02 TQM
02 TQM
02 TQM
approaches. Deming worked with passion until his death in December 1993
at the age of 93, knowing he had little time left to make a difference in his
home country. When asked how he would like to be remembered, Deming
replied, “I probably won’t even be remembered.” Then after a long pause, he
added, “Well, maybe . . . as someone who spent his life trying to keep Amer-
ica from committing suicide.”2
Unlike other management gurus and consultants, Deming never defined
or described quality precisely. In his last book, he stated, “A product or a
service possesses quality if it helps somebody and enjoys a good and sus-
tainable market.”3 Deming’s philosophy is based on improving products
and services by reducing uncertainty and variability in the design and man-
ufacturing processes. In Deming’s view, variation is the chief culprit of poor
quality. In mechanical assemblies, for example, variations from specifications
for part dimensions lead to inconsistent performance and premature wear
and failure. Likewise, inconsistencies in service frustrate customers and
damage a firm’s image. To achieve reduced variation, he advocates a never-
ending cycle of product design, manufacture, test, and sales, followed by
market surveys, then redesign, and so forth.
Deming stresses that higher quality leads to higher productivity, which
in turn leads to long-term competitive strength. The Deming “chain reac-
tion,” shown in Figure 2.1, summarizes this view. This theory states that
improvements in quality lead to lower costs because of less rework, fewer
mistakes, fewer delays and snags, and better use of time and materials.
Lower costs, in turn, lead to productivity improvements. With better quality
and lower prices, the firm can achieve a higher market share and thus stay
Improve quality
Productivity improves
Stay in business
in business, providing more and more jobs. Deming states emphatically that
top management has the overriding responsibility for quality improvement.
The Deming philosophy of quality and management is complex; indeed,
several books have been written in an effort to explain and interpret it.
Many of the principles are very basic yet difficult to put into practice. Dem-
ing has summarized his philosophy in what he calls “A System of Profound
Knowledge.”
Profound Knowledge
Profound knowledge consists of four parts: (1) appreciation for a system, (2)
some knowledge of the theory of variation, (3) theory of knowledge, and (4)
psychology.
Systems
A system is a set of functions or activities within an organization that work
together to achieve organizational goals. For example, a McDonald’s restaurant
can be viewed as a system. It consists of the order-taker/cashier subsystem,
grill and food preparation subsystem, drive-through subsystem, and so on.
The components of any system must work together for the system to be
effective. When parts of a system interact, the system as a whole cannot be
understood or managed solely in terms of its parts. To run any system, man-
agers must understand the interrelationships among all subsystems and the
people that work in them. One example is performance appraisal. The fol-
lowing are some of the factors within a system that affect the individual per-
formance of an employee:
• training received
• information and resources provided
• leadership of supervisors and managers
• disruptions on the job
• management policies and practices
of such inferior quality that they will cause excessive costs in adjustment and
repair during manufacture and assembly. Although the purchasing depart-
ment’s track record might look good, the overall system will suffer.
This theory applies to managing people also. Pitting individuals or depart-
ments against each other for resources is self-destructive. The individuals or
departments will perform to maximize their expected gain, not that of the
firm as a whole. Employees must cooperate with each other. Likewise, sales
quotas or arbitrary cost reduction goals do not motivate people to improve
the system and, ultimately, customer satisfaction; workers will perform only
to meet the quotas and goals.
Variation
The second part of Profound Knowledge is some understanding of statisti-
cal theory, particularly as it applies to variation. Just as no two snowflakes
are exactly alike, no two outputs from any production process are exactly
alike. A production process contains many sources of variation. Different lots
of material will vary in strength, thickness, or moisture content, for example.
Cutting tools will have inherent variation in strength and composition. Dur-
ing manufacturing, tools will experience wear, machine vibrations will cause
changes in settings, and electrical fluctuations will cause variations in power.
Operators may not position parts on fixtures consistently.
The complex interaction of all these variations in materials, tools,
machines, operators, and the environment cannot be understood. Variation
due to any individual source appears random; however, their combined
effect is stable and can usually be predicted statistically. Factors that are pres-
ent as a natural part of a process are called common causes of variation.
