TQM Dem Plan

8/13/2019 TQM Dem Plan

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Quality is dependent'on ethical behavior. poil g what is right in the first place is a provenway to reduce costs, improve competitiveness, imd create customer satisfaction. Manycompanies are hiring ethics consultants to help them achieve their goals.

'.l Unethical behavior by Enron and Worldcom executives in 2002 resulted in bliIlk-ruptcy for those companies.

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lE ERSHIP

The third step is promotion, which is the continuous advertising of ethical behaviorin order to develop an ethical organizationill cultUre that is Clear, positive, and effective. To be clear the philosophy needs to be written, with iiiput from all personnel, and

posted. Standardized ethics training should be given to everyone to: (1) teach themhow to clarify ethical issues, (2) encourage them to get theJacts before acting, (3)encourage them to consider all the consequences before acting, and (4) show themhow to test their actions in advance. This testing can be accomplished by asking (1)Is it legal? (2) Is it right? (3) Is it beneficial for all involved? and (4) How would Ifeel If it was published on the front page of thenewsv.aper1, ,

To be positive, the cul~e should he about dci~g what isnght, encouraging principled organizational dissent, and rewarding ethical behavior . To be effective, the philosophy must be set and adopted by senior management,

with input from all personnel. Senior management should act as they would wantothers to act and make no exceptions.

Final Comment

~Deming's philosophy is given in his 14 po~l)ts.Most of these points were given in a sem-,inar for 21 Presidents ofIeading Japanese industry in 1950.The rest were developed andthe/original ones modified over a period of three decades.

Create and Publish the Aims and Purposes of the OrganizationManagement must demonstrate constantly their coiiunitment to this statement. Itmust incluc\e investors, customers, suppliers employees, the-'community, and a quality philosophy, The statement i a forever-changing document that requires inputfrom everyone. Organizations must develop a Ii:>ng-termview of at l~t ten years and6 Adapted from Out of the Crisis by W. Edwards Deming by permission of MIT and the W. Edwards Deming

Institute, Published by MIT, Center for Advanced Engineering Study, Cambridge, MA 02139, Copyright19860y W. Edwards Demirig,


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CHAPTER

plan to stay in business by setting long-range goals. Resources must be allocated for research training and continuing education to achieve the goals. Innovation is promotedto ensure that the product or service does not become obsolete. A family organizationalphilosophy is developed to send the message that everyone is part of the organization.

Learn the New PhilosophyTop management and everyone must learn the new philosophy. Organizations must seeknever-ending improvement ind refuse to accept nonconformance. Customer satisfactionis the numher one priority because dissatisfied customers will not continue to purchasenonconforming products and services. The organization must concentrate on defect prevention rather than defect detection. By improving the process the quality and productivity will improve. Everyone in the organization including the union must be involvedin the quality journey arid change his or her attitude about quality. The supplier must behelped to improve quality by requiring statistical evidence of conformance and sharedinformation relative to customer expectations.

3 Understand the Purpose of InspectionManagement must understand that the purpose of inspection is to improve the processand reduce its cost. For the most part mass inspection is costly and unreliable. Whereappropriate it should be replaced by never-ending improvement using statistical techniques. Statistical evidence is required of self and supplier. Every effort should be madeto reduce and then eliminate acceptance sampling. Mass inspection is managing for failure and defect prevention is managing for success.

4 Stop Awarding BusinessBased on PriceAlone. l-The organization must stop awarding business based on the low bid because price has nomeaning without quality.The goal is tohave single suppliers for each item todevelop a longterm relationship of loyalty and trust -thereby providing improved products and services.Purchasing agents must be trained in statistical process control and require it from suppliers.They must follow the materials throughout the entire life cycle in order to examine how customer expectations are affected and provide feedback to the supplier regarding the quality.

S Improve Constantly and Forever the SystemManagement must take more-responsibility for problems by actively fmding and correcting probiems so that quality and productivity are continually and permanently improved and costs are reduced. The focus is on preventing problems before they happen.Variation is expected but there must be a continual striving for its reduction usIng control charts. RespOnsibilities are assigned to.teams to remove the causes of problems andcontinually improye the process.


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LEADERSHIP

6. Institute Training Each employee must be oriented to the organization s philosophy of commitment tonever-ending improvements. Management must allocate resources to train employees toperform their jobs in the best manner possible. Everyone should be trained in statisticalmethods, and these methods should be used to monitor the need for further training.

7. Teach and Institute LeadershipImproving supervision is management s responsibility. They must provide supervisorswith training in statistical methods and these 14 points so the new philosophy can be implemented. Instead of focusing on a negative, fault-fmding atmosphere, supervisorsshould create a positive, supportive one where pride in workmanship can flourish. Allcommunication must be clear from top management to supervisors to operators.

