INTRODUCTION TO TOTAL QUALITY MANAGEMENT Quality Control- Fitness to Use

What is Quality? Three Main Purposes

Quality is essential for satisfying our consumers and
maintaining their loyalty so that they will continue to buy
from you in the future. Quality products contribute
significantly to long-term income and profitability.
What is Total Quality Management?
To discover flaws or variations in the raw materials and
the manufacturing processes in order to ensure smooth
and uninterrupted production.
To establish the desired quality standards which are
acceptable to the customers?

Total Quality Management (TQM) is a technique of A direct connection between quality inspector and
including management and employees in the continual workers.
improvement of products and services production. It is a
set of quality and management tools targeted at growing Quality Assurance - Fitness for Purpose
business and decreasing losses caused by inefficient Three Main Purposes
processes.
To fulfill front- and back-end processes in the most
Benefits of TQM includes: efficient and fluid manner,
• Improves competitive position. A way of preventing mistakes and defects in
• Increase adaptability to global markets. manufactured products and avoiding problems when
delivering products or services to customers
• Elevated productivity.
A method for assuring management, owners, customers
• Eliminates defects. or anyone that the organization is producing products or
services at a predetermined level of quality.
• Significantly reduces waste.
Total Quality Management- Fitness to Latent
• Reduces quality costs. Requirements
• Improves management communication.
Three Main Benefits
• Raises profits.
Less product defects, Lower costs, Satisfied customers
• Customer Loyalty.
Definitions, Concepts, and Features of TQM
Evolution of Quality
Total - made up of the whole.
Historical Evolution of Quality in the Middle Ages
Quality - degree of excellence of products or services.
1920 Quality Inspection
Management - art or science of handling, directing,
1940 Quality Control
controlling, etc.
1960 Quality Assurance
1900’s up to current Total Quality Management TQM is a management philosophy of achieving
continuous improvement in functional areas such as
marketing, finance, design, engineering, production and
Stage Approach Focus customer services etc.

Quality Inspection Detection

Sorting good from bad Basic Concept of TQM
Quality Control Detection
Using statistics to
a. Top management commitment
control processes
Quality Assurance Prevention Compliance assume to b. Focus on the customer
“zero defects”
Total Quality Prevention Effective Leadership c. Effective involvement and utilization of the entire work
Management Commitment force
Quality Inspection-Fitness to Standard
d. Continuous improvement
Three Main Purposes
e. Treating suppliers as partners
-Identification of the quality problem
f. Establishing performance measures for the processes
-Provision of information to managers

