International Journal of Mechanical Engineering and Technology (IJMET)
Volume 10, Issue 01, January 2019, pp. 1602–1608, Article ID: IJMET_10_01_164
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=1
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication
Scopus Indexed
DOES THE TOTAL QUALITY MANAGEMENT
ENHANCE THE QUALITY? EVIDENCE FROM
SELECTED MANUFACTURING UNITS; BRICKS
Harshitha M and Dr. Ravi Kumar
Department of Management and Commerce,
Amrita School of Arts and Sciences, Mysuru,
Amrita Vishwa Vidyapeetham, India
ABSTRACT
In the study an attempt was made to know the different total quality management
practices adopted by the selected manufacturing brick units and effects of it on the
process thinking, customer satisfaction, employee commitment, strategic thinking,
integrated system, decision based on facts, continuous improvement and effective
communication . The elements of total quality management has been studied about the
quality enhancement, increase in customer base, profitability and sales. The data was
collected through primary sources as company records and field observations. The
study was conducted to know more about the TQM practices followed by the selected
manufacturing units. In those days they used to take more time for manufacturing the
bricks and now the time maintenance has been able to manage. The company’s growth
was realized only after adoption of TQM and it has been able to increase their
customers. Dynamic thinking process was adopted wherein they were able to assess
and give the changes that are happening in the market.so we can conclude by saying
that total quality management has brought the considerable changes in the
organization.
Keywords: Bricks, Manufacturing, Total quality management, quality, sales, profitability
Cite this Article: Harshitha M and Dr. Ravi Kumar, Does the Total Quality
Management Enhance the Quality? Evidence from Selected Manufacturing Units;
Bricks, International Journal of Mechanical Engineering and Technology 10(1), 2019,
pp. 1602–1608.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=1
1. INTRODUCTION
In this competitive environment sustainability and growth to the manufacturing units is a
challenge. Quality management and effective cost management along with innovations of the
product and services is the only way to sustain. Cost can be varied to take care the needs of
the customer but any change in quality will have long term adverse impact on the growth of
organizations and retaining customer base. It is only through quality where they can enhance
their goodwill. Consistent quality management can be done only on adoption of certain
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Does the Total Quality Management Enhance the Quality? Evidence from Selected Manufacturing
Units; Bricks
quality management techniques. TQM is one of the techniques that enhances the quality is
what addressed through various researchers. The present paper tries to understand does really
“TQM enhances the quality”. When it comes to TQM it helps the manufacturing units to
upgrade the quality.
2. CONCEPT OF TOTAL QUALITY MANAGEMENT
The TQM is geared to ensure consistency in quality of goods and services over a period of
time and to meet customer requirements. This method is used to improve the quality and
productivity in the business. TQM has also had an impact on quality enhancement, sales,
increase in customer base and profitability.
The key factors of TQM towards successful quality maintenance and management are:

Process thinking

Customer satisfaction

Total employees commitment

Strategic thinking

Integrated system

Decision based on facts

Continuous improvement

Effective communication.
3. STATEMENT OF PROBLEM
The present study tries to understand whether TQM practices can be adopted in the brick
manufacturing units and the impact of the same if adopted.
4. OBJECTIVES

To understand the TQM practices followed in bricks manufacturing units.

To understand how TQM practices had an impact on quality enhancement, sales, increase in
customer base and profitability.
5. METHODOLOGY
The present study is conducted on the basis of primary as well as secondary data .Primary
data was collected from the supervisors and the production department of the selected brick
manufacturing units. Simultaneously observation was also used to collect more authentic data.
The secondary data was collected towards understanding the quality process, quality
management techniques and manufacturing process of bricks. Percentile method statistical
tool is adopted for the study.
6. REVIEW OF LITERATURE

Thomas C Powell (1995) in his article “Total quality management as a competitive advantage:
A review and empirical study”. He says that TQM is a potential source to sustain for a longer
period and he has done an empirical study on TQM performance. In his article he has
suggested that the total quality management gives advantage on open culture, employee
empowerment and executive commitment. He also says that the quality training, process
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Harshitha M and Dr. Ravi Kumar
improvement and benchmarking does not generally produce advantage. He concludes that the
organization can acquire the competitors with or without TQM ideology.

Ismail Sila and Maling Embrahimpour (2000) “An investigation of total quality management”.
His study focus on factors of total quality management and he also says that TQM factors are
classified into 25 categories. TQM is an important factor to be considered in a manufacturing
process and managing helps in better development of quality.