8. Drive Out Fear Create Trust and Create a Climate for InnovationManagement must encouiage open, effective communication and teamwork. Fear iscaused by a general feeling of being powerless to control important aspects of one s life.It is caused by a lack of job security, possible physical haml, performance appraisals, ignorance of organization goals, poor supervision, 1mdnot knowing the job. Driving fearout,of,the workplace involves managing for success. Management can begin by providing workers with adequate training, goOd supervision, and proper tools to do the job, aswell as removing physical dangers. When people are treated with dignity, fear can beelinlinated and people will work for the general good of the organization. In this climate,they .will provide, ideas for ,improvement.

9. Optimize the Efforts of Teams Groups and Staff AreasMlHlagementmust optiJ.nizethe efforts of teams, work groups, and staff areas to achieve~e.aims and pllJ.--psesf the organization. Barriers exist internally among levels of man~~em~nt, among. ,departJnents, within depaJ1ments, and among shifts. Externally, theyMist between the organization and its customers and suppliers. These barriers exist because of poor communication, ignorance of the organization s mission, competition,fear, and personal grudges or jealousies. To break down the barriers, management willneed a long-term perspective. All the different areas must work together. Attitudes needto be changed; communication channels opened; project teams organized; and trainingin ~work im.pJ.l


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Z CHAPTER 2

desires. They do not produce a better product or service, because the workers are limited by the system. Goals should be set that are achievable and are committed tothe longterm success of the organization. Improvements in the process cannot be made unlessthe tools and methods are available.

11a. Eliminate Numerical Quotas for the Work ForceInstead of quotas, management must learn and institute methods for improvement. Quotas and work standards focus on quantity rather than quality. They encourage poorworkmanship in order to meet their quotas. Quotas should be replaced with statistical .methods of process control. Management must provide and implement a strategy fornever-ending improvements and work with the work force to reflect the new policies.

11b. Eliminate Management by ObjectiveInstead of management by objective, management must learn the capabilities of theprocesses and how to improve them. Internal goals set by management, without amethod, are a burlesque. Management by numerical goal is an attempt to manage without knowledge of what to do..An excellent analysis supporting this point is given byCastellano and Roehm.?

12. Remove Barriers That Rob People of Pride of WorkmanshipLoss of pride in workmanship exists throughout organizations because (I) workers donot know how to relate to the organization's mission, (2) they are being blarried for

. system problems, (3) poor designs lead to the production of junk, (4) inadequatetraining is provided, (5) punitive supervisioil exists, and(6) inadequate or ineffective 'equipment is provided for performing the required work. Restoring pride will require 'a long-term commitment by management. When workers are proud of their work, theywill grow to the fullest extent of their job. Management must give employees opera-.tionafjob descriptions, provide the proper tools and materials, and stress the workers'understanding of their role in the total process. By restoring pride, everyone in the or-

., ganiZatio-n will be working for the common good.'A barrier for pe~ple on salary is theannual rating of performance. 0

13., Encourage.EduCation and Self Improvement for EveryoneWhat an organization needs is people who are improving with education. A long-termcommitment to continuously train and educate people must be made by management.Deming's 14 points and the organization's mission should be the foundation of the edu-

--:r----.., ...~,..;; ~~: Aof~h;F. Caste lano and Harper A. Roehm, 'The Problems With Managing By Objectives and Results.


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Everyone is responsible for quality, especially senior management and the CEO; however, only the latter can provide tlie leadership system to achieve results ..For instance,in the 1980's, General Electric's CEO, Jack Welch, instituted leadership trainingcourses at all ievels of the organization. The Geb.eral Ell~ctric training courses taughtleadership approaches and models and provided the opportunity for teams to developsolutions 'to real business problems. Many of the solutions the teams developed wereimplemented. Jack Welch supported the development of a leadership system wherebyqrlality control leaders were developed ,at all leyels in all functions of the organization,including research, marketing, manufacturing, sales, finance, and human resources. Senior managtrs needto be provided with the skills to implement quality control techniques and actively participate in the qiullity council.

Senior management Pes numerous responsibilities. Senior management must practicethe philosophy cf Management by Wairdering AroUnd (MBWA). Management shouldget out of the office and visit customers, s'uppliers, departments within the orgllI ization,and plants within the organization. That way, managers learn what is happeriing with aparticular customer, supplier, or project MBo/.A can substantially n~duce paperwork.Encourage subordinates to write only impOitulii'me:ssagesthat need to be part of the permanent record. For example, Kinko's executives perform normal operating duties fortwo ef three days at one location. This.approach is an excellent technique forgaiilingfirsthand information .. '., --.' . ' . - .,, ThtU?ea is to let employees thJ~ forthemselves, ';e~iQ.rm< I1agement's role is nolonger t~ II).akethe fmal decision, butto make sute the t~am's decision is aligned with

n. the quality statements of the organizaiiori ..Push problem sQlving IIlddecision making tothe low~sr~ppiopri~t~Clevd by ddeg~ting autp6rity and'respnhsibiliiY.