-Elimination of the problem by managers

 Features of TQM
• TQM is customer oriented
• TQM required a long term commitment
• TQM is a teamwork
• TQM requires the commitment of the top level
management and continuous involvement
• TQM is a strategy for continuous improvement of
performance at all levels
4 Pillars of TQM
1. Problem solving discipline
2. Interpersonal skills
3. Teamwork
4. Quality improvement success
Eight Building Blocks of TQM
Eight Building Blocks can be divided into four groups
according to their functions:
1. Foundation 2. Building Bricks
3. Binding Mortar 4. Roof
I. Foundation ~ This is the key to unlocking ultimate
potential of TQM. It includes Ethics, Integrity, and Trust.
1. Ethics - Ethics of an organization set up the business
code which outlines the guidelines that every employee
is expected to follow.
2. Integrity- This is one of the most important
characteristics for which the customers to expect.
3. Trust- It improves the relationship among employees
which help in better decision making.
II. Building Bricks ~ bricks are placed to reach the roof
of recognition.
1. Training- is very important for employees to be highly
productive and learn specific knowledges.
2. Teamwork- To be successful in the business,
teamwork is also a key element of TQM.
Three Types of Teams in TQM Organization
• Quality improvement teams
• Problem-solving Team
• Natural Work Team
3. Leadership- It possibly the most important element in
TQM.
-It appears everywhere in organization.
III. Binding Mortar is an element which binds all the
other elements together.
Communication- communication binds together and is
the core elements together.
The communication song employees or member of
the organization is done in three ways:
• Downward Communication
• Upward Communication
• Sideways Communication
IV. Roof The roof consists of a final element which tops
off all the other elements of TQM.
Recognition is the last and final element in the entire
system. It should be provided for both suggestions and
achievements for teams as well as individuals.
TOYOTA MOTOR CORPORATION (THE KING OF
TQM)
Sakichi Toyoda - His most famous invention was the
automatic power loom in which he implemented the
principle of jidoka.
- Toyoda Loom works founder
Kiichiro Toyoda - His decision to change Toyoda’s
focus from automatic loom manufacture into automobile
manufacturing created what would become Toyota
Motor Corporation.
Eiji Toyoda - guided Toyota Motor Company into global
automotive market
Taiichi Ohno - considered to be the father of the Toyota
Production System.
• 67 manufacturing campanies worldwide
• 10 million vechicles/year
The Toyota Way
The Toyota Way is a set of principles and behaviors that
underlie the Toyota Motor Corporation’s managerial
approach and production system
THE 14 STANDARDS OF THE TOYOTA WAY ARE
COORDINATED IN FOUR SEGMENTS:
 PHILISOPHY
P1: Management decisions are based on long- term
principles even at the expenses of short-term loss
PROCESS
P2: One-piece flow
P3: Use pull system to avoid overproduction
P4: Heijunka-leveled workload
P5: Jikoda- build in quality
P6: Standardized work
P7: Visual management
P8: Use reliable and proven technology
PEOPLE & PARTNER
P9: Grow leaders who understand the work and live the
philosophy
P10: Develop exceptional people and teams
P11: Respect extended network of partners and
suppliers.
PROBLEM SOLVING
P12: Genchi genbutsu- go see yourself
P13: Decisions by slow consensus; implement quickly
P14: Kaizen, become a learning organization
TOYOTA PRODUCTION SYSTEM
- A production system based on the philosophy of
achieving the complete elimination of all waste in pursuit
of the most efficient methods.
Just-in-time(JIT)- The right parts needed in assembly
reach the assembly line at the time they are needed and
only in the amount needed.
Autonomation (jidoka)- Signifies that machines can
prevent errors autonomously.
Lean Manufacturing- it is a management philosophy
primarily focuses on eliminating muda (waste) within a
manufacturing system.
ENEMIES OF LEAN
Muda (waste)- Any activity that consumes resources
without creating value for the customer.
Mura – refers to “unevenness” or “irregularity”—
specially, irregularity in production level.
Muri- “beyond one’s power” as it refers to employees or
equipment that have been overburdened.
8 WASTES OF LEAN MANUFACTURING
-Overproduction - Waiting
- Transport -Overprocessing
-Inventory -Motion
- Defects - Non- utilized talents
Best Practices of Toyota Motor Corporation
-Customer Focus
-Strong Leadership
-Continuous Improvement (kaizen)
-Workforce Focus
-Lifelong Learning
-Factual approach to decision-making
DISCUSSION QUESTION
What are the differences between Muda, Mura and
Muri? Muda is any activity that doesn’t contribute to
adding value to customer. Mura is the unevenness,
either on the inventory or in the process. Muri refers to
being overburden of either employees or machine.
What is the relationship between integrity and trust?
People with integrity are considered trustworthy. You
can’t trust someone who isn't in integrity ith themselves.
If you are a person with integrity, you’ll easily develop a
relationship with your co-workers and gain trust and
respect from them. Moreover, the lack of integrity leads
to distrust “You can’t have one without the other”
What are the four stages of evolution of Quality?
Explain them briefly.
The evolution of quality has taken place in four stages.
Quality inspection, Quality control , quality assurance
and total quality management.
On the first stage is the quality inspection was that the
poor quality found by the inspectors would be separated
from the acceptable quality product and then be
scrapped, rework or sold as lower quality. The second
stage is quality control. it is used to verify the quality of
the output. Quality was controlled through supervised
skills, written specification, measurement and
standardization which help products and services to
meet customers needs. The third stage is quality
assurance which is the process of managing for quality.
it contains all the previous stages in order to provide
sufficient confidence that a product or service will satisfy
customers needs. The fourth and last stage is the tqm
which means thinking about the quality in terms of all
functions of the enterprise and a start to finish process
that integrates interrelated functions at all levels.