Quality
Quality
Quality
INTRODUCTION
Current global competitive environment requires
companies to become customer driver and making
customer satisfaction a key priority.
This is so because customers are demanding over
improving levels of service regarding cost, quality,
reliability, delivery and the choice of innovative new
products.
Companies that develop a reputation of low quality
products loss market share and face declining profits
A quality product results in no defects.
Defective products results in high warrant costs and
dissatisfied customers.
Garrison (2006) note ‘”that customers who have bad
experience tell approximately 11 people about it” - and
is the worst form of advertising.
Eliminating inferior quality can therefore result in
substantial savings and higher revenues.
Refers to a process where all business functions are
TOTAL QUALITY MANAGEMENT
improvement.
TQM is not a technique, a broad management
approach or methodology dealing with processes and
attitudes.
T Q M besides focusing on statistical monitoring of
manufacturing process now includes customer
oriented process of continuous improvement that
focuses on delivering products or services of consistent
high quality in a timely fashion.
Initially developed for manufacturing organisations
but now suits any environment such as a university—
cut has a director of quality who regulates quality
issues.
It is cheaper now to produce quality product than
producing inferior products which result in excessive
expenditure on inspection, rework, scrap and warranty
repairs.
T Q M therefore focuses on designing on building
quality rather than trying to inspect focusing on
causes rather than symptoms of poor quality.
Principles of TQM
Continuous improvement
Involves achieving excellence in an incremental way
It is an ongoing process
Employees involvement-need continuous training
and motivation to consistently achieve better and
better quality .
Customer involvement
Commitment of top management
Their willingness and participation must be clear and
visibly seen by all.
Supplier relationships
TQM aims to prevent and allow immediate detection
of errors and problems solved at root source rather
than correction of problems after their occurrence.
Thus quality designs works better than inspection
quality after poor designs.
TQM attempts to expose problems rather than hide or
burry them.
TQM- creates, encourages and nurtures simplicity,
instead of bureaucratic approach of adding controls.
It attempts to identify and eliminate non-value added
activities thus naturally motivating people to use
quality procedures.
Thus it is better and hence it is cheaper to do every
process right at first time, rather than not to do it right
then correct it afterwards.
TQM practices include the use of statistical process
control ,customer focus, and interfunctional design
efforts and quality performance measures include
customer’s perception of quality, defects in parts per
million and the percentage of units that pass through
final inspection without requiring rework.
TQM practices leads to improved JIT performance by
reducing manufacturing process variance.
Variance reduction permits stock safety inventory
reduction and yields shorter cycle times, both
standard measures of JIT performance through
elimination of rework.
JUST IN TIME SYSTEM(JIT)
Is a management philosophy aimed at eliminating
manufacturing waste by producing only the right
amount and contribution of parts at the right place at
the right time.
JIT aims to minimise the presence of non-value adding
operations and non-moving inventories in the
production line.
The result is shorter throughout times better on –time
delivery performance, higher equipment utilisation,
lesser space requirement, lower costs and greater profits
Founded in Japan in the 1970s.
It was developed and perfected by Taiichi Ohno of
Toyota and he is now referred as the father of JIT.
JIT aims to achieve zero inventories , minimal work in
progress through the entire supply chain.
JIT practices include set up time reduction, schedule
flexibility and use of Kanban.
JIT performance can be measured by inventory
turnover, cycle time, lead time, delivery
performance and other measures
JIT aims at eliminating waste through simplification
of manufacturing process.
Major objectives of JIT
Increasing the organisation ‘s ability to compete with
and remain competitive over long run.
Competitiveness is increased by use of JIT
manufacturing process as they can develop a more
optimal process for the firm.
Increasing efficiency within the production process.
Efficiency is obtained through the increase of
productivity and decrease of cost.
Reducing wasted materials, time and effort which in
turn help reduce costs.
other benefits
Identify and respond to consumer needs.
Optimal quality/cost relationship-eliminate large
amount of resources and efforts in inspection and
reworking the production of defected goods.
Development of a reliable relationship between
suppliers
Plant design for maximizing efficiency.
Adopting the work for continuous improvement
Reduce unwanted waste- JIT eliminates waste from
over production, waiting time, transportation waste
and inventory waste, waste of motion and waste from
defects.
Basic elements of JIT
PEOPLE involvement
Maintaining a good support and agreement from
people involved in production.
Reduces time and effort in implementation of JIT and
minimises chances of creating implementation
problems.
Maximising people ‘s involvement carry through
introduction of quality circles and total involvement
concept.
Management gets support from stockholders and
owners of the company, labour organisation,
management support and government support.
