1. Roberta Russell & Bernard W. Taylor, III
Chapter 3
Quality Management
Operations Management - 5th Edition
Roberta Russell & Bernard W. Taylor, III

2. Meaning of Quality Webster’s Dictionary American Society for Quality
Degree of excellence of a thing
American Society for Quality
Totality of features and characteristics that satisfy needs
Google’s Definition?
Are there different perspectives?

3. Meaning of Quality: Consumer’s Perspective
Fitness for use
How well product or service does what it is supposed to
Quality of design
Designing quality characteristics into a product or service
A Mercedes sports car and a Ford truck are equally “fit for use,” but with different design dimensions

4. Dimensions of Quality
What are some of the dimensions of quality for a manufactured product?
What about for a service?
Do they differ?
If yes, should they?
If no, why not?

5. Dimensions of Quality: Manufactured Products
Performance
Basic operating characteristics of a product; how well a car handles or its gas mileage
Features
“Extra” items added to basic features, such as a leather interior in a car
Reliability
Probability that a product will operate properly within an expected time frame; that is, a TV will work without repair for about seven years

6. Dimensions of Quality: Manufactured Products (cont.)
Conformance
Degree to which a product meets pre–established standards
Durability
How long product lasts before replacement
What’s the life expectancy of the tires on your car?
Serviceability
Ease of getting repairs, speed of repairs, courtesy and competence of repair person
iPhone, anyone?

7. Dimensions of Quality: Manufactured Products (cont.)
Aesthetics
How a product looks, feels, sounds, smells, or tastes
Safety
Assurance that customer will not suffer injury or harm from a product; an especially important consideration for automobiles
Perceptions
Subjective perceptions based on brand name, advertising, etc.

8. Dimensions of Quality: Service
Time and Timeliness
How long must a customer wait for service, and is it completed on time?
Is an overnight package delivered overnight?
Completeness
Is everything customer asked for provided?
Is a mail order from a catalogue company complete when delivered?

9. Dimensions of Quality: Service (cont.)
Courtesy
How are customers treated by employees?
Are catalogue phone operators nice and are their voices pleasant?
Consistency
Is the same level of service provided to each customer each time?
Is your newspaper delivered on time every morning?

10. Dimensions of Quality: Service (cont.)
Accessibility and convenience
How easy is it to obtain service?
Does a service representative answer you calls quickly?
Accuracy
Is the service performed right every time?
Is your bank or credit card statement correct every month?
Responsiveness
How well does the company react to unusual situations?
How well is a telephone operator able to respond to a customer’s questions?
What about Internet-based service – does it differ?

11. Meaning of Quality: Producer’s Perspective
Quality of Conformance
Making sure a product or service is produced according to design
If new tires do not conform to specifications, they wobble
If a hotel room is not clean when a guest checks in, the hotel is not functioning according to specifications of its design

12. Meaning of Quality: A Final Perspective
Consumer’s and producer’s perspectives depend on each other
Consumer’s perspective: PRICE
Producer’s perspective: COST
Consumer’s view must dominate
Why?

13. Producer’s Perspective Consumer’s Perspective
Meaning of Quality
Fitness for
Consumer Use
Producer’s Perspective
Consumer’s Perspective
Quality of Conformance
Conformance to specifications
Cost
Quality of Design
Quality characteristics
Price
Marketing
Production
Meaning of Quality

14. Total Quality Management
Commitment to quality throughout the organization
Principles of TQM
Customer-oriented
Leadership
Strategic planning
Employee responsibility
Continuous improvement
Cooperation
Statistical methods
Training and education

15. Deming Wheel: PDCA Cycle
1. Plan
Identify problem and develop plan for improvement.
2. Do
Implement plan on a test basis.
3. Study/Check
Assess plan; is it working?
4. Act
Institutionalize improvement; continue cycle.

