teams they add a component of varied culture that is important for
TQM. Tools are the knowledge and techniques that are used for measurement,
metrics and improvements. Systems are the set of activities; mostly the
processing, communicating and controlling that should be applied to interact with
the other activities in the organization.
These components are used together efficiently and effectively along with
measurement of the performance; the ZYTEC achieved mission and goals
successfully and have sustainable growth.
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Supplier Partnership:
As the company and its suppliers are now working as partners, there are values
and norms they need to follow which would help them cultivate their relation for
better returns. Company achieves high quality levels with profit, aim for supplier
partnerships.
6. Quality Results:
Based on customer data and information, ZYTEC has defined, monitored, and
improved most relevant customer performance measures on an ongoing basis.
Ultimately, the purpose of being in business is to stay in business. This category
examines a company’s performance and improvement in several key business
areas including customer satisfaction, product and service performance, financial
and marketplace performance, workforce, and operational performance.
Benchmarking is encouraged to see how the company compares with its
competitors. ZYTEC studied customer results, product and service results,
financial and market results, workforce results, operational results, and public
responsibility and citizenship results.
7. Customer Focus:
ZYTEC knows its customers. It focuses on serving the external customers, it first
knows the customers’ expectations and requirements and then offers the
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products/services, accordingly. By the aid of successful customer focus efforts,
production can be arranged with respect to the customers’ needs, expectations,
and complaints. This encourages firm to produce high quality and reliable
products/services on time with increased efficiency and productivity. When
customer expectations are met, their satisfaction will be increased, and the firm’s
sales and the market share will increase. Customer focus positively affects
operational performance, inventory management performance, employee
performance, innovation performance, customer satisfaction/results, sales, and
aggregate firm performance.
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inventory to a manufacturer that is able to meet the demand of the
customers and provide short lead-time.
2) Six Sigma:
It can be best described as a business improvement approach that seeks to
find and eliminate causes of defects and errors in manufacturing and
service processes by focusing on outputs that are critical to customers and
a clear financial return for the organization. Six Sigma improvement teams
use the DMAIC (Define, Measure, Analyze, Improve, and Control)
methodology to find and eliminate the causes of defects.
The analytical tools are common to all quality efforts including Six Sigma.
These tools consist of flowcharts, run charts, Pareto charts, histograms,
check sheets, cause and effect diagrams and control charts. The other tools,
which are extensively used, are failure mode and effect analysis and design
of experiments.
Successful implementation of Six Sigma is a combination of personnel as
well as technical methodologies.
It is implemented in virtually every ZYTEC business category such as return
on sales, return on investment, employment growth and stock value
growth. It is attentive to the entire business processes and training is
integral to the management system where the top-down approach ensures
that every good thing is capitalized and every bad thing is quickly removed.
Implementing TQM is not an easy concept and does have cost related to it. At
times implementing TQM may need huge financing and company would want to
know if its efforts have given any results. These performance measures have a
huge role to play in the success or failure of the company. Some of the basic ways
to know the performance of the ZYTEC can be seen by the level of employee
interaction, improvement in teams, level of customer complaints, customer
loyalty, reduction in defects, machine failure rates, quality performance by
suppliers, relations with suppliers and customers, increase in revenue, sales,
shareholder investors, etc. There are various models, which can measure the
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performance of the success of TQM; ‘The Malcolm Baldrige National Quality
Award (MBNQA) (American Model)’ framework is a very close replica of what
TQM is.
The Baldrige Criteria for performance excellence framework has seven categories
that help company’s achieve excellence. Company’s who truly follow TQM would
fulfill the criteria of the MNBQA. The seven categories are:
1. Leadership
2. Strategic Planning
3. Customer focus
6. Operations focus
7. Business results
By assessing ZYTEC quality standards and performance along with the employee’s
involvement and customer’s satisfaction, it can be found that ZYTEC applied
MNBQA criteria as well as Deming fourteen points to achieve its TQM as
mentioned above.
The Sudan’s industries have arrived late to TQM, probably due to the
tendency to easily brush aside anything in management that is new, or to
dismiss TQM as a fad.
Continuous improvement is not a fad but a necessary part of management’s
obligation to properly run its company. Gone are the boom days when quality
did not matter due to the volume of product available and the ease of
obtaining products. Customers are now demanding higher quality, and at a
lower cost. In attempting to keep pace with the new attitude, a quality
management system that helps keeps costs down is well worth implementing.
