Friday, February 25, 2011

Six Sigma – what does it mean?



Six Sigma at many organizations simply means a measure of quality that strives for near perfection. Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard deviations between the mean and the nearest specification limit) in any process -- from manufacturing to transactional and from product to service.
The statistical representation of Six Sigma describes quantitatively how a process is performing. To achieve Six Sigma, a process must not produce more than 3.4 defects per million opportunities. A Six Sigma defect is defined as anything outside of customer specifications. A Six Sigma opportunity is then the total quantity of chances for a defect. Process sigma can easily be calculated using a Six Sigma calculator.
The fundamental objective of the Six Sigma methodology is the implementation of a measurement-based strategy that focuses on process improvement and variation reduction through the application of Six Sigma improvement projects. This is accomplished through the use of two Six Sigma sub-methodologies: DMAIC and DMADV. The Six Sigma DMAIC process (define, measure, analyze, improve, control) is an improvement system for existing processes falling below specification and looking for incremental improvement. The Six Sigma DMADV process (define, measure, analyze, design, verify) is an improvement system used to develop new processes or products at Six Sigma quality levels. It can also be employed if a current process requires more than just incremental improvement. Both Six Sigma processes are executed by Six Sigma Green Belts and Six Sigma Black Belts, and are overseen by Six Sigma Master Black Belts.
According to the Six Sigma Academy, Black Belts save companies approximately $230,000 per project and can complete four to 6 projects per year. General Electric, one of the most successful companies implementing Six Sigma, has estimated benefits on the order of $10 billion during the first five years of implementation. GE first began Six Sigma in 1995 after Motorola and Allied Signal blazed the Six Sigma trail. Since then, thousands of companies around the world have discovered the far reaching benefits of Six Sigma.
Many frameworks exist for implementing the Six Sigma methodology. Six Sigma Consultants all over the world have developed proprietary methodologies for implementing Six Sigma quality, based on the similar change management philosophies and applications of tools.

Thursday, February 24, 2011

A case study - can you solve it


Implement Total Quality Management (TQM) requires regular review its performance and effectiveness. A typical management review meeting is held to review its implementation, project status and project performance. This article present a case study of a typical Management Review Meeting
I was in a management review meeting of a company . The Agenda for the day was to review the progress of the Total Quality Management ( TQM ) in implementation in the organization.
A few days before the management meeting, I did some research into the TQM implementation data from several companies under this organization. I collated data such as Vision and Mission Statements, Strategic Planning worksheets, SWOT Analysis data, TQM implementation projects and their respective results etc.
I started to analysis these data and correlate the results with the key actions. I compiled those key actions that achieved the targeted results etc..... and presented to the management team. Despite having data to quantify the progress of the TQM implementation, the management team could not conclude whether the companies has succeeded in TQM implementation.
A question was raised by one of the management team member, "How exactly do we measure TQM Implementation for its success?"
A moment of silence !!! I think he is right, said the chairman of the management meeting. We do not have a measurement or indicator to gauge the success of TQM implementation. The chairman go around the table asked the management team members to site example of any measures that can represent TQM Implementation and its success. Although there were several input but they do not seems to represent the success of TQM Implementation.
I was assigned to make a thorough research into ways to measure TQM Implementation Success and present the research in the next Management Review Meeting.
Do you face with similar situation in your organization? You still do not have a clue how to measure TQM Implementation?
Different organization implementing TQM has their uniqueness of issues. There is no one answer to it. If you faced with the same issue, let's share this among TQM practitioners on various aspect of TQM tools and its applications.

A journey can inspire you


Dhirajlal Hirachand Ambani, (Gujarati: ધીરુભાઈ અંબાણી) also known as Dhirubhai, (28 December 1932 – 6 July 2002) was an Indian rags-to-riches business tycoon who founded Reliance Industries in Mumbai with his cousin. Ambani took his company (Reliance) public in 1977, and by 2007 the combined fortune of the family (sons Anil and Mukesh) was 60 billion dollars, making the Ambani's the second richest family in the world, next to the Walton family. Dhirubhai has been one among the select Forbes billionaires and has also figured in the Sunday Times list of top 50 businessmen in Asia.
Dhirubhai started off as a small time worker with Arab merchants in the 1950s and moved to Mumbai in 1958 to start his own business in spices. After making modest profits, he moved into textiles and opened his mill near Ahmedabad. Dhirubhai founded Reliance Industries in 1958. After that it was a saga of expansions and successes.
Reliance's story as a company has been a 'bitter-sweet' saga in India. While on one hand it remains one of the biggest Indian conglomerates,on the other hand it is well known as a company which evades taxes and is nontransparent. It has presence in various sectors like petrochemicals, textiles and is involved in the production of crude oil and gas, polyester and polymer products. The company's refinery at Jamnagar accounts for over 25% of India's total refining capacity and their plant at Hazira is the biggest chemical complex in India. The company has further diversified into Telecom, Insurance and Internet Businesses, Power Sector and so on. The Reliance group with over 85,000 employees provides almost 5% of the Central Government's total revenue.