Common causes generally account for about 80 to 90 percent of the
observed variation in a production process. The remaining 10 to 20 percent
result from special causes of variation, often called assignable causes. Special
causes arise from external sources that are not inherent in the process. A bad
batch of material purchased from a supplier, a poorly trained operator, exces-
sive tool wear, or miscalibration of measuring instruments are examples of
special causes. Special causes result in unnatural variations that disrupt the
random pattern of common causes. Hence they are generally easy to detect
using statistical methods, and it is usually economical to remove them.
A system governed only by common causes is said to be stable. Under-
standing a stable system and the differences between special and common
causes of variation is essential for managing any system. Management can
make two fundamental mistakes in attempting to improve a process:
In the first case, tampering with a stable system will actually increase the vari-
ation in the system. In the second case, we can miss the opportunity to elim-
Chapter 2: Approaches to Total Quality 47
Target
Specification limits
48 Part I: Introduction to Total Quality
Theory of Knowledge
The third part of Profound Knowledge is the theory of knowledge—a branch
of philosophy concerned with the nature and scope of knowledge, its pre-
suppositions and bases, and the general reliability of claims to knowledge.
Deming was influenced greatly by Clarence Irving Lewis, author of Mind
and the World.5 Lewis stated, “There is no knowledge without interpretation.
If interpretation, which represents an activity of the mind, is always subject
to the check of further experience, how is knowledge possible at all? . . . An
argument from past to future at best is probable only, and even this proba-
bility must rest upon principles which are themselves more than probable.”
Deming emphasizes that there is no knowledge without theory and that
experience alone does not establish a theory. To copy an example of success
without understanding it with the aid of theory may lead to disaster. Expe-
rience only describes; it cannot be tested or validated. Theory establishes a
cause-and-effect relationship that can be used for prediction. Theory leads
to questioning and can be tested and validated—it explains why. Many
companies have jumped on the latest fads advocated by popular business
consultants. Methods that have sustained success are grounded in theory.
Managers have a responsibility to learn and apply theory.
Psychology
Psychology helps us to understand people, interactions between people and
circumstances, interactions between leaders and employees, and any system of
management. People differ from one another. A leader must be aware of these
differences and use them to optimize everybody’s abilities and inclinations.
Many managers operate under the supposition that all people are alike
and treat them as interchangeable components of a process. However, peo-
ple learn in different ways and at different speeds and perform at different
levels. Leaders have an obligation to make changes in the system of manage-
ment that will bring improvement. People have an innate need for relation-
ships with other people and for self-esteem and respect. Circumstances pro-
vide some people with dignity and self-esteem and deny them to other
people. People inherit the right to enjoy work. Psychology helps us to nur-
ture and preserve people’s positive innate attributes.
1. Create and publish to all employees a statement of the aims and purposes of
the company or other organization. The management must demonstrate
constantly their commitment to this statement.
2. Learn the new philosophy, top management and everybody.
3. Understand the purpose of inspection, for improvement of processes and
reduction of cost.
4. End the practice of awarding business on the basis of price tag alone.
5. Improve constantly and forever the system of production and service.
6. Institute training.
7. Teach and institute leadership.
8. Drive out fear. Create trust. Create a climate for innovation.
9. Optimize toward the aims and purposes of the company the efforts of teams,
groups, staff areas.
10. Eliminate exhortations for the workforce.
11. (a) Eliminate numerical quotas for production. Instead, learn and institute
methods for improvement.
(b) Eliminate MBO (Management by Objective). Instead, learn the capabilities
of processes and how to improve them.
12. Remove barriers that rob people of pride of workmanship.
13. Encourage education and self-improvement for everyone.
14. Take action to accomplish the transformation.
Hillerich & Bradsby Co. (H&B) has been making the Louisville Slugger brand of
baseball bat for more than 115 years. In the mid-1980s, the company faced
significant challenges from market changes and competition. CEO Jack Hil-
lerich attended a four-day Deming seminar, which provided the basis for the
company’s current quality efforts. Returning from the seminar, Hillerich decided
to see what changes that Deming advocated were possible in an old company
with an old union and a history of labor-management problems. Hillerich per-
suaded union officials to attend another Deming seminar with five senior man-
agers. Following the seminar, a core group of union and management people
developed a strategy to change the company. They talked about building trust
and changing the system “to make it something you want to work in.”