16. Quality Improvement and Role of Employees
Should employees be involved?
Participative problem solving
Employees involved in quality management
Every employee has undergone extensive training to provide quality service to Disney’s guests

17. Quality Circle Organization Training Presentation
Implementation
Monitoring
Solution
Problem results
Problem Analysis
Cause and effect
Data collection and analysis
Problem Identification
List alternatives
Consensus
Brainstorming
Training
Group processes
Data collection
Problem analysis
Organization
8-10 members
Same area
Supervisor/moderator

18. Strategic Implications of TQM
Strong leadership
Goals, vision, or mission
Operational plans and policies
Mechanism for feedback

19. Six Sigma
A process for developing and delivering near perfect products and services
Measure of how much a process deviates from perfection
3.4 defects per million opportunities
Champion
An executive responsible for project success

20. Black Belts and Green Belts
Project leader
Master Black Belt
A teacher and mentor for Black Belts
Green Belts
Project team members

21. Six Sigma: DMAIC DEFINE MEASURE ANALYZE IMPROVE CONTROL 67,000 DPMO
cost = 25% of sales
3.4 DPMO

22. TQM in Service Companies
Principles of TQM apply equally well to services and manufacturing
Services and manufacturing companies have similar inputs but different processes and outputs
Services tend to be labor intensive
Service defects are not always easy to measure because service output is not usually a tangible item

23. Quality Attributes in Service
Benchmark
“Best” level of quality achievement one company or companies seek to achieve
Timeliness
How quickly a service is provided
“quickest, friendliest, most accurate service available.”

24. Cost of Quality Cost of Achieving Good Quality Cost of Poor Quality
Prevention costs
Costs incurred during product design
Appraisal costs
Costs of measuring, testing, and analyzing
Cost of Poor Quality
Internal failure costs
Include scrap, rework, process failure, downtime, and price reductions
External failure costs
Include complaints, returns, warranty claims, liability, and lost sales

25. Quality Management and Productivity
Ratio of output to input
Yield: a measure of productivity
Yield=(total input)(% good units) + (total input)(1-%good units)(% reworked) or
Y=(I)(%G)+(I)(1-%G)(%R)

26. Product Cost Product Cost where:
Kd = direct manufacturing cost per unit
I = input
Kr = rework cost per unit
R = reworked units
Y = yield

27. Computing Product Yield for Multistage Processes
Y = (I)(%g1)(%g2) … (%gn)
where:
I = input of items to the production process that will result in finished products
gi = good-quality, work-in-process products at stage i

28. Quality–Productivity Ratio
QPR
Productivity index that includes productivity and quality costs
QPR =
(non-defective units)
(input) (processing cost) + (defective units) (reworked cost)

29. Seven Quality Control Tools
Pareto Analysis
Flow Chart
Check Sheet
Histogram
Scatter Diagram
SPC Chart
Cause-and-Effect Diagram

30. Pareto Analysis NUMBER OF CAUSE DEFECTS PERCENTAGE Poor design 80 64 %
Wrong part dimensions 16 13
Defective parts 12 10
Incorrect machine calibration 7 6
Operator errors 4 3
Defective material 3 2
Surface abrasions 3 2 %

31. Percent from each cause
Causes of poor quality
Machine calibrations
Defective parts
Wrong dimensions
Poor Design
Operator errors
Defective materials
Surface abrasions 10 20 30 40 50 60 70
(64)
(13)
(10)
(6)
(3)
(2)
Pareto Chart

32. Flow Chart
Operation
Decision
Start/ Finish

33. Check Sheet COMPONENTS REPLACED BY LAB
TIME PERIOD: 22 Feb to 27 Feb 2002
REPAIR TECHNICIAN: Bob
TV SET MODEL 1013
Integrated Circuits ||||
Capacitors |||| |||| |||| |||| |||| ||
Resistors ||
Transformers ||||
Commands
CRT |

34. Histogram 5 10 15 20

35. Scatter Diagram Y X

36. Control Chart Number of defects Sample number 18 12 6 3 9 15 21 24 2 410 14 16
Sample number
Number of defects
UCL = 23.35
LCL = 1.99
c = 12.67

37. Cause-and-Effect Diagram
Quality
Problem
Out of adjustment
Tooling problems
Old / worn
Machines
Faulty
testing equipment
Incorrect specifications
Improper methods
Measurement
Poor supervision
Lack of concentration
Inadequate training
Human
Deficiencies
in product design
Ineffective quality
management
Poor process design
Process
Inaccurate
temperature
control
Dust and Dirt
Environment
Defective from vendor
Not to specifications
Material-
handling problems
Materials

38. American Customer Satisfaction Index (ACSI)
Measures customer satisfaction
Established in 1994
Web site:
Who do you think is top in ‘Breweries’?
Automobiles?