PLANTS –certain specifications are needed to
implement JIT such as:
Plant layout-allow maximum working flexibility- use
of “multifunctional workers”.
Demand pull production- producing only when order
is received.
Kanban-use of card or tag system
Self improvement
Continuous improvement
SYSTEM-
Technology and process that combines the different
processes and activities together. – Material
Requirement Planning and Manufacturing Resource
planning.
When Just In Time is in use, the following goals can be
achieved:
Elimination of non-value added activities
Zero inventory (no buff inventory)
Zero defects
Both sizes of one
Zero breakdowns
100% on time delivery service.
NB Though the above targets may not be achieved in
real life situation the aim is to strive to achieve them so
as to realize substantial savings.
Elimination of non-value added activities
Just in Time aims to eliminate waste.
Waste is anything that does not add value to a
product.
The lead or cycle time for manufacturing or selling a
product consists of process time, inspection time,
move time queue time and storage time but only
process time adds value to product with all other
adding cost only.
Adopting Just in Time philosophy and focusing on
reducing lead times total costs can greatly be reduced.
Group 25
E and E ltd produces a range of products. The
company recently upgraded its production facilities to
modern standards replacing labour intensive system.
While problems existed initially the new system has
performed well to E and E ltd’s specifications.
However , Eand E’s customers have complained of on
going problems in terms of quality and late deliveries.
Mr Emmanuel the Chief executive officer is disturbed
at the second issue as he had authorised a huge
increase in the level of work in progress inventory to
keep the new system at full capacity.
At a recent strategic conference in Dubai , he heard of
TQM and JIT production. He is now in the middle of
the road as to whether these philosophies might be the
answer to E and E ltd .
Required
You have been appointed the management accountant
of E and E ltd, advise Mr Emmanuel on the scope for
TQM and JIT to solve the problems faced by
customers. (25 marks.)
COST OFcost
Quality QUALITY
are cost that are incurred to prevent
defective products from falling into the hands of
customers or that are incurred as a result of defective
units.
Quality costs are divided into four groups two of
which are prevention and appraised costs (incurred to
in an effort to keep defective products from falling into
customer’s hands)and internal failure costs and
external failure costs (incurred for the failure to
prevent defects despite efforts).
PREVENTION COSTS
Are costs incurred to keep defects from occurring?
It therefore relates to any activity that reduces the
number of defects in products or services.
They includes costs of preventative maintenance,
quality planning and training, system
development, quality engineering, quality circles,
statistical process control activities, and the extra
costs of acquiring higher quality raw material,
technical support to suppliers.
QUALITY CIRCLES
Consist of small groups of employees that meet on a
regular basis to discuss ways to improve the quality of
output (includes both management and workers)
STATISTICAL CONTROL PROCESS
Is a technique used to detect whether a process is in or
out of control. An out of control result in defective
units and may be caused by a miscalibrated machine
or some other factor.
In this method workers use charts to monitor the
quality of units that pass through their work stations.
By using charts workers can quickly spot processes
that are out of control and creating defects.
Problems are then corrected immediately thereby
preventing further defects rather than waiting for an
inspection to catch defects.
JIT systems can be employed as support systems to
suppliers.(see inside)
INTERNAL FAILURE COSTS
Are costs associated with materials and products that
fail to meet quality standard
These cost result from identification of defect during
the appraisal process.
Examples of such cost include scrap, rejected
products, reworking of defective units delay time
caused by quality problems.
It should be noted that appraisal activities focus on
symptoms rather on causes and they do nothing to
reduce the number of defective items.
However appraisal activities do bring defects to the
attention of management, which may head to efforts
to increase prevention activities so that defects do not
happen
EXTERNAL FAILURE COSTS
Costs that result when a defective product is delivered
to a customer.
Examples of cost in this Category include warranty
repairs and replacement, products recalls e.g Toyota in
2011 call over 20 000 defective cars which were on the
market.
The company suffered Liability arising from legal
action against a company and lost sales arising from a
reputation of poor quality.
When these costs are incurred they can devastate
profits.
DISTRIBUTION OF QUALITY COSTS
Studies in United States shows cost of quality to range
between 10% and 20% of total sales where as experts
say these range between 2% and 4%.
When the quality of Conformance is Low, total quality
cost is high due to costs Internal external failure costs.
A low quality of Conformance means a high
percentage of units are defective and have high failure
costs.
However, as the Company Spends more and more on
prevention and prevention, the percentage of
defective units drops and hence Low Internal and
External failure cost
close to zero.
The best way to prevent defects from happening to
design Some experts and managers Contend that the
total quality cost is not minimized until quality of
Conformance approach 100% and defect rates get as
low as 1 in a million Units .