Employees were interested, but skeptical. To demonstrate their commit-
ment, managers examined Deming’s 14 Points, and picked several they
believed they could make progress on through actions that would demon-
strate a serious intention to change. One of the first changes was the elimi-
nation of work quotas that were tied to hourly salaries and a schedule of
warnings and penalties for failures to meet quotas. Instead, a team-based
approach was initiated. While a few workers took advantage of the change,
overall productivity actually improved as rework decreased because workers
were taking pride in their work to produce things the right way first. H&B also
eliminated performance appraisals and commission-based pay in sales. The
company has also focused its efforts on training and education, resulting in
an openness for change and capacity for teamwork. Today, the Deming phi-
losophy is still the core of H&B’s guiding principles.
54 Part I: Introduction to Total Quality
ISO 9000:2000
As quality became a major focus of businesses throughout the world, vari-
ous organizations developed standards and guidelines. Terms such as qual-
ity management, quality control, quality system, and quality assurance acquired
different, and sometimes conflicting meanings from country to country,
within a country, and even within an industry.10 As the European Commu-
nity moved toward the European free trade agreement, which went into
effect at the end of 1992, quality management became a key strategic objec-
tive. To standardize quality requirements for European countries within the
common market and those wishing to do business with those countries, a
specialized agency for standardization, the International Organization for
Standardization, founded in 1946 and composed of representatives from the
national standards bodies of 91 nations, adopted a series of written quality
standards in 1987, which were revised in 1994, and again (significantly) in
2000. The most recent version is called the ISO 9000:2000 family of standards.
The standards have been adopted in the United States by the American
National Standards Institute (ANSI) with the endorsement and cooperation of
the American Society for Quality (ASQ). The standards are recognized by about
100 countries, including Japan. In some foreign markets, companies will not
buy from noncertified suppliers. Thus, meeting these standards is becoming a
requirement for international competitiveness. The standards are intended to
apply to all types of businesses, including electronics and chemicals, and to
services such as health care, banking, and transportation.
ISO 9000 defines quality system standards, based on the premise that cer-
tain generic characteristics of management practices can be standardized,
and that a well-designed, well-implemented, and carefully managed quality
system provides confidence that the outputs will meet customer expecta-
tions and requirements. The standards were created to meet five objectives:
1. Achieve, maintain, and seek to continuously improve product quality
(including services) in relationship to requirements.
2. Improve the quality of operations to continually meet customers’ and stake-
holders’ stated and implied needs.
3. Provide confidence to internal management and other employees that qual-
ity requirements are being fulfilled and that improvement is taking place.
4. Provide confidence to customers and other stakeholders that quality
requirements are being achieved in the delivered product.
5. Provide confidence that quality system requirements are fulfilled.
Source: The terms and definitions taken from the quality management principles of ISO 9000 are reproduced with the
permission of the International Organization for Standardization, ISO. They can be obtained from any ISO member and
from the Web site of the ISO Central Secretariat at the following address: www.iso.org. Copyright remains with ISO.
The criteria consist of a hierarchical set of categories, items, and areas to address.
The seven categories are
1. Leadership: This category examines how an organization’s senior leaders
address values, direction, and performance expectations, as well as their
focus on customers and other stakeholders, empowerment, innovation,
and learning. Also examined is how an organization addresses its respon-
sibilities to the public and supports its key communities.
2. Strategic Planning: This category examines how an organization develops
strategic objectives and action plans. Also examined are how chosen strate-
gic objectives and action plans are deployed and how progress is measured.
3. Customer and Market Focus: This category examines how an organization
determines requirements, expectations, and preferences of customers and
markets. Also examined is how the organization builds relationships with
customers and determines the key factors that lead to customer acquisi-
tion, satisfaction, and retention and to business expansion.
4. Information and Analysis: This category examines an organization’s infor-
mation management and performance measurement systems and how
the organization analyzes performance data and ensures hardware and
software quality.
