Management of Quality
Chapter 9
GM Recall
• http://www.cbsnews.com/videos/gm-recalls8-2-million-more-cars/
• Work as a group and prepare to answer the
following questions:
– What is the defect?
– How many have GM recalled?
– (discussion) Will GM survive?
Learning Objectives
• Define the term quality as it relates to
products and as it relates to services.
• Identify the determinants of quality.
• Explain why quality is important and the
consequences of poor quality.
• Describe TQM.
• Describe and use various quality tools.
Quality Management
• For a decade or so, quality was an important focal point in business. After
a while, this emphasis began to fade as other concerns took precedence
• There has been a recent resurgence in attention to quality given recent
experiences with the costs and adverse attention associated with highly
visible quality failures:
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Auto recalls
Toys
Produce
Dog food
Pharmaceuticals
• Quality
– The ability of a product or service to consistently meet or exceed customer
expectations
Dimensions of Product Quality
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Performance—main characteristics of the product
Aesthetics—appearance, feel, smell, taste
Special features—extra characteristics
Conformance—how well the product conforms to
design specifications
Reliability—consistency of performance
Durability—the useful life of the product
Perceived quality—indirect evaluation of quality
Servicebility—handling of complaints or repairs
Consistency—quality doesn't vary.
Dimensions of Service Quality
• Convenience—the availability and accessibility of the service
• Reliability—ability to perform a service dependably, consistently,
and accurately
• Responsiveness—willingness to help customers in unusual
situations and to deal with problems
• Time—the speed with which the service is delivered
• Assurance—knowledge exhibited by personnel and their ability to
convey trust and confidence
• Courtesy—the way customers are treated by employees
• Tangibles—the physical appearance of facilities, equipment,
personnel, and communication materials
• Consistency—the ability to provide the same level of good quality
repeatedly
• Expectations—Meet (or exceed) customer expectations.
Determinants of Quality
• Quality of design
– Intention of designers to include or exclude features in a product or
service
• Quality of conformance
– The degree to which goods or services conform to the intent of the
designers
• Ease-of-Use and user instructions
– Increase the likelihood that a product will be used for its intended
purpose and in such a way that it will continue to function properly
and safely
• After-the-sale service
– Taking care of issues and problems that arise after the sale
Benefits of Good Quality
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Enhanced reputation for quality
Ability to command premium prices
Increased market share
Greater customer loyalty
Lower liability costs
Fewer production or service problems
Lower production costs
Higher profits
The Consequences of Poor Quality
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Loss of business
Liability
Productivity
Costs (e.g., repair, replacement)
The Costs of Quality
• Appraisal Costs
– Costs of activities designed to ensure quality or uncover defects
• Inspectors, testing, test equipment, labs, quality audits, quality control, field
testing
• Prevention Costs
– Cost of preventing defects from occurring
• Planning, administration, working with vendors, training, quality assurance,
design and production.
• Failure Costs
– Costs incurred by defective parts/products or faulty services.
– Internal Failure Costs
• Costs incurred to fix problems that are detected before the product/service is
delivered to the customer.
– External Failure Costs
• All costs incurred to fix problems that are detected after the product/service is
delivered to the customer
Costs of Quality
Total
Cost
Total Cost
External Failure
Internal Failure
Prevention
Appraisal
Quality Improvement
MIS 373: Basic Operations Management
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Case Study
• Toyota settles with government for $1.2 billion in recall
probe (washingtonpost.com 3/19/14)
– In 2009, the driver of a borrowed Lexus — made by Toyota —
was unable to stop the vehicle as it careened off the highway at
120 miles per hour, killing three people. “There’s no
brakes…Hold on and pray,” one of the passengers said to a 911
operator.
– Toyota Motor Corp. has agreed to a $1.2 billion settlement to
end a U.S. Justice Department criminal probe into its handling of
safety problems, Attorney General Eric Holder announced.
– “The $1.2 billion payment represents the largest criminal
penalty imposed on a car company in U.S. history,” Holder said
in a statement. “This is appropriate given the extent of the
deception carried out by Toyota in this case. Put simply,
Toyota’s conduct was shameful,” Holder said.
Responsibility for Quality
• Everyone in the
organization has some
responsibility for
quality, but certain
areas of the
organization are
involved in activities
that make them key
areas of responsibility
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Top management
Design
Procurement
Production/operations
Quality assurance
Packaging and shipping
Marketing and sales
Customer service
Quality Certification
• ISO 9000
– Set of international standards on quality management and quality
assurance, critical to international business
• ISO 14000
– A set of international standards for assessing a company’s
environmental performance
• ISO 24700
– Pertains to the quality and performance of office equipment that
contains reused components
– A Marketed product that contains reused components performs
equivalent to new.
