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1995 - Dveloping CoQ System-Key Feature & Outcome PDF
1995 - Dveloping CoQ System-Key Feature & Outcome PDF
567-575,1995
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BG DALE
Quality Management Centre, UMIST, Manchester, England
This paper discusses the development and operation of a system of quality costing in a manufacturer
of coatings for industrial applications. The work reported is of particular value since most of the
well-poblicised material on quality costing is in relation to mechanical and electrical engineering type
situations. Attention is drawn to the difficulties encountered in establishing the system, including the
adaptiuns and additions needed to the cost elements which had been identified from the quality costing
literature, deciding what was a quality-related cost, determining the reporting format for quality
costs, the elimination of double counting, and dealing with the operating practices of accountants.
The collection, reporting and uses of quality cost data are also examined. It is also pointed out that
many of the practical findings support much of the quality costing theory.
Key words--quality costing, coatings manufacture, quality cost collection, quality cost reporting,
quality cost uses
a reasonable time frame. The specific problems When designing a quality costing system
encountered, included: the scope of the system is difficult to specify as
it is not known at the outset what sort of
• The calculation of the cost of re-tests on
accuracy, detail and traceability is needed. The
reworked material was not practical.
system was initially designed with a wide scope
Reworked material was always mixed
covering the whole operation but without much
with good material (the amount dependent
detail. It was hoped that subsequent usage of the
on the circumstances) and this made
system and feedback of information could be
the calculation of the cost of re-test
used to refine and develop the system in clearly
impractical.
identified areas.
• No data were available or likely to be so in
The cost elements decided upon and the
the near future on the machine downtime
sources of information are given in [17].
attributable to quality-related problems.
As already mentioned the first difficulty
• Costs under warranty contracts do not
encountered was deciding upon the cost elements
apply to coatings in the same way as in the
and a suitable format for their reporting.
case of mechanical-type goods.
It was not easy to decide what was or was not
• Stock evaluation in relation to quality-
a quality cost. Dale and Plunkett [7] are of the
related problems was carried out on an
view that definitions is a key issue in quality
ad hoc basis and this made it impractical
costing and devote a complete chapter of their
to cost.
book to a discussion of the issues involved in
• The costs involved, during the early stages
helping to decide this issue. The definition used
of the quality improvement process, with
at the company was "costs that are avoidable by
quality planning in terms of process
improvement action". This would seem to apply
control costs and improvement projects
to all the categories used except for quality
were unclear and not readily available.
control functions under the appraisal costs
• Technical service costs, which are con-
heading.
sidered as prevention costs by writers such
The question of whether testing is a quality
as Juran [14], Campanella [2] and BS.6143:
cost was also the cause of some dispute.
Part 2 [1], were regarded by the company
Carson [4] is positive that testing is about
as external failure costs.
detecting defects, that it is an appraisal cost,
These types of problems were discussed at and there is an onus on the manufacturing
some length with the Accountant who knew department to "get it right the first time".
the likelihood of data being made available Dale and Plunkett [7] acknowledge this
for the cost elements identified. The Accountant argument but balance it with circumstances
also provided invaluable advice in helping to where testing may not be a quality cost but
interpret the various reports from the costing an integral part of manufacturing operations
system. The approach adopted was for the (e.g. state of technology, inability to give
Quality Assurance Department representative to guarantees without testing, inability to get
describe the category to be costed (e.g. yield insurance cover without testing and a contrac-
losses) to the Accountant who would then try tual requirement of the customer). These latter
to extract this information from the costing circumstances, although genuine testing costs,
system data. It was not always clear what systems are not 'avoidable' by the direct action of the
data information was relevant from a quality department or indeed the company. In certain
management viewpoint. In some cases, infor- cases, testing is part of a company's contracted
mation from the cost accounting system would agreement with the customer, in other cases
be combined with other information to give the customers require a test report with each batch
required quality cost. For example, the 'make of coating. These cases fall outside the 'avoidable
cost per litre' for a particular department costs' guidance but it was decided to include
retrieved from the cost accounting system was these aspects of testing costs on the grounds
multiplied by the number of litres rejected of simplicity at least in the first instance,
obtained from the production report, in this way as differentiating between avoidable and
giving the manufacturing cost in monetary terms unavoidable testing costs would have proved
of the rejected batches. complex.
570 Pursglove and Dale--Developing a Quality Costing System
batches because it keeps the measure in terms of concluded that the packing precision was
money enabling easy calculation of the savings. poor and due almost entirely to the operatives
From the outset it was clear that the major use of the filling equipment. Some equipment was
contribution to quality costs was internal failure. not sufficiently accurate for certain applications.