5. Human Resource Focus: This category examines how an organization moti-
vates and enables employees to develop and utilize their full potential in
alignment with the organization’s overall objectives and action plans.
Also examined are the organization’s efforts to build and maintain a
work environment and an employee support climate conducive to per-
formance excellence and to personal and organizational growth.
6. Process Management: This category examines the key aspects of an organi-
zation’s process management, including customer-focused design, product
66 Part I: Introduction to Total Quality
and service delivery, key business, and support processes. This category
encompasses all key processes and all work units.
7. Business Results: This category examines an organization’s performance
and improvement in key business areas—customer satisfaction, product
and service performance, financial and marketplace performance, human
resource results, and operational performance. Also examined are per-
formance levels relative to those of competitors.
You should consult the actual criteria document (which is updated annu-
ally) for clarifying notes and explanations. Slightly different criteria are writ-
ten for business, health care, and education, and all may be downloaded
from the Baldrige Web site.
The seven categories form an integrated management system as illustrated
in Figure 2.3. The umbrella over the seven categories reflects the focus that
organizations must have on customers through their strategy and action
plans for all key decisions. Leadership, Strategic Planning, and Customer
and Market Focus represent the “leadership triad,” and suggest the impor-
tance of integrating these three functions. Human Resource Focus and Process
Management represent how the work in an organization is accomplished and
leads to Business Results. These functions are linked to the leadership triad.
Organizational Profile:
Environment, Relationships, and Challenges
2 5
Strategic Human
Planning Resource
Focus
1 7
Leadership Business
Results
3 6
Customer Process
and Market Management
Focus
4
Information and Analysis
Chapter 2: Approaches to Total Quality 67
• How do senior leaders set and deploy organizational values, short- and
longer-term directions, and performance expectations, including a focus
on creating and balancing value for customers and other stakeholders?
Include how senior leaders communicate values, directions, and expec-
tations through your leadership system and to all employees.
• How do senior leaders create an environment for empowerment, inno-
vation, organizational agility, and organizational and employee learning?
When Horst Schulze (who retired in 2001) became president in 1988, he and his
leadership team personally took charge of managing for quality because they
realized that managing for quality could not be delegated. They personally estab-
lished the Gold Standards, which are the foundation of The Ritz-Carlton quality phi-
losophy. The Gold Standards, in their simplicity, represent an easy-to-understand
definition of service quality, and are aggressively communicated and internalized
at all levels of the organization. The constant and continuous reinforcement tech-
niques of the Gold Standards, led by senior leaders, include lectures at new
employee orientation, developmental training, daily lineup meetings, administra-
tion of both positive and negative reinforcement, mission statements displayed,
distribution of Credo cards, The Credo as first topic of internal meetings, and peer
pressure. As a result, employees have an exceptional understanding and devotion
to the company’s vision, values, quality goals, and methods.
Since 1984, all members of senior leadership have personally ensured that
each new hotel’s goods and services are characteristic of The Ritz-Carlton on
opening day. An important aspect of this quality practice takes place during the
concentrated and intense “seven-day countdown” when senior leaders work side
by side with new employees using a combination of hands-on behavior modeling
and reinforcement. During these formative sessions, which all new employees
must attend, the president and COO personally interacts with every new employee,
both individually and in a group setting. The president personally creates the
employee-guest interface image and facilitates each department’s first vision state-
ment. Throughout the entire process, the senior leaders monitor work areas for
“start-up,” instill Gold Standards, model the company’s relationship management,
insist upon 100 percent compliance to customers’ requirements, and recognize
outstanding achievement. Senior leaders set direction through seven specific
approaches:
10-Year Vision: To Be The Premier Worldwide Provider of Luxury Travel and Hos-
pitality Products and Services
5-Year Mission: Product and Profit Dominance
3-Year Objectives: The Vital Few Objectives
1-Year Tactics: Key Production and Business Processes
Strategy: Customer and Market Focus Strategy with Action Plans
Methods: TQM—Application of Quality Sciences; Malcolm Baldrige National
Quality Award Criteria; The GreenBook, 2d edition (the company’s handbook of
quality processes and tools)
Foundation: Values and Philosophy—The Gold Standards, Credo, Motto, Three
Steps of Service, Basics, Employee Promise
Leadership effectiveness is evaluated on key questions of a semiannual employee
satisfaction survey and through audits on public responsibility. Gaps in leadership
effectiveness are addressed with development and training plans and extensive
use of developmental job assignments.