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The characteristics that are common to companies that successfully
implement TQM in their daily operations are listed here:
♦ Strive for owner/customer satisfaction and employee satisfaction
♦ Strive for accident-free jobsites
♦ Recognize that the owner/customer provides the revenue while the
employees are responsible for the profit
♦ Recognize the need for measurement and fact-based decision making
♦ Arrange for employees to become involved in helping the company
improve
♦ Train extensively
♦ Work hard at improving communication inside and outside the
company
♦ Use teams of employees to improve processes
♦ Place a strong emphasis on the right kind of leadership, and provide
supervisors with a significant amount of leadership training
♦ Involve suppliers, requiring them to adopt TQM
♦ Strive for continuous improvement
The goal of management is to create a culture of quality across the entire
firm, get the job done right, the first time, and every time. Every effort to
incorporate the above principles into the company’s actions will further
quality production.
SUDANESE Public Sector and Private Companies:
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teams are assigned responsibility of uplifting the quality of the organization or in
other words their main goal / target is to acquire quality certification. This make
the situation worst in such kinds of organizations provided with the inappropriate
sponsorship; and Results of this deficiency are endless dead loops of problems.
A. Education:
B. Health field:
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TQM implementation in Sudan E-G, Firms and manufacturing organizations,
identified quality problems as listed below:
1. Leadership:
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the organizational reporting hierarchy. Following are few major problems that
exist in Sudan regard to organizational hierarchy:
Many of the quality experts in Sudan believe that local HR is not trained for
quality management activities within most industry. This statement is true both
for the general staff that are present within the organization and the quality
management staff members as well.
Essential deficiencies related to quality management in local human resource
include (but not limited to):
Lack of necessary knowledge concerning computer science; software engineering
(or related) and quality management discipline, improper technical writing and
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documentation skills, lack of knowledge concerning soft skills; management in
general, languages and communications.
Major consequence (as obvious) of lack of high-quality manpower that matches
the requirement of quality management skill set is that the industry is unable to
acquire suitable human resource for the management of quality.
To start with, most of the organizations do not have a defined long or short term
objectives, goals, mission and vision. Since mostly; these things are not defined
therefore individually people fail to understand their role within the organization
and their performance criterion. Absence of mission, vision, goals and objectives
also does not allow people in understanding how these four things relate to one
another and what should be their direction of work for achieving necessary
objectives then goals then mission and then vision.
Some organizations define mission, vision, objective or goal but they do not
define objective to vision relationship as discussed earlier. Absent or unclear
objective to vision relationship hinders organization’s overall productivity.
Very few (needle in a hay stack) organizations actually understand, document,
maintain and clarify objective to goal to mission to vision relationship to their
employees. In nearly a wide majority of organizations vision, mission, objectives
and goals (defined or undefined) do not include quality as an important
parameter of consideration. The result is that general staff members lose interest
in quality as an important function of the organization.
Major reasons of discrepancies in this area are management’s limited vision and
interest in this activity.
6. Transparency:
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people like to hide information from one another in order to flatter their
supervisors whenever possible. There are other several reasons as well that are
not being discussed here due to chances of deviation from core agenda.
Other than the indirect causes, since transparency causes information hiding
therefore quality management implementation becomes difficult and weaker.
Career development and growth are most important motivation factors for any
employee. Unfortunately in Sudan staff members belonging to quality
management function experience problems in this area. In most of the
organizations, employees working on quality management are not given any
career growth and development options. In simpler words employees from
quality management discipline are usually not given any raises in designation and
not many options are made available to them for their general career
development.
Reason behind this phenomenon is that management in firms of Sudan usually
does not focus on quality management as an important area / function within the
organization. Mostly management members believe that staff members
belonging to quality management function play a secondary role in organization’s
core business and their importance therefore; is relatively less. Lack of
management’s commitment to quality management function results in
management’s negligence towards quality and the quality management staff
members.
Consequence of this attitude of organization’s management towards quality
management staff is that generally; the quality management staff feels de
motivated, depressed, they experience less sense of ownership within the
organization and general employee and job satisfaction is seriously affected.
It is also important to note that mostly these reasons are the core problems due
to high quality management employee turnover. Quality management
employee’s career growth and development problems create barriers for quality
management and implementation due to unstable and unsatisfied human
resource.
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8. Returns, Awards to Quality Management Staff in Case of Successful
Quality Certification:
9. Quality is Subjective:
Most of the quality management experts in Sudan believe that general perception
of staff members is that quality is subjective and theoretical mainly. This approach
towards quality makes staff members lose interest in quality for objective
improvement. Although it is true that quality is slightly subjective but as far as
quality sub functions like for instance quality engineering, control, monitoring,
implementation and other sub functions are concerned, quality is extremely
objective. Since most of the staff members like to be objective in their work
therefore they perceive quality as a redundant and unimportant part of business.