Ozden Bayazit, Birsen Karpak (January 2007) “An analytical network process-based
framework for successful total quality management: An assessment of manufacturing
industry”. In his study he has done an analytic network process to identify the impact of
different factors on TQM.

Lisbeth M Ottosen (November 2007) “Salt-related problems in brick masonry and electro
kinetic removal of salts”. In his study he had said that if the newly plastered brick shows the
dark area at certain the height, it means that there is a problem in the salt content. He also says
that the salt content can be removed by applying the electric DC field to the bricks.

Alaa.A.Shakir, Siva Kumar Naganathan, Kamal Nasharuddin Bin Mustapha (January 2013)
“Development of bricks from waste material: A review paper”. This paper reviewed recycling
various waste material in bricks manufacturing. The effects of wastes on the bricks as
physical, mechanical properties will be reviewed and recommendations for future research as
out comings of this review will be given. This reviewed approach on bricks manufacturing
from waste is useful to provide potential and sustainable solution to improve their business
and they recycled the raw materials.

Mohamed Ismail Mohideen Bawa (January 2011) “Quality control in small and medium brick
industry”: In his study he has identified the causes for the quality defects and has suggested
about the quality improvements. He has attempted to find out the length quality of brick and
has been able to improve the quality by continuous improvement.

Piotr Matysek and Michal Witkowski (October 2015) “A Comparative Study on the
Compressive Strength of Bricks from Different Historical Periods”. This was conducted based
on the hand model and mechanically formed bricks and the strength was determined on
rectangular premises and on cylindrical cut out from the bricks.