Chapter 2: Approaches to Total Quality 69
Score Approach/Deployment
Score Results
1 Leadership 120
1.1 Organizational Leadership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
1.2 Public Responsibility and Citizenship . . . . . . . . . . . . . . . . . . . . . . . . . 40
2 Strategic Planning 85
2.1 Strategy Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2 Strategy Deployment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6 Process Management 85
6.1 Product and Service Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.2 Business Processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3 Support Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
All applicants receive a feedback report that critically evaluates the com-
pany’s strengths and areas for improvement relative to the award criteria. The
feedback report, frequently 30 or more pages in length, contains the evaluation
team’s response to the written application. It includes a distribution of numer-
ical scores of all applicants and a scoring summary of the individual applicant.
This feedback is one of the most valuable aspects of applying for the award.
As the criteria have evolved to reflect the changing business environ-
ment, the word quality has been replaced by performance as a conscious
attempt to recognize that the principles of total quality are the foundation for
a company’s entire management system, not just the quality system. As Curt
Reimann, former director and architect of the Baldrige Award Program,
noted, “The things you do to win a Baldrige Award are exactly the things
you’d do to win in the marketplace. Our strategy is to have the Baldrige
Award criteria be a useful daily tool that simulates real competition.”
Texas Instruments (TI) Defense Systems & Electronics Group (acquired by Raytheon
Corporation in 1997) faced a critical issue that many businesses struggle with: Is
the payoff of greater competitive advantage worth the effort of achieving total qual-
ity, specifically competing for the Baldrige Award? Their answer is a definite yes.
TI understands firsthand that the real benefit of applying for the Baldrige Award lies
in adopting its quality criteria. The application itself is the single most powerful cat-
alyst for the kinds of organizational and cultural changes that companies must
make to compete.
TI’s commitment to quality and productivity improvement dates back to the
1950s. But, like most corporations, most of its efforts were aimed at improving
manufacturing and product quality. In the early 1980s, a total quality initiative was
formalized across the entire corporation. Some business units made tremendous
progress; the semiconductor operation in Japan won the Deming Prize in 1985.
When the Baldrige Award criteria appeared, TI used them to provide focus and
coherence to the activities across the corporation. Using the criteria, they were
able to tackle a part of total quality that previously had been unreachable: imple-
menting quality efforts in staff, support, and nonmanufacturing areas. In 1989, TI
asked every business unit to prepare a mock award application as a way of meas-
uring its progress. This task represented a radical change for some operations
because, until that time, most staff functions were not required to measure their
processes or their results.
The Defense Systems & Electronics Group’s self-assessment revealed that
they were a long way from applying for and winning the Baldrige Award. But the
group aggressively adopted the criteria as a blueprint for improving its business.
Many executives did not believe that the criteria could be applied to defense con-
tractors. Similarly, many executives today question whether small businesses can
realistically meet the Baldrige Award criteria. TI discovered that all companies have
one thing in common: customers. Focusing on customers to make the company
more competitive gives meaning to the award.
The Baldrige Award application process changed almost everything within the
Defense Systems & Electronics Group. Before applying, the group had no way of sys-
tematically measuring how well it understood its customers’ concerns, captured cus-
tomers’ feedback, or made improvements in interacting with customers. Mountains
of data were being collected, but most of the data measured internal criteria, not cus-
tomer satisfaction. The structured, hierarchical management environment made it dif-
ficult to adopt ideas from outside sources.
The Baldrige Award process provided a way to make the customer the center-
piece of daily activities. It led to much better communication with customers and
employees and accelerated progress toward less hierarchical, more functional work
teams. It changed the management process from an individual activity to a team
effort, leading to better decisions. Finally, it introduced two radical new ideas: bench-
marking and stretch goals. Changing the culture was not easy and did not happen
quickly. It took teamwork, consensus building, and buy in. At TI, it took about five
years of dedicated pulling in the same direction to begin seeing measurable results.
