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    3.4 Total Quality Management (TQM)

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    danishakimi
    Total Quality Management (TQM) is a management approach focused on quality that involves all members of an organization. It utilizes methods like 5S, Kaizen, and Just-in-Time (JIT) to continuously improve production and services. 5S establishes organization and cleanliness standards. Kaizen focuses on incremental improvements through PDCA cycles. JIT eliminates waste like overproduction and inventory to improve efficiency. Together, these TQM methods aim to enhance quality, productivity, and customer satisfaction for long-term organizational success.

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    3.4 Total Quality Management (TQM)

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    danishakimi
    106 views24 pages
    Total Quality Management (TQM) is a management approach focused on quality that involves all members of an organization. It utilizes methods like 5S, Kaizen, and Just-in-Time (JIT) to continuously improve production and services. 5S establishes organization and cleanliness standards. Kaizen focuses on incremental improvements through PDCA cycles. JIT eliminates waste like overproduction and inventory to improve efficiency. Together, these TQM methods aim to enhance quality, productivity, and customer satisfaction for long-term organizational success.

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    3.4 Total Quality Management (Tqm)

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    Total Quality Management (TQM) is a management approach focused on quality that involves all members of an organization. It utilizes methods like 5S, Kaizen, and Just-in-Time (JIT) to continuously improve production and services. 5S establishes organization and cleanliness standards. Kaizen focuses on incremental improvements through PDCA cycles. JIT eliminates waste like overproduction and inventory to improve efficiency. Together, these TQM methods aim to enhance quality, productivity, and customer satisfaction for long-term organizational success.

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    © All Rights Reserved
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    Download as pdf or txt
    106 views24 pages

    3.4 Total Quality Management (TQM)

    Uploaded by

    danishakimi
    Total Quality Management (TQM) is a management approach focused on quality that involves all members of an organization. It utilizes methods like 5S, Kaizen, and Just-in-Time (JIT) to continuously improve production and services. 5S establishes organization and cleanliness standards. Kaizen focuses on incremental improvements through PDCA cycles. JIT eliminates waste like overproduction and inventory to improve efficiency. Together, these TQM methods aim to enhance quality, productivity, and customer satisfaction for long-term organizational success.

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    of 24

    EA015 / EM015/ EE015/ EB015

    TOPIC 3 : ENGINEERING MANAGEMENT

    3.4 TOTAL QUALITY


    MANAGEMENT (TQM)
    LEARNING OUTCOMES
    3.4.1 Define Total Quality
    Management (TQM)

    3.4.2 Explain the following


    TQM Methods
    i) 5S
    II) KAIZEN
    III) JUST-IN-TIME (JIT)
    3.4.1 DEFINE TOTAL QUALITY MANAGEMENT
    A method or approach by which management and employees can
    involve in the continuous improvement of the production of goods and
    services.

    The combination of quality and management tools will increase buisness


    capability and reducing losses due to wasteful practice.

    Thus, TQM refers to management methods used to enhance quality and


    productivity in organizations.
    REFERRING TO ISO
    8402:1994
    "TQM is a management approach for
    an organisation, centered on quality,
    based on participation of all
    members and aiming at long term
    success through customer
    satisfaction , and benefit to all
    members of the organisation and
    society"
    3.4.2
    KAIZEN

    5S JIT
    3.4.2 TQM Method
    In matriculation syllabus,
    Total Quality Management
    consists of three methods ;
    KAIZEN, 5S and JIT

    These three methods can be


    use dependent and
    independent of one another.
    KAIZEN
    Kaizen means continual Focuses on simplification by
    improvement in which, Kai breaking down complex
    means “change” and zen means processes into their sub-
    “good.” processes and then improving
    them.
    Means making changes for the
    better on a continual, never- Since Kaizen discuss about
    ending basis. continual improvements, it is
    often inter-related to the use of
    The improvement aspect of 5S and Just-In-Time (JIT) in the
    Kaizen refers to people, process as a whole.
    processes, and products.
    KAIZEN:
    Another important aspect in
    KAIZEN is the implementation of
    PDCA Cycle.

    This cycle can be repeated as


    many times as is necessary to
    eliminate the problem
    successfully.

    If progress is not evident after


    several cycles, however, it would
    be a good idea to take another
    look at the original problem,
    perhaps aided by some new
    viewpoint
    THE PDCA CYCLE
    PLAN, DO, CHECK, ACT

    Include problem definition, gathering relavant


    information, identifying the root cause, Implement the solution chosen as best
    developing possible solution , and selecting
    the best alternative to implement, before
    undertaking any corrective steps .