Others argue that eventually total quality cost increase
as the quality of Conformance increases or approaches
100% and defect rates are very processes that reduce
the Likelihood of defects and to continually monitor
processes using statistical process Control method.
QUALITY COSTS
These provide REPORTS
an estimate of the financial
Consequences of the company’s current level of
defects.
It details the prevention costs, approval costs, and
costs of Internal and external failure that arise from
the company’s current level of defective products and
services
Uses of quality cost information
Helps managers to see the financial significance of
defects as they may not be aware of the magnitude
since such costs cut across departmental lines and are
not normally tracked and accumulated by the cost
system.
It also helps managers identify the relative importance
of the quality problems faced by the firm i.e. the report
may show that scrap is a major quality problem or that
the company is having huge warranty costs giving
managers a better idea of where to focus efforts.
It also helps managers to see whether their quality
costs are poorly distributed. In general quality costs
should be distributed more towards prevention and
appraisal activities and less towards failures.
Limitations of cost of quality information
Simply measuring and reporting quality cost does not
solve quality problems
Results usually lag behind quality improvement
programs.
Total quality cost may even increase as quality control
system designed and installed. Decreases in the cost
may not begin to occur until the quality program has
been in effect for a year or more.
The most important quality cost, lost sales arising
from customers’ ill will, is normally omitted from the
quality cost report because it is difficult to quantify
International Aspect of Quality
The Japanese companies borrowed heavily from the
work of W. Edwards Deming and introduced quality
circles, JIT, the idea that quality is everyone’s
responsibility, and the emphasis on prevention rather
than an inspection.
In the 1980s, quality re-emerged as a pivotal factor in
the market and hence need to have a strong quality
program in place.
The I. S. O 9 000 standards
(international standards
organisation)
Is based in Geneva, Switzerland established quality
control guidelines.
To get certification producer must demonstrate that
A quality control system is in use, and the system
clearly defines an expected level of quality.
The system is fully operational and is backed up with
detailed documentation of quality control procedures.
The intended level of quality is being achieved on a
sustained; consistent basis
Documentation is important here, that is it should be
detailed precise that if all the employees in a company
were suddenly replaced, the new employees could us
the documentation to make the product exactly as it
was made by the old employees.
I.S.O certification is not limited to manufacturing
companies only.
*Give examples in Zimbabwe of C O.S that attained
I.S.O
Benefits of certification
Meet Customer Requirements
Many companies want ISO 9001 certification just to
satisfy one customer requirement.
The customer states that it will only do business with vendors
that are certified as ISO 9001 compliant, so to get (or keep)
the business they need that certification.
The problem with these companies is that they’re looking for
a short-term payoff.
They see nothing but that one benefit — we need money —
and ignore the long-term benefits, like “if we keep the
customer well satisfied, they will want to come back again
and again”.
They don’t embrace the concept of quality through
continual improvement.
They don’t understand that continued customer
satisfaction is the ultimate goal of a QMS.
broad scope
Cost leadership differentiation
targets whole
market
STRATEGIC narrow scope
SCOPE targets one
FOCUS
segment
Cost leadership --basically being the lowest cost
producer in a particular industry.
Differentiation--- this is creation of a customer
perception that the product is superior to that of
competitors so that a premium can be charged (that is
it is different) .
Focus ---this involves utilising either of the above in a
narrow profile of market segments or “niching”
Porter argues that organisations need to address two
key questions namely:
*should the strategy be one of differentiation or cost
leadership?
*should scope be wide or narrow?
He argues that organisations that can run trying to
satisfy all ,end up being ‘stuck in the middle”
The implication is that Porter advocates that
organisations need to make a basic competitive
decision early on in the strategic determination
process.
Cost Leadership Strategy
This is based on the view that the business be the
lowest cost producer.
Potential Benefits
Business can earn higher profits by charging the same
price or even moving to undercut where demand is
elastic.
Enables Company to build defense against price wars.
Allows price penetration entry strategy into new
markets.
It enhances barrier to entry
Allows development of new market segments.
Value Chain
Is central analysiswhere cost saving can be made
to identifying
at various stages in the value chain. Attainment
depends upon arranging value chain activities so as to:
Reduce cost by copying rather than originating
designs, using cheaper material and other cheaper
resources, producing products with “no frills”,
reducing labour costs and increasing labour
productivity.
Achieving economics of scale by high volume sales
allowing fixed costs to be spread over a wider
production base.
Allow specialization.
Less competition
These tell a story about the past, but not the future
and hence do not guide performance in creating value.
THE LEARNING AND GROWTH
PERSPECTIVES
Employee capabilities
Innovation
Operation processes