Wednesday, February 23, 2011

TQM implementation in china and The European Model for TQM


TQM Implementation in China
Based on the author’s thorough literature review, the TQM implementation in China has
been identified. This section presents the brief review results. In 1978, the Beijing Internal
Combustion Engine Factory and the Qinghe Woollen Mill started to implement TQM
through cooperating with their foreign partners. In the meantime, a number of experts and
scholars began to disseminate the knowledge of TQM to firms. In September 1978, some
firms began to introduce QC circle activities. On 24 August 1979, the excellent QC circles’
reports were presented in Beijing. On 31 August 1979, the China Quality Control
Association was established. One of its duties was to cooperate with relevant governmental
agencies to promote TQM in the country. Because of the significant effects of TQM
implementation in the Beijing Internal Combustion Engine Factory, it was concluded that
TQM could be effectively implemented in China. Thus, the experiences of TQM
implementation were then popularized and disseminated to other firms. In order to
encourage firms in implementing TQM, the State Economic Commission issued the
Provisional Regulations on TQM Implementation in Industrial Firms in March 1980. The
provisional regulations, which integrated TQM theory with Chinese national specific
conditions, stipulated the significance, role, and implementation method of TQM. In order to
help firms implement TQM, a large number of training courses and seminars were organized
by the quality control associations at various levels
2
The statistical data in 1985 showed that .
38,000 firms implemented TQM while 500,000 QC circles were established in various
firms. Today, there are tens of thousands of firms that have implemented TQM, which has
been implemented not only in state-owned firms but also in collective and township firms,
not only in industrial firms but also in service firms.
                                                  
2
 China has different levels of quality control associations such as state, ministry, province,
municipality, and county.4
In fact, TQM was not well defined in China, but was still an ambiguous concept. However,
the major TQM implementation practices in Chinese manufacturing firms could be
summarized as: Using various kinds of quality management tools such as the QC seven tools
and statistical process control in practice; implementing QC circles activities; analyzing and
identifying quality-related costs; emphasizing quality inspection; establishing quality bodies
(e.g., TQM implementation offices) in manufacturing firms; conducting quality audits;
strengthening process control and improvement, product design, and after sales services. In
the meantime, many people working in firms accepted education and training on TQM.
Over the past several years, China has become a focus of interest for Western organizations
and management researchers, along with the awareness of the important role it has played in
the global economy. Accordingly, more and more researchers have been involved in
conducting research projects in relation to China in various fields, such as culture (e.g.,
Adler et al., 1989), organizational studies (e.g., Shenkar and von Glinow, 1994), technology
transfer (e.g., Tackaberry, 1998), and marketing (e.g., Fock and Woo, 1998). Research on
China’s TQM domain, however, has not attracted much attention. As a result, little research
has been conducted in this field, especially on TQM implementation at the firm level.  Table
1.2 lists main articles published in international journals before 1996, dealing with general
China’s quality management.
Table 1.2 Articles Concerning China’s Quality Management Appeared in International          
 Journals Before 1996
- Stephens, K.S. (1989), China’s emerging quality emphasis, Quality Progress, December,
pp. 56-61.
- Liu, D.X. and Willborn, W. (1990), Quality improvement in China, International
Journal of Quality & Reliability Management, Vol. 7 No. 5, pp. 27-33.
- Chou, Y., Chang, P.L. and Tuan, C. (1993), Total quality control Chinese style and its
management implications - Taiwan versus China, Total Quality Management, Vol. 4,
No. 3, pp. 283-303.
- Liu, Y.Z. (1994), TQM in the socialist market economy of China, Asia Pacific Journal
of Quality Management, Vol. 3 No. 3, pp. 36-44.
- Barad, M. (1995), Some cultural/geographical styles in quality strategies and quality
costs (P.R. China versus Australia), International Journal of Production Economics,
Vol. 41, pp. 81-92.
- Zhao, X.D., Young, S.T. and Zhang, J.C. (1995), A survey of quality issues among
Chinese executives and workers, Production and Inventory Management Journal, Vol.
36 No. 1, pp. 44-48.
- Tang, C.L. and Tummala, V.M.R. (1996), The PCB industry in Hong Kong and China:
A 14-step implementation strategy for ISO 9002 certification, International Journal of
Quality & Reliability Management, Vol. 13 No. 2, pp. 99-113.5
The existing Chinese literature
3
 related to the TQM showed that there are three main streams
of published Chinese articles. First, a number of articles were published dealing with
institutional policies. Such articles mainly discussed what kinds of governmental quality
policies should be drawn up in order to encourage Chinese firms to emphasize quality
management, implement TQM, and improve product quality. Second, some articles reported
the specific experiences of implementing TQM in firms. These articles generally discussed
the benefits, importance, and methods of implementing TQM in firms. These writers adopted
case study research methodologies in their studies. Third, a few articles addressed how to use
specific quality tools (e.g., the seven QC tools, statistical process control, experimental
design, and quality function deployment) in practice.
Although many Chinese manufacturing firms began to implement TQM in the late 1970’s
and early 1980’s, to date no large-scale empirical survey has been conducted to study the
effects of TQM implementation on overall business performance in Chinese manufacturing
firms. In addition, no research has been conducted about the confusion of TQM concept and
TQM effects. Furthermore, no research has been conducted for developing a TQM
implementation model that can be used by Chinese manufacturing firms to improve their
TQM implementation efforts.  The lack of sufficient guidelines to assist firms’ TQM
implementation has contributed to a number of unsuccessful TQM implementations in
China.