    If the Check step confirmed that the problem


    Monitor the implemented solution and has been eliminated and that it is not likely to
    gather data relevant to the original recur, then the job is done. If, however, it was
    problem and any other areas of concern found otherwise that there is still a possibility
    of recurrence, then it will be necessary to
    “adjust” or "act" the implemented solution
    Able to identify exactly where things are going wrong and
    change the processes to reduced waste of resources.
    All people get certain responsibilities, thereby the employee
    morale increases tremendously.
    Teamwork increases because team able to think beyond the
    needs of their specific department.
    Customer requirements are placed at the forefront.

    Some companies need to bring about an immense change in


    their mind set and style of functioning.
    The initial excitement around using a new management style
    dies down all too soon, companies are not able to get the results
    they are looking for.
    KAIZEN EXAMPLE : Staff Driven “Stamp Out the Stamp
    5S
    SEIRI SEITON SEISO SEIKETSU SHITSUKE

    The Five-Step Plan or 5S is the Japanese approach to implementing


    Kaizen (continuous improvement) in their organisation

    5S is a framework that is not only focusing on cleanliness, it also


    emphasizes the use of a specific mindset and tools to maximise
    efficiency and profit

    It involves observing, analyzing, collaborating, and searching for


    waste and also involves the practice of removing waste.
    SEIRI (SORT)
    Sort out unnecessary items in the workplace and
    discard them

    SEITON (STORE)
    Arrange necessary Items in good order so they can
    easily be selected for use.

    SEISO (SHINE)
    Clean your workplace completely So that there is no
    dust on floors, machines or equipment

    SEIKETSU (STANDARDISE)
    Maintain one’s workplace so that it is productive
    and comfortable By repeating Seiri-Seiton-Seiso

    SHITSUKE (SUSTAIN)
    Train people to follow good work habitsand to strictly
    follow workplace rules
    ADVANTAGES- 5S DISADVANTAGES - 5S
    Establishes standards for Misunderstanding of what 5S
    operating equipment and accomplishes
    conducting processes thus
    reducing equipment Resistance to change
    breakdowns
    Not addressing problems in the
    Increase in productivity by workplace
    improving efficiency of the
    workspace Lack of management support

    Able to conduct a less chaotic


    mass-scale production due to
    the cleanliness and orderliness
    of the plant.
    5S - EXAMPLE
    Look at the example below to see 5S in action. Before 5S, spaces are
    cluttered and confusing. After 5S, everything has an assigned place,
    which is often marked with floor marking tape, labels, and other visual
    cues.
    JIT
    Just-In-Time

    Just-in-time (JIT) is also known as Lean Manufacturing


    or Lean.
    JIT brings the concept of reduction of waste and the
    improvement of work flow.
    The operation of JIT is one in which a better product is
    developed or a better service is delivered using less of
    everything required
    Lean focuses on reducing and, ideally, eliminating the following types
    of waste :

    Overproduction waste
    Making more of a product or delivering more of a service than is
    needed. For example, producing 100 parts when only 50 are needed.

    Inventory waste
    Carrying more inventory than is needed at a given time. For example, a
    bookstore carrying more copies of a given book than it is likely to sell.

    Motion waste
    Incorporating unnecessary movement into the production process or
    into the delivery of services. For example, programming too many
    motions into a CNC milling machine.
    Lean focuses on reducing and, ideally, eliminating the following types
    of waste :

    Transportation waste.
    Excess movement of parts in a manufacturing setting. For example, a part is
    machined at one side of the shop and need to be transported to the other
    end of the shop for assembling.

    Over-processing waste
    Going beyond customer requirements in ways that create no additional
    value when producing a product. For example, holding a given part to
    tighter tolerances than required in the specifications.

    Defects waste
    Creating rejected work or causing rework as the result of production or
    processing errors. For example, creating a mass-production faulty parts
    because it does not meet customer specifications
    Lean focuses on reducing and, ideally, eliminating the following types
    of waste :

    Waiting waste
    People, machines, or processes idling because something that is
    needed is not yet available. For example, airliner idling on the
    taxiway waiting for clearance to take off.

    Underutilization waste
    Underuse of the talent, skills, and creativity of people and the
    capabilities of technology. For example, failing to include the
    people who operate processes in brainstorming sessions aimed at
    improving the performance of those processes
    ADVANTAGES - JIT DISADVANTAGES - JIT
    Reduction in storage space Little room for mistakes

    Less working capital Production is very reliant on


    suppliers
    Less likelihood of stock
    perishing No spared finished product to
    meet the expected demand
    Avoids the build up of unsold
    finished product
    JIT EXAMPLE :
    Dell approach is provide
    lead times that are shorter
    than most of their
    competitors by negotiating
    with suppliers to carry
    inventory instead of
    carrying it themselves. It is
    simple for Dell to assemble
    and ship to customers.
    REFERENCE
    Goetsch, D., & Davis, S. (2014). Quality Management for
    Organizational Excellence : Introduction to Total Quality (7th ed.).
    Pearson Education Limited.
    - End of lecture -

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