vd ,fie ,,-cation program. Everyone should be retrained as the organization requirements change T 2.~:'.,to 'meet the changing environment

1\ fu;l1' i.14~Take ction to ccomplish the TransformationManagement has to accept the primary responsibility for the never-ending improvementof the process. It has to create a corporate structure to implement the philosophy. A cul- .tural change is required from the previous business as usual attitude. Management mustbe Committed, involved, and accessible if~e organization is to succeed in implementingthe new philosophy. Hillerich Bradsby Co., the mak~rs of the Louisville Slugger baseball bat, have used Deming's 14points since 1985 and now have 70% of the professionalbaseball bat market. 8

8 March.v' Jacques. Big League Quality, Quality rogress (August 2(01): 27- 34.


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winner, if you ask them to show you their quality strategy, they will show you their business strategy; if you ask them to show you their quality plans, they will show you their,business plans. In fact, the term q~:not1lSedtuo-much:-'FtRrtitne horizon for stniteicplanning is for three to ten y rs. and short-term plarining is for one year or less.

~als and Objectivess ~d objeC?ves have basicaIl~ the same meanipg. However, it is possible to differentiate between the two by using g2als for 10DQ--teIJ;DlanninQ- and Q~~orshort-term Dlanning. The goal is to win the war; the objective is to capture the bridge.' COncrete goiliS are needed to provide a focus, such as improve customer satisfaction.

employee satisfaction, and processes. Goals can force changes in leadership style fromreward and punishment to identifying and improving system problems. 12 .

Goals must be based on ~tatistical eviclen~Without statistical knowledge of the system, goals merely reflect the assumption that slogans, exhortations, and hard work willmiraculously change the system. Goals must be definitive, specific. and understandable.using concrete results'rather than behaviors or attitudes ':fhe most important character

istic of goals is that they be measurable. Only measurable goals can be~aluated.Goals must have a.p1/lpnr rnpthnd with resources for its achievement. there is Dota cause-and-effect relationship between the goals and the method, then e goal is not avalid one. In addition, a speciflC timeframe or tleadline for achieving the goal should be,given.

Goals must be ch en' g yet achievable. Those individuals, work groups, departments, and functional areas that ec flhe goals should be involved in their development. Btretch goals are satisfactory. provided they are based on benchmark data. 13

The characteristics of objectives are identical to those given here for goals. They areoperational approaches to attain the goals.

Seven Steps to Strategic PlanningThere are seven basic steps to strategic quality planning. The process starts with the principle that quality and customer satisfaction are the center of an organization's future. Itbrings together all the key stakeholders.

I. ustomer Needs The first step is to discover the future needs of the customers.Who will they be? Will your customer base change? What will they want? How will theorganization meet and exceed expectations?

12 George P. Bohan. Focus theStrategy to Achieve Results, Quality Progress (July 1995): 89-92.13 Adapted from John Pessico Jr. and Gary N. McLean, Manage With Valid Rather Than Invalid 'Goals,


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Customer Positioning Next, the planners determine where the organization wantsto be in relation to the customers. Do they want to retain, reduce, or expand the customerbase? Products or services with poor quality performance should be targeted for breakthrough or eliminated. The organization needs to concentrate its effu~ on areaS of ex-ce~nce. '

3 Predict the Future Next, the planners must look into their crystal balls to prediet future conditions that will affect their product or service. Demographics, economicforecasts, and technical assessments or projections are tools that help predict the future. More than one organization's product or service has become obsolete because itfailed to foresee the changing technology. Note that the rate of change is continuallyincreasing.

4 Gap Analysis This step requires the planners to identify the gaps between the current state and the future state of the organization. An analysis of the core values and concepts, given earlier in the chapter, is an excellent technique for pinpointing gaps.

5 CkJsing the Go? The plan can now be developed to close the gap by establishinggoals and responsibilities. All stakeholders should be included in the development of theplan.

6 Alignment As the plan is devetoped, it must be aligned with the mission, vision,and core values and concepts of the organization. Without this alignment, the plan willhave little chance of success. -:-

7 Implementation This last step is frequently the most difficult. Resources must beallocated to collecting data, designing changes, and overcoming resistance to change.Also part of this step is the monitoring activity to ensure that progress is being made.The planning group should meet at least once a year to assess progress and take any correcti veaCtion.

Strategic planning can be performed by any organization. It can be highly effective,allowing organizatio-ifi;to do the right thing at the right time, every time:

nnual Quality mprovement ProgramAn annual pWgmo is developed along with a long-term strategic plan. Some of thestrategic it~P1r:Willeventually become part of the annual Plan, which will include newshort -temi items.

In additiOn to creating the items, the program should develop among all managers,specialists; and operating personnel

A sense of responsibility for active participation in making improvements.n h The skills needed to make improvements .t .i .. 'The habit of anIlul\ improvemen S so that each year the organization's quality is sig-. nificantly better\than the previous year's.

TQM Dem Plan

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