The European Model for TQM
The European Quality Award was officially launched in 1991. The primary purpose of the
award is to support, encourage, and recognize the development of effective TQM by
European firms. The model of the European Quality Award is divided into two parts,
Enablers and Results. The enablers are leadership, people management, policy & strategy,
resources, and processes. These five aspects steer the business and facilitate the
transformation of inputs to outputs. The results are people satisfaction, customer
satisfaction, impact on society, and business results (the measure of the level of output
attained by the firm).  The European Quality Award model (1994) consists of nine primary21
elements, which are further divided into a number of secondary elements. The primary and
secondary elements are listed below:
(1) Leadership
- Visible involvement in leading total quality;
- A consistent total quality culture;
- Timely recognition and appreciation of the effects and successes of   
individuals and teams;
- Support of total quality by provision of appropriate resources and assistance;
- Involvement with customers and suppliers;
- Active promotion of total quality outside the organization.
(2) Policy and strategy
- How policy and strategy are based on the concept of total quality;
- How policy and strategy are formed on the basis of information that is   
relevant to total quality;
- How policy and strategy are the basis of business plans;
- How policy and strategy are communicated;
- How policy and strategy are regularly reviewed and improved.
(3) People management
- How continuous improvement in people management is accomplished;
- How the skills and capabilities of the people are preserved and developed through
recruitment, training and career progression;
- How people and teams agree on targets and continuously review performance;
- How the involvement of everyone in continuous improvement is promoted and people
are empowered to take appropriate action; 
- How effective top-down and bottom-up communication is achieved.
(4) Resources
- Financial resources;
- Information resources;
- Material resources and fixed assets;
- The application of technology.
(5) Processes
- How processes critical to the success of the business are identified;
- How the organization systematically manages its processes;
- How process performance measurements, along with all relevant feedback, are used to
review processes and to set targets for improvement;
- How the organization stimulates innovation and creativity in process   
improvement;
- How the organization implements process changes and evaluates the benefits.
(6) Customer satisfaction.
(7) People satisfaction.
(8) Impact on society


TQM introduction part 2

Total Quality Management (TQM) is a business philosophy that seeks to encourage both individual and collective responsibility to quality at every stage of the production process from initial design and conception through to after sales service.

Many businesses may not use the term TQM anymore but the philosophy is still very much part of most business thinking. It is seen as being a way in which a business can add value to its product and to gain competitive advantage over its rivals. The former may allow a business to charge a higher price for its product or service whilst the latter can be a key feature of its marketing programme.