This fact and requests from management and The packing accuracy data showed that most
director level resulted in a monthly generation of packs were overfilled. This is necessary when
information specific to the internal failure costs filling to minimum fill regulations, but 33% of
of the company's departments. the batches tested were more than 1% overfilled.
When the quality costing system was first The fact that batches are dispensed in 25-205
started, historical data for the previous 9 months litre packs indicates that this level of overfill is
were compiled. The requests for departmentally significant.
specific internal failure costs came approximately From the data collected, it was forecast
six months after launch of the system. This meant that the company were overfilling by approx.
that sufficient data were available for a moving 57,800 litres per annum. The problem depart-
annual total (MAT) graph to be constructed, ments were identified and recommendations
providing an assessment of trends. This periodic made to overcome the inaccuracies. These were
review of cumulative results and trends is actioned by the management team and included
circulated to the Managing Director, members of new filling equipment, new packing methods,
the senior management team and other interested operator training and an increased awareness
personnel. of the importance of accurate filling tech-
niques. One minor modification to the packing
method of a product which was produced in very
USES OF QUALITY COST DATA
large amounts resulted in a yield increase of
Two specific uses made of the quality cost data 2-3% on packing, in addition to an increase in
are now described: accuracy.
Internal failure costs comprise 70% of the total A number of efforts were made to reduce mix
quality costs and within this the largest cost variance costs over a period of time. In one
elements are mix variance and yield variance at department a statistical process control pro-
26 and 19% of the total quality costs respectively. gramme was implemented, in which control
An analysis of internal failure costs over a 16 charts were constructed for initial colour
month period for the three main manufacturing difference to standard and initial viscosity before
departments highlighted specific areas for any tinting to shade or adjustment to viscosity
improvement. was carried out. The object was to make the first
In an effort to reduce yield variance costs a sample as close to the required specifications as
number of initiatives were employed (i) batch possible and so minimize any additions needed.
cards with yield losses over 10% were returned to A system was installed in the department for
the department supervisor for explanation colour matching the batches by computer, which
before filing, (ii) an improvement in cleanliness speeded up the process of colour matching and
and housekeeping was encouraged, this tied in also optimized the amount of expensive stainer
with the work needed to achieve ISO 9002 [12] used to tint a batch to shade.
registration, (iii) the coatings are dispensed into Both these initiatives assisted in ensuring that
tins by weight but are sold by volume, which the actual amounts of raw materials used in a
means that accurate measurement of specific batch, closely matched the agreed formulation,
gravity is necessary for consistency and pack so decreasing the mix or usage variance.
weight accuracy. A number of other means were also used to
A study was undertaken to examine the address the remaining internal failure cost
effect of measurement errors on specific gravity elements. These included improvements in
and the conclusion reached was that greater batch card discipline (i.e. operatives recording
accuracy was needed. Consequently, a more everything they add to a batch). The reporting
accurate measuring balance was purchased for and analysis of the cost of rejected batches
the works laboratory and a study of packing helped in identifying the significant problems.
accuracy and precision was carried out to These aspects were addressed by the use of
quantify the extent of the problem. The study multidisciplinary problem solving teams.
572 Pursglove and Dale--Developing a Quality Costing System
13. Juran JM (1974) Quality Control Handbook, 2nd edition. 17. Pursglove AB (1994) A comparison of quality costing in
McGraw-Hill, New York. three coating manufacturers. M.Sc. Thesis, Manchester
14. Krzikowski K (1963) Quality control and quality School of Management, UMIST.
costs within the mechanical engineering industry. 18. Sandretto MJ (1995) What kind of a cost system do you
Proceedings of the 7th EOQC Conference, Copenhagen, need? Harvard Busin. Rev. Jan/Feb, 110-118.
pp. 42-48. 19. Whitehall FB (1986) Review of problems with a quality
15. Peet WJ (1990) Poor man's guide to quality costs. costing system. Int. J. Qual. Reliab. Mgmt 3, 43-59.
Annual Quality Congress Transactions, Vol. 44,
pp. 839-844. American Society for Quality Control,
Milwaukee. ADDRESS FOR CORRESPONDENCE: Dr B. G. Dale, Quality
16. Ponemon LL (1990) Accounting for quality costs. Management Centre, Manchester School of Management,
J. Cost Mgmt 4, 44-48. UMIST, PO Box 88, Manchester M60 IQD, UK.