This attitude makes quality management cumbersome for the quality
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management staff members. In addition to this, quality is generally an ignored
function within the organizations.
Quality management experts in Sudan feel that lack of team work extremely
undermine the quality management programs. Lack of team work is mostly due to
individualistic attitude where every person likes to represent the idea that he /
she is the reason of success and not the reason of failure.
Lack of team work also occurs due to office politics, job dissatisfaction, de
motivation among employees and most importantly due to supervisors and team
members who do not allow benefits / rewards to be dispersed equally within the
team. Since quality improvement totally depends on collective and unanimous
effort therefore lack of team work hinders quality implementation. Lack of team
work also occurs due to unclear organizational objectives, goals, performance
indicators, mission and vision.
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The second reason of resistance to change is that the new change in itself does
not seem better to relevant stakeholders than previous scenario. These two
reasons are due to lack of expertise of change agents or in our case quality
management staff members.
The third reason of deprived change management is commitment towards
improvement which is essentially less, organization wide. Some staff members are
also resistant to change as they suffer from superiority complex and feel that
their working methodology is better than anyone else as because they possess
more experience or larger knowledge pool.
Resistance to change also occurs due to general individualistic attitude, lack of
team work, office politics, less interest of staff members, job dissatisfaction and
de motivation among employees Etc.
Unsuccessful change management within the organization creates hurdles for
quality management.
12. Trainings:
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13. Staffing & Recruitment:
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Reason behind this lack of knowledge of the quality management’s sub function is
lack of knowledge and expertise within the Sudanese Organizations and lack of
knowledge at the academic end.
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Conclusion:
TQM is a holistic and ethical approach of the firms to continuously improve their
products/services or processes involving all stakeholders in order to satisfy their
customers and to improve performance and sustainability. The results give that
overall TQM practices improve all performance measures.
A ZYTEC has able to produce more with its existing resources through an
improved customer focus and streamlined work processes. With its increased
awareness of its internal and external customers, there is a greater focus on what
really needs to be accomplished in order to meet their customers’ needs and
expectations, therefore increasing their profitability through increased customer
retention; more satisfied customers’ results in greater market share. Because of
improved communication and teamwork, ZYTEC has good management-employee
relations. All problems are solved and the organization begins to run more
smoothly, employee involvement and satisfaction will increase, which will lower
turnover and absenteeism. Beside Effective customer focus efforts increase
operational performance, customer results, and market and financial
performance. Effective strategic quality planning efforts improve employee
performance and social responsibility of the firm. It can be concluded that TQM
practices improve various performance measures in the firms.
All aspects of TQM practices effectively managed in a ZYTEC because each factor
in TQM practices improves different aspects of firm performance. The synergy
among the TQM factors brings about exceptional or crucial improvements in the
firm performances. Firms in Sudan should improve employee involvement/skill
and firm structure and allocate sufficient resources to implement TQM
successfully.
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increase from time to time. By the training provided, the employees also might
have a deeper understanding on their daily jobs which lead to successful
implementation of Total Quality Management in the firms or any industries. So,
why we need continuous improvement?
This is because for proactive reasons and reactive reasons. Proactive reason are
necessary for our own vision for the future improvement and how we will be
competitive in the coming time while reactive reason focus more on the
customers and the company itself.
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at hand. According to Peter Drucker, "Efficiency is doing things right; Effectiveness
is doing the right things." Efficiency is always called for, at work. Every
organization demands dexterous and efficient people who maximize the
throughput and act as a boon for the organization. Efficiency can be acquired by
regular practice and hard work. Becoming efficient at a job increases your
chances of success tremendously. In the context of sports and winning games, Pat
Riley had remarked the following lines. Quote verbatim, "A particular shot or way
of moving the ball can be a player's personal signature, but efficiency of
performance is what wins the game for the team.”
REFERENCES:
Culp, G., Smith, A., and Abbott, J. (1993). “Implementing TQM in consulting
engineering firm.” J. Management in Engineering, Vol.9, No. 4, pp. 340-356.
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Alukal, G. and Manos, A., 2006. Lean Kaizen. A Simplified Approach to Process
Improvement. Pearson Education: Dorling Kindersley(India) Pvt. Ltd.
http://www.12manage.com/forum.asp?TB=deming_14_points_management&
S=10. [Accessed 04 October 2014].
http://www.flexstudy.com/catalog/schpdf.cfm?coursenum=9561a [Accessed
13 Oct 2014].
Asq.org, n.d. Define Measure Analyze Improve Control (DMAIC) - ASQ. [Online]
http://www.zerowaste.org/nwpub2/nwpub2/EMS%20Benefits%20050103b.p
df [Accessed 13 Oct 2014].
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