Chapter 2: Approaches to Total Quality 75
Many school districts are using the criteria. One large Chicago-area hospital
applied for the Baldrige-based Lincoln Award for Excellence and prepared
for its accreditation visit by JCAHO at the same time, recognizing the syn-
ergy and overlap of Baldrige principles and JCAHO standards.
Most states have developed award programs similar to the Baldrige
Award. State award programs generally are designed to promote an aware-
ness of productivity and quality, foster an information exchange, encourage
firms to adopt quality and productivity improvement strategies, recognize
firms that have instituted successful strategies, provide role models for other
businesses in the state, encourage new industry to locate in the state, and
establish a quality-of-life culture that will benefit all residents of the state.21
Each state is unique, however, and thus the specific objectives will vary. For
instance, the primary objectives of Minnesota’s quality award are to encour-
age all Minnesota organizations to examine their current state of quality and to
become more involved in the movement toward continuous quality improve-
ment, as well as to recognize outstanding quality achievements in the state.
Missouri, on the other hand, has as its objectives to educate all Missourians
in quality improvement, to foster the pursuit of quality in all aspects of Mis-
souri life, and to recognize quality leadership. Information about state award
programs can be found at the NIST Web site cited earlier in this section.
Electric Quality24
Florida Power and Light (FPL) is one of the largest electric utilities in the United
States. During the 1970s the company was forced to increase utility rates repeat-
edly because of increasing costs, slower sales growth, and stricter federal and state
regulations. The company had become bureaucratic and inflexible. In 1981 Marshall
McDonald, then chairman of the board, realized that the company had been con-
cerned with keeping defects under control rather than improving quality. Due to his
concern for quality, McDonald introduced quality improvement teams at FPL. Man-
agement knew this was a step in the right direction, but such teams alone would
not bring about the change needed for the company to survive. McDonald tried to
convince other executives that a total quality improvement process was needed,
but all the experts that FPL talked to were in manufacturing, while FPL was prima-
rily a service company. In 1983, while in Japan, McDonald met a president of Kan-
sai Electric Power Company, a Deming Prize winner, who told him about their total
quality efforts. Company officials began to visit Kansai regularly, and with their help,
FPL began its quality improvement program (QIP) in 1983.
Its quality efforts included empowering each department to develop improve-
ment plans, standardizing work routines, removing waste from them, promoting the
concept of internal customers, and enabling better practice to be replicated from one
location to another. FPL revamped a centralized suggestion system it had been using
for many years. Only about 600 suggestions had been submitted annually and it usu-
ally took six months for evaluation. A new decentralized system was proposed with
simplified procedures to improve the response time. Employees participated in the
implementation of their own suggestions. In 1988, 9,000 suggestions were submit-
ted; in 1989 this number increased to 25,000. As a result of these efforts, the aver-
age length of service interruptions dropped from about 75 minutes in 1983 to about
47 minutes in 1989; the number of complaints per 1,000 customers fell to one-third
of the 1983 level; safety has improved; and the price of electricity has stabilized. In
1989, FPL became the first non-Japanese company to win the Deming Prize.
Five years after winning the Deming Prize, FPL still had an unwavering commit-
ment to quality initiatives, which was noted by Dr. Noriaki Kano of the Union of Japan-
ese Scientists and Engineers, after observing presentations from 11 FPL business
units. Dr. Kano, who had served as a counselor to FPL since 1986, was “pleasantly
surprised” that FPL had simultaneously reduced costs and improved quality. Kano
noted that recent improvements were based on skills developed through QIP prac-
tices. For example, one team improved service reliability by reducing transformer fail-
ures due to lightning. Before, an average of 23 transformers out of 761 on their worst-
performing feeder failed each year. This number was reduced to zero failures, even
though lightning strikes had increased 250 percent. Newly installed transformers
incorporate the team’s recommended changes, and existing transformers are modi-
fied as needed. The team leader stated that they found creative ways to use quality
improvement tools and techniques to their best advantage without getting caught up
in excessive paperwork or attending compulsory meetings. “Like most employees,
we’re so familiar with the quality processes that it’s almost second nature.”