TQM requires a change in the way in which businesses operate. It implies a number of things if it is to work successfully:

  • Management structures have to be more consultative and less hierarchical.
  • Workers have to be empowered to be able to make decisions at all levels of the organisation.
  • Workers have to be trained and involved in the building of the philosophy.
  • Communication links between workers and management and between the business and all aspects of the supply chain must be excellent.
  • Commitment to TQM must be backed by action, which the customer can see, and experience.
  • Commitment to the process must be led by the senior management of the business - paying 'lip service' will invariably end up in failure.
TQM can be addressed in a business in a number of ways. The most common are:

  • A policy of zero defects - any problems in the production process are filtered out before they get anywhere near the customer.
  • Quality chains - each stage of the production process is seen as being a link in the chain right down to the relationship between one worker in the process and another.
  • Quality circles - meetings of those directly involved in the production process to discuss and solve problems and make improvements to the production process.
  • Statistical monitoring - the use of data and statistics to monitor and evaluate production processes and quality.
  • Consumer feedback - using market research and focus groups to identify consumer needs and experiences and to build these into the process.
  • Changing production methods - many businesses, where appropriate, have looked at the layout of their production processes - it could be the move to open plan offices, the development of teams or the use of cell production to improve worker commitment to the philosophy.
TQM invariably involves some sort of cost. Re-organising the business in any of the ways above not only involves capital cost but also the cost of training staff. High quality change management is therefore an essential ingredient of the success of such strategies.

Costs can however be saved if the change is successful. The cost of replacing damaged or faulty goods can be high - if the business waits until the end of the process other resources will have been wasted. The improved communication between suppliers and the firm should help to reduce defective components.

Other benefits may involve the effect on customer loyalty and repeat purchases, as well as winning over customers from rivals. Image and reputation can take many years to win but only a short time to lose so the stakes for the business are high.

To prove that the business has rigorous quality standards, external certification by a respected body is seen as being important. Such external certification could be through the Investors in People programme - a recognised standard in the training and professional development of staff in a business - and through such bodies as the ISO.

Two certificates are particularly sought after - ISO 9000 and ISO 14000. The former is concerned with quality management in relation to customer requirements, customer satisfaction, adherence to regulations and the pursuit of continuous improvement.

ISO 14000 is related to the impact of the firm's activities on the environment and the firm's attempts to improve its performance in this respect. Getting certification means that the company can send a message to companies throughout the world, which recognise this standard - currently, around 90 countries - of the quality that they can expect when dealing with the company.

The standards for the ISO 9000 family deal with the following areas:

  1. Quality management systems - establishing and monitoring the process whereby product and service quality are maintained.
  2. Management responsibility - how the management establish, maintain, monitor and communicate their commitment to the standards.
  3. Resource management - how the business provides the resources - both physical and human - to enable the standards to be met and maintained.
  4. Product realisation requirements - how businesses establish and monitor quality from concept to final product or service delivery.
  5. Measurement, analysis and improvement requirements - how businesses use data to monitor their quality control and how this data is used to improve quality provision.

Monday, February 21, 2011

"Being ignorant is not so much a shame as being unwilling to learn to do things the right way"

What is TQM:
TQM is a management approach for an organization:
- centered on quality (Product, Service, Process & System)
- based on the participation of all its members and
aiming at
- long-term success through customer satisfaction, and
- benefits to all members of the organization and to society.

Definition of Quality
Joseph M. Juan:
Quality is fitness for use or purpose
W. Edwards Deming
A predictable degree of uniformity and dependability at low cost and suited to market
QuantifiedQ=P/E
P-Performance E-Expectations
ISO 9000:2005
Quality is the degree to which a set of inherent characteristics fulfills requirements.

Basic Approach towards TQM:- Committed and involved management to provide long-term top - to - bottom organizational support.
- An unwavering focus on the customer, both internally and externally.
- Effective involvement and utilization of the entire work force. Continuous improvement of the business and production process.
- Treating supplier as partners.
- Establish performance measures for the processes.

Change of Dimension
Quality Product to TQM
Decisions- Short term to Long Term
Emphasis- Detection to Prevention
Errors- Operations to System
Responsibility- QC to Every Body
Problem Solving Managers to Teams

Guru’s of TQM
Walter. A. Shewhart: TQC & PDSA
W. Edwards Deming: 14 Points & PDCA
Joseph M. Juran: Juran’s Trilogy
A. Feiganbaum: Customer requirement, CWQC, Employee, Involvement,TQC.
Kaoru Ishikawa: Disciple of Juran & Feigenbaum. TQC in Japan, SPC, Cause & Effect Diagram, QC.
Philips. B. Crosby: Four Absolutes - Quality - Req, Prevention of NC, Zero Defects & Measure of NC.
Taguchi. G: Loss Function

Obstacles- Top management commitment
- Changing Organization Culture
- Improper planning
- Continuous Training & Education
- Organization Structure & Departments
- Data’s & Facts For Effective Decisions
- Internal & External Customers-Dissatisfaction
- Empowerment & Teamwork
- Continuous Improvement

Benefits
- Improved Quality
- Employee Participation
- Team Work
- Internal & External Customer Satisfaction
- Productivity ,Communication
- Profitability & Market Share