Total Quality Management

Assignment 01
Lasitha Nawarathna

1)

A) Give the differences of among quality control, quality assurance and total quality control.

Quality control
describes the directed use of testing to measure the achievement of a specified standard

quality assurance Improving and stabilizing production and associated process to avoid or least minimize. QA focus on prevention of quality problems rather than defect detection

total quality management

Quality check and find a defect and give feed back to the process

A process foe maintain standards not for creating standards

Related to systems and not to a product as in quality control.

total quality management is a management approach to long-term success through customer satisfaction In a TQM effort, all members of an organization participate in improving processes, products, services and the culture in which they work TQM will make strategies to get sure of the support service effectives and efficiently. but QC and QA not concert about support services
Benefits may not be seen.

Defect detect after the manufacturing

Cannot absolutely guarantee the production of quality products

B) Why is total quality control a more successful way to run any organization?

1. Improves reputation- faults and problems are spotted and sorted quicker (zero defects) Reduction of defects because TQM promotes quality awareness and participation of all members of the organization, not just the QA or QC department. It means quality at the source.

2. TQM

leads

to quality

products,

which

leads

to customer

satisfaction

The first thing trying to implement TQM is quality. Quality is vital to the success of your company and to the proper implementation of TQM. Implement a quality policy that will allow you to meet the needs of the customers and your companies needs as well. Satisfying every single customer may not be feasible but satisfying the majority of them is important to the success of your company.

3. Give speed service for customers without any problem Total quality management system leads to ease of problem solving and resolves problems faster. Through measurements such as SPC and other techniques such as failure analysis, defects and failures (even potential failures) can be identified and addressed

4. Higher employee morale workers motivated by extra responsibility, team work and involvement in decisions of TQM

5. Can achieve profit margins Decrease waste as fewer defective products and no need for separate. Because in TQM improving all the suppler quality. Then we can get quality raw materials. All workers work as team. They have higher efficiency scraps are decreases.

6. Lowers Production Costs A Total Quality Management program eliminates defects and waste, which reduces production costs in a business. As teams gather to identify and eliminate weaknesses in the business, the company continues to enjoy reduced costs and higher profit. Quality improvement teams can eliminate defects, reduce lead time and identify redundancies in the production process that can significantly add to the profit the company earns.

C) what are the key elements/ principle of total quality management and why are they important to achieve a total quality management for any production /service organization Preventions o Prevention is better than cure. the end, it is cheaper to stop products defects than trying to find them. In TQM improve and companywide systems

Zero defects o The ultimate aim is no defects. Reduction of defects because TQM promotes quality awareness and participation of all members of the organization.

Getting thing right first time o Better not to produce at all than produce something defective

Involves quality every one o Quality is not just the concern of the production or operation department. Involves every one including suppler to after servicers employees

Continuous improvement o Business should always be looking for ways to improve processes to help quality

Employee involvement o those involved in products and have vital role to play in spotting improvement opportunities for quality and in identifying quality problems

2. select a problems what you feed at your work place or in a day to day life. Analysis the problems using cause effect diagram concept and give the possible solutions for the problems Problem:- when I was in my in plant training that factory final inspection team have founded a wrong label attached garments steps to solve a problem with a Cause and Effect Diagram Identify the problem Attached wrong labels Work out the major factors involved Labels issuing team Labels loading team to line In line quality checker End line quality checkers AQL team Identify possible causes o Issue wrong label . Issuing team must refer the buyer specification before issue labels. o Loader not refer trim card normally loader has responsibility to before get labels from stores refer to trim card o In line QC not check production process and he couldnt update data o End line checkers not check all quantity. All the finished garment go to packing trough end line checkers. But some garment they not checked under the buyer requirement

Analyze your diagram

Communication
In line check

Quality check
Final check found defect

Tools and machines

Marinating

Merchandiser
RM issuing team

In line QC not check

End line checkers not check correctly

7-0 quality check

End line checking

Machines condition

Quantity

Issuing team Issue wrong label

Trim card

Incorrect label attached

Correct information

Specification

Trainings

Loading team
Loader not refer trim card Stores Skill of operators

Raw materials Supply

Supply to production

Production

Decision of management Should display issuing place trim card and refer it before issuing labels and all things Loaders train again for refer to trim cards In line quality checker and end line quality checkers training to check garment every time under buyer correct requirement Wrong garment sent to production place to rework

03. How do following quality management techniques help to improve total quality of an organization?

Quality circles:Quality Circles are small groups of people doing similar work who, together with their supervisors volunteer to meet for an hour a week to study and solve work related problems which affect them. Circle leaders and members are trained in simple problem solving techniques which identify causes and develop solutions. At an appropriate time, presentations are made by the quality circles to the management who decide whether to accept, modify or decline the proposals

How help to TMQ

To identify and solve work related problems that interferes with production. To permit employees to develop and use greater amount of knowledge and skill and motivate them to apply to a wide range of challenging tasks To tap the creative intelligence of the persons working in the organisation and to make full use of its human resources. To permit employees to develop and use greater amount of knowledge and skill and motivate them to apply to a wide range of challenging tasks. To improve communication within the organization. To increase employees' loyalty and commitment to the organization and its goals. To respect humanity and build a happy bright work place environment which is meaningful to work in.

Six sigma concept In statistical terms, the purpose of Six Sigma is to reduce process variation so that virtually all the products or services provided meet or exceed customer expectations. This is defined as being only 3.4 defects per million occurrences How help to TMQ

1. Among the benefits of six sigma is the decrease in defects that are allowed to

reach the customer.

2. Six Sigma is successfully implemented in virtually every business category including return on
sales, return on investment, employment growth and stock value growth. 3. Six Sigma targets Variation in the processes and focuses on the process improvement rather than final outcome. 4. Six Sigma is prospective methodology as compared to other quality programs as it focuses on prevention on defects rather than fixing it. 5. It is attentive to the entire business processes and training is integral to the management system where the top down approach ensures that every good thing is capitalized and every bad thing is quickly removed

Lean manufacturing:the lean manufacturing process is a comprehensive way to reduce waste of all types. It could be a waste of time or material, it is still waste. Many studies have measured the amount of waste a typical manufacturer has, and it is usually shocking, as well as revealing how to help TQM
1. Reduced Waste; Less transport, moving, waiting, space, and physical waste. 2. Improved Lead Times; Business able to respond quicker, quicker set ups, fewer delays. 3. Reduce inventory 4. Less space required to build product

5. Enhancement to overall manufacturing flexibility 6. Ensure a safer work environment

Seven quality control tools

How help to TQM

1. Organize verbal data and easy to Eliminate errors and omissions 2. Generate ideas of all employees can Improve planning 3. Explain problems intelligibly it help to solve problems quickly. 4. Assess situations from various angles 5. Prioritize tasks effectively and Change proactively