Chapter 2: Approaches to Total Quality 79
20. Summarize the framework of the Baldrige Award. What are its key
philosophical underpinnings?
21. Describe the key issues addressed in each of the seven categories of the
Criteria for Performance Excellence.
22. Prepare a list of specific actions that a high-scoring company in the
Baldrige Award process might take in each of the seven categories. How
difficult do you think it is for a company to score well in all the categories?
23. Create a matrix diagram in which each row is a category of the Baldrige
Award criteria and four columns correspond to a level of organizational
maturity with respect to quality:
• traditional management practices;
• growing awareness of the importance of quality;
• development of a solid quality management system;
• outstanding, world-class management practice.
In each cell of the matrix, list two to five characteristics that you would
expect to see for a company in each of the four situations above for that
criteria category. How might this matrix be used as a self-assessment
tool to provide directions for improvement?
24. Map the elements of ISO 9000:2000 against the Baldrige criteria. How are
they similar? How are they different?
CASES
Discussion Questions
1. What is Mary’s job? What might Deming say about this situation?
2. Drawing upon Deming’s principles, outline a plan to improve this
situation.
demand for its products was enormous, and the investors were plentiful.
Sales in the first three years were so good that backlogs of orders began to
pile up midway through the second year. Even with steadily increasing man-
ufacturing capacity (more factories, more shifts, more advanced technology),
the demand grew so fast that delivery times began to slip. Originally Won-
derTech promised to deliver machines within eight weeks. It intended to
return to that standard, but management told investors, “Our computers are
so good that some customers are willing to wait 14 weeks for them. We know
it’s a problem, and we’re working to fix it, but nonetheless they’re still glad
to get the machines, and they love ‘em when they get ‘em.”
The top managers knew that they had to add production capacity. After
six months of study, they decided to borrow the money to build a new fac-
tory. To make sure the growth continued, they pumped much of the incom-
ing revenue directly back into sales and marketing. The company sold its
products only through a direct sales force, so they had to hire and train more
salespeople. During the company’s third year, the sales force doubled.
Despite these efforts, sales started to slump at the end of the third year.
At this point, the new factory came on-line. Top management began to panic.
The marketing VP was under fire to turn sales around. He held high-powered
sales meetings with a single message: “Sell! Sell! Sell!” He fired the low per-
formers and increased sales incentives, added special discounts, and ran
new advertising promotions.
Sales rose again, as did order backlogs. After delivery times began to rise
again—first to 10 weeks, then to 12, and eventually to 16—the debate over
adding capacity started anew. This time management was more cautious.
Eventually the approval of a new facility was granted, but no sooner had the
papers been signed than a new sales crisis began. The same situation recurred
over the next several years. High sales growth occurred in spurts, followed
by periods of low or no growth. The company prospered modestly, but never
came close to fulfilling its original potential. Gradually, top managers began
to fear competition and frantically introduced ill-conceived improvements in
the product. They continued to push hard on marketing, but sales never
returned to their original rate of growth. Eventually the company collapsed.
Discussion Questions
1. What factors led to the demise of WonderTech?
2. Could these factors have been overcome through a better understanding
of a system as advocated in Deming’s Profound Knowledge?
ENDNOTES
1. W. Edwards Deming, Out of the Crisis, Cambridge, Mass.: MIT Center for Advanced Engi-
neering Study, 1986.
2. John Hillkirk, “World-Famous Quality Expert Dead at 93,” USA Today, December 21, 1993.
3. W. Edwards Deming, The New Economics for Industry, Government, Education, Cambridge,
Mass.: MIT Center for Advanced Engineering Study, 1993.
4. April 17, 1979; cited in L.P. Sullivan, “Reducing Variability: A New Approach to Quality,”
Quality Progress, Vol. 17, No. 7, July 1984, pp. 15–21.