Shikhar Shrimali (January 2017) “Bricks from waste plastic”. In this paper the author has
studied about the all scenario and she has developed the effective way for utilizing the soft
plastic waste and recycling into plastic bricks which are very light in weight and can resist
high amount of pressure as compared to standard modular bricks.
7. ANALYSIS AND INTERPRETATION
7.1. Objective
To understand the TQM practices followed in bricks manufacturing units.
The present study reviles that the TQM practices have been adopted in the selected brick
manufacturing units. It was observed that TQM practices have brought in considerable
changes towards the approach of modern business techniques, quality consciousness and
changes accordingly in the TQM variables studied about.
Process Thinking
From past to 10-20 years there is a change in the process of manufacturing of the bricks.
Before they used to do the soft mud process and now they have change to more quality bricks.
The hand work has reduced and they also have checking the bricks in each process by
pressure check. In those days they used to take more time for manufacturing the bricks and
now the time maintenance has been able to manage.
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Does the Total Quality Management Enhance the Quality? Evidence from Selected Manufacturing
Units; Bricks
Table 1 Shows about customer satisfaction in terms of sales increase on adoption of TQM practice
Increase in sales
Years
Increase in units
2010-2012
42800 units
2012-2014
52600 units
2014-2016
56800 units
2016-2018
63100 units
[Source: company records]
It can be observed from the Tale 2.1 that customer satisfaction towards the product and
servicing is increasing year by year that can be witnessed from increase in sales. Respondent
stated this growth was realized only after adoption of TQM practice in manufacturing the
units.
Table 2 Shows about Employee commitment
Financial years
Total no of
employees joined
the organization
2010-2012
8
2012-2014
3
2014-2016
4
2016-2018
1
[Source: Company records]
Cumulative
strength
28
31
34
35
Total no of
employees left the
organization
0
1
0
0
Cumulative
strength
28
30
34
35
The block of financial year from 1010-2018 shows an increase of 8 employee’s average
increase of 1.2 employees in the block of 2 years. The increase in the employees was to fill
the production labor gap for the increased production demand. The attrition rate is almost
negligible which shows which high lights the employee consistency in their commitment.
Strategic Thinking
The respondent stated about strategic thinking process adopted that helped effective decision
making for the growth of organization. Dynamic thinking process was adopted wherein they
were able to assess and give the changes that are happening in the market. Looked into SWOT
analysis of the concern and developed futuristic development plans for themselves. Result of
which could be noticed in the form of effective advertisement , change in approach of
employment where in an employment mix was developed including skilled, semi-skilled,
unskilled strategically in requirement of the work force in relation to production demand.
Change In the investment pattern including different capital mixes, change in procurement
pattern, credit management where some of them.
Integrated system
Adoption of 4 P’s can be seen in this company responded explained about the changes in the
product processing method adopted (Pressure check). Further he explained about the
promotion methods adopted to increase the market share (marketing promotional methods).
The price change adoption also has been taken into consideration as and when price change
has been observed in the market. The new three agents covering 3 untapped areas of Mysore
(Bogadi, Vijaynagara, and Saraswathipuram) and one outlet yet (Hebbal) where demand is
growing up is opened.
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Table 3 Shows about the Decision based on facts
Years
Increase in investment Increase in production
Development of
quantity
production units
2010-2012
15000
48200 units
0
2012-2014
25300
52600 units
0
2014-2016
36700
56800 units
1 production unit
2016-2018
52100
63100 units
1 outlet
[Source: Company records]
It can be observed from the table that decisions has been taken appropriately based on the
need of the hour and market facts. Increase in investment can be observed as and when the
demand for and production of bricks manufacturing has increased. In order to meet the
increased production and sales one production unit at (Vijaynagara) and one outlet at (Hebbal)
has been expanded.
Effective Communication
The adoption of effective communication channels has been witnessed. Initially it was word
of mouth, pleasant interaction with the customer base followed by adoption of new
advertising techniques like print media, multi-media is observed as change in the adoption of
effective communication methods by the manufacturing unit.
Continues Improvement
The respondent stated about continues improvement has been able to notice after adoption of
TQM. The quality of bricks has improved and they also change in the bricks. The continuous
improvement of technology, training the staff has helped the company to increase their sales
and quality.
7.2. Objective
To understand how TQM practices had an impact on quality enhancement, sales
improvements, increase in customer base and profitability.
Table 1 Shows about the Quality enhancement
Parameters
Time consumption in
manufacturing per unit
wastage
Durability
Concrete mix
consumption(plastering)
Before adoption of TQM
After adoption of TQM
18-20 minutes
11-12 minutes
Solid wastage of some 300
grams per unit
20 years
7.29 bags of cement for 1
cubic meter of concrete
Solid waste of some 162
grams per unit
28 years
6 bags of cement for one
cubic meter of concrete
[Source: Company records]
It can be observed from the table that there is improvement in the quality enhancement of
the company. We can see that there is a change in all the parameters after adopting TQM. The
consumption of time in manufacturing per unit of the bricks has reduced. Further there is also
decrease in wastage and has been able to utilize the resources properly. The durability of
bricks has almost extended to 28 years than before the adoption of TQM. The decrease in the
concrete consumption can be seen and they have now decrease to 6 bags of cement for one
cubic meter of concrete.
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Does the Total Quality Management Enhance the Quality? Evidence from Selected Manufacturing
Units; Bricks
Table 2 Shows about the Sales improvements
Years
2010-2012
2012-2014
2014-2016
2016-2018
[Source: Company records]
Improvements
9200 units
13800 units
16400 units
19700 units
It can be observed from the table that sales improvements towards the product and
servicing is increasing year by year that can be witnessed from sales improvements.
Respondent stated this growth was realized only after adoption of TQM practice in
manufacturing the units.
Table 3 Shows about the Increase in the customer base
Years
Increase in customer
2010-2012
20
2012-2014
17
2014-2016
19
2016-2018
15
[Source: Company records]
It can be observed from the table that there is increase in the customer base. The
customers are the contractors that are constantly purchasing from the selected manufacturing
units. The company has been able to maintain their customers year by year after adoption of
TQM practices.
Table 4 Shows about the profitability
Year
2010-2012
2012-2014
2014-2016
2016-2018
[Source: Company records]
profitability
Rs.68480
Rs.92576
Rs.85200
Rs.99698
It can be observed from the above table that there is increase in the profit of the company
by adoption of the total quality management. The company has able to meet their company
targets. We can see that there is constant increase of profit in the 2010-2012 and 2012-2014.
There is a small amount off decrease in the 2014-2016 and again there was a decrease in the
year 2016-2018. We can able see the increase in profit year by year.
8. KEY FINDINGS

It was found that the selected manufacturing unit of brick has adopted all 8 TQM parameters
as their TQM practices.

The study shows that on the adoption of TQM practices has impacted positively on quality
enhancement, sales improvement, increase in customer base and profitability.
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9. CONCLUSIONS
The study started with the investigating questions of TQM practices adoption in selected brick
manufacturing units. On the observation made through the field study and the records of the
manufacturing units it was found that TQM practices have brought in considerable change in
the organizational growth. The growth is observed in quality enhancement of bricks, effective
employment management, modern communicative adoption increase in sales and customer
base and ultimately an enhancement in goodwill and profit of the organization.
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[4]
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Development of bricks from waste material: A review paper.
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