ISO 9000 series standards
• ISO 9000
– International recognition
– Encourages quality management procedures, detailed
documentation, work instructions, and recordkeeping
– Applies to any organization regardless of size or
industry
– Over one million certifications in 178 countries
– Critical for global business
– Includes ISO 9000:2005 (definitions), ISO 9001:2008
(requirements) and ISO 9004:2009 (continuous
improvement)
ISO 9000 series standards
• Management principles
– Top management leadership
– Customer satisfaction
– Continual improvement
– Involvement of people
– Process analysis
– Use of data-driven decision making
– A systems approach to management
– Mutually beneficial supplier relationships
Total Quality Management
• A philosophy that involves everyone in an organization in a
continual effort to improve quality and achieve customer
satisfaction.
• TQM approach
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Find out what the customer wants.
Design a product or service that meets or exceeds customer
wants.
Design processes that facilitate doing the job right the first
time.
Keep track of results.
Extend these concepts throughout the supply chain.
Top management must be involved and committed.
Elements of TQM
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Continuous improvement
Competitive benchmarking
Employee empowerment
Team approach
Decisions based on facts rather than opinions
Knowledge of tools
Supplier quality
Champion
Quality at the source
Suppliers
BMW QUALITY MANAGEMENT
Can we identify the TQM elements from this video?
•Continuous improvement
•Competitive benchmarking
•Employee empowerment
•Team approach
•Decisions based on facts rather than opinions
•Knowledge of tools
•Supplier quality
•Champion
•Quality at the source
•Suppliers
PDSA Cycle
• Plan-Do-Study-Act (PDSA) Cycle
– Plan
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Begin by studying and documenting the current process.
Collect data on the process or problem
Analyze the data and develop a plan for improvement
Specify measures for evaluating the plan
Act
Plan
Study
Do
– Do
• Implement the plan, document any changes made, collect data for analysis
– Study
• Evaluate the data collection during the do phase
• Check results against goals formulated during the plan phase
– Act
• If the results are successful, standardize the new method and communicate it to the
relevant personnel
• Implement training for the new method
• If unsuccessful, revise the plan and repeat the process
MIS 373: Basic Operations Management
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Six Sigma
• Two meanings
– Statistical definition of a process that is 99.9997% capable, 3.4
defects per million opportunities (DPMO)
– A program designed to reduce defects, lower costs, save time,
and improve customer satisfaction
• A comprehensive system for achieving and sustaining
business success
Lower limits
2,700 defects/million
6
Upper limits
3.4 defects/million
Mean
±3
MIS 373: Basic Operations Management
±6
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Basic Quality Tools
• Flowcharts. A flowchart is a visual representation of a process. As a problemsolving tool, a flowchart can help investigators in identifying possible points in a
process where problems occur.
• Check Sheets. A check sheet is a simple tool frequently used for problem
identification. Check sheets provide a format that enables users to record and
organize data in a way that facilitates collection and analysis.
• Histograms. A histogram can be useful in getting a sense of the distribution of
observed values.
• Pareto Analysis. Pareto analysis is a technique for focusing attention on the
most important problem areas.
• Scatter Diagrams. A scatter diagram can be useful in deciding if there is a
correlation between the values of two variables.
• Cause-and-Effect Diagrams. A cause-and-effect diagram offers a structured
approach to the search for the possible cause(s) of a problem.
• Run Charts. A run chart can be used to track the values of a variable over
time. This can aid in identifying trends or other patterns that may be occurring.
• Control Charts. A control chart can be used to monitor a process to see if the
process output is random. It can help detect the presence of correctable causes
of variation.
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MIS 373: Basic Operations Management
Basic Quality Tools
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Basic Quality Tools
Check Sheet
Pareto Diagram
(the 80/20 rule)
14
10
5
2
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25
Basic Quality Tools
Scatter Diagram
Cause-and-Effect Diagram
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Basic Quality Tools
• Run Charts. A run chart can be used to track the
values of a variable over time. This can aid in
identifying trends or other patterns that may be
occurring.
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Basic Quality Tools
• Control Charts. A control chart can be used to
monitor a process to see if the process output is
random. It can help detect the presence of
correctable causes of variation.
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Recap