5. Mineola, N.Y.: Dover, 1929.
6. Peter R. Scholtes, “Communities as Systems,” Quality Progress, July 1997, pp. 49–53.
86 Part I: Introduction to Total Quality
7. Reprinted from Out of the Crisis by W. Edwards Deming by permission of MIT and W.
Edwards Deming. Published by MIT, Center for Advanced Engineering Study, Cambridge, MA
02139. Copyright © 1986 by W. Edwards Deming.
8. Adapted from March Laree Jacques, “Big League Quality,” Quality Progress, August 2001, pp.
27–34.
9. Philip B. Crosby, Quality Is Free, New York: McGraw-Hill, 1979, pp. 200–201.
10. Michael J. Timbers, “ISO 9000 and Europe’s Attempts to Mandate Quality,” Journal of Euro-
pean Business, March/April 1992, pp. 14–25.
11. Amy Zuckerman, “ISO/QS-9000 Registration Issues Heating Up Worldwide,” The Quality
Observer, June 1997, pp. 21–23.
12. Amy Zuckerman and Rosalind McClymont, “Tracking the Ongoing ISO 9000 Revisions,”
Business Standards, Vol. 2, No. 2, March/April 2000, pp. 13–15. Jack West, with Charles A. Cian-
frani, and Joseph J. Tsiakals, “A Breeze or a Breakthough? Conforming to ISO 9000:2000,” Qual-
ity Progress, March 2000, pp. 41–44. See also by West et al., “Quality Management Principles:
Foundation of ISO 9000:2000 Family, Part 5,” Quality Progress, February 2000, pp. 113–116, and
“Quality Management Principles: Foundation of ISO 9000:2000 Family, Part 6,” Quality Progress,
March 2000, pp. 79–81.
13. Implementation guidelines are suggested by the case study by Steven E. Webster, “ISO 9000
Certification, A Success Story at Nu Visions Manufacturing,” IIE Solutions, April 1997, pp. 18–21.
14. AT&T Corporate Quality Office, Using ISO 9000 to Improve Business Processes, July 1994.
15. Hank Rogers, “Benchmarking Your Plant against TQM Best-Practices Plants, Part 2,” Qual-
ity Progress, April 1998, pp. 60–64.
16. ISO 9000 Update, Fortune, September 30, 1996, p. 134[J].
17. Astrid L. H. Eckstein, and Jaydeep Balakrishnan, “The ISO 9000 Series: Quality Management
Systems for the Global Economy,” Production and Inventory Management Journal, Vol. 34, No. 4,
Fourth Quarter 1993, pp. 66–71.
18. “Home Builder Constructs Quality with ISO 9000,” Quality Digest, February 2000, p. 13.
19. Adapted from The Ritz-Carlton Hotel Co., 1992 and 1999 Malcolm Baldrige National Qual-
ity Award application summaries. © 1992 The Ritz-Carlton Hotel Company. All rights reserved.
Reprinted with the permission of The Ritz-Carlton Hotel Company, L.L.C.
20. Adapted from Jerry R. Junkins, “Insights of a Baldrige Award Winner,” Quality Progress, Vol.
27, No. 3, March 1994, pp. 57–58.
21. Paul M. Bobrowski and John H. Bantham, “State Quality Initiatives: Mini-Baldrige to
Baldrige Plus,” National Productivity Review, Vol. 13, No. 3, Summer 1994, pp. 423–438.
22. Letter from W. Edwards Deming, Harvard Business Review, January-February 1992, p. 134.
23. JUSE, The Deming Prize Guide for Oversea Companies, TOKYO, 1992, p. 5.
24. Brad Stratton, “A Beacon for the World,” Quality Progress, May 1990, pp. 60–65; Al Henderson
and Target Staff, “For Florida Power and Light After the Deming Prize: The “Music Builds . . . and
Builds . . . and Builds,” Target, Summer 1990, pp. 10–21.
25. B. Nakkai, and J. Neves, “The Deming, Baldrige, and European Quality Awards,” Quality
Progress, April 1994, pp. 24–29.
26. Adapted from Peter Senge, The Fifth Discipline, New York: Doubleday, 1990.
27. Developed from a term paper by Ms. Debra Bergerhouse. Her contribution is gratefully
acknowledged.