Operations

Management
Chapter 6 –
Managing Quality

PowerPoint presentation to accompany

Heizer/Render
Principles of Operations Management, 7e
Operations Management, 9e
© 2008 Prentice Hall, Inc. 6–1
 Outline
 Global Company Profile: Arnold
Palmer Hospital
 Quality and Strategy
 Defining Quality
 Implications of Quality
 Malcolm Baldrige National Quality
Award
 Cost of Quality (COQ)
 Ethics and Quality Management
© 2008 Prentice Hall, Inc. 6–2
 Outline – Continued
 International Quality Standards
 ISO 9000
 ISO14000

© 2008 Prentice Hall, Inc. 6–3

 Outline – Continued
 Total Quality Management
 Continuous Improvement
 Six Sigma
 Employee Empowerment
 Benchmarking
 Just-in-Time (JIT)
 Taguchi Concepts
 Knowledge of TQM Tools
© 2008 Prentice Hall, Inc. 6–4
 Outline – Continued
 Tools of TQM
 Check Sheets
 Scatter Diagrams
 Cause-and-Effect Diagrams
 Pareto Charts
 Flowcharts
 Histograms
 Statistical Process Control (SPC)
© 2008 Prentice Hall, Inc. 6–5
 Outline – Continued
 The Role of Inspection
 When and Where to Inspect
 Source Inspection
 Service Industry Inspection
 Inspection of Attributes versus
Variables
 TQM in Services

© 2008 Prentice Hall, Inc. 6–6

 Learning Objectives
When you complete this chapter you
should be able to:
 Define quality and TQM
 Describe the ISO international
quality standards
 Explain Six Sigma
 Explain how benchmarking is used
 Explain quality robust products and
Taguchi concepts
 Use the seven tools of TQM
© 2008 Prentice Hall, Inc. 6–7
 Managing Quality Provides a
Competitive Advantage
Arnold Palmer Hospital
 Deliver over 13,000 babies annually
 Virtually every type of quality tool is
employed
 Continuous improvement
 Employee empowerment
 Benchmarking
 Just-in-time
 Quality tools
© 2008 Prentice Hall, Inc. 6–8
 Quality and Strategy
 Managing quality supports
differentiation, low cost, and
response strategies
 Quality helps firms increase sales
and reduce costs
 Building a quality organization is
a demanding task

© 2008 Prentice Hall, Inc. 6–9

 Two Ways Quality
Improves Profitability
Sales Gains via
 Improved response
 Flexible pricing
 Improved reputation
Improved Increased
Quality Profits
Reduced Costs via
 Increased productivity
 Lower rework and scrap costs
 Lower warranty costs
Figure 6.1
© 2008 Prentice Hall, Inc. 6 – 10
 The Flow of Activities
Organizational Practices
Leadership, Mission statement, Effective operating
procedures, Staff support, Training
Yields: What is important and what is to be
accomplished
Quality Principles
Customer focus, Continuous improvement, Benchmarking,
Just-in-time, Tools of TQM
Yields: How to do what is important and to be
accomplished
Employee Fulfillment
Empowerment, Organizational commitment
Yields: Employee attitudes that can
accomplish
what is important
Customer Satisfaction
Winning orders, Repeat customers
Yields: An effective
Figure 6.2 organization with
a competitive
© 2008 Prentice Hall, Inc.
advantage 6 – 11
 Defining Quality

The totality of features and

characteristics of a product or
service that bears on its ability to
satisfy stated or implied needs

American Society for Quality

© 2008 Prentice Hall, Inc. 6 – 12

 Different Views
 User-based – better performance,
more features
 Manufacturing-based –
conformance to standards,
making it right the first time
 Product-based – specific and
measurable attributes of the
product

© 2008 Prentice Hall, Inc. 6 – 13

 Implications of Quality
1. Company reputation
 Perception of new products
 Employment practices
 Supplier relations
2. Product liability
 Reduce risk
3. Global implications
 Improved ability to compete
© 2008 Prentice Hall, Inc. 6 – 14
 Key Dimensions of Quality

 Performance  Durability
 Features  Serviceability
 Reliability  Aesthetics
 Conformance  Perceived quality
 Value

© 2008 Prentice Hall, Inc. 6 – 15

 Malcom Baldrige National
Quality Award
 Established in 1988 by the U.S.
government
 Designed to promote TQM practices
 Recent winners
 Premier Inc., MESA Products, Sunny
Fresh Foods, Park Place Lexus, North
Mississippi Medical Center, The Bama
Companies, Richland College, Texas
Nameplate Company, Inc.
© 2008 Prentice Hall, Inc. 6 – 16
 Baldrige Criteria
Applicants are evaluated on:
Categories Points
Leadership 120
Strategic Planning 85
Customer & Market Focus 85
Measurement, Analysis, and
Knowledge Management 90
Workforce Focus 85
Process Management 85
Results 450
© 2008 Prentice Hall, Inc. 6 – 17
 Takumi

A Japanese character
that symbolizes a
broader dimension
than quality, a deeper
process than
education, and a more
perfect method than
persistence

© 2008 Prentice Hall, Inc. 6 – 18

 Costs of Quality
 Prevention costs - reducing the
potential for defects
 Appraisal costs - evaluating
products, parts, and services
 Internal failure - producing defective
parts or service before delivery
 External costs - defects discovered
after delivery
© 2008 Prentice Hall, Inc. 6 – 19
 Costs of Quality

Total Total Cost

Cost
External Failure

Internal Failure

Prevention

Appraisal
Quality Improvement

© 2008 Prentice Hall, Inc. 6 – 20

 Leaders in Quality

W. Edwards Deming 14 Points for

Management
Joseph M. Juran Top management
commitment,
fitness for use
Armand Feigenbaum Total Quality
Control
Philip B. Crosby Quality is Free,
zero defects
© 2008 Prentice Hall, Inc. 6 – 21
 Ethics and Quality
Management
 Operations managers must deliver
healthy, safe, quality products and
services
 Poor quality risks injuries, lawsuits,
recalls, and regulation
 Organizations are judged by how
they respond to problems
 All stakeholders much be
considered
© 2008 Prentice Hall, Inc. 6 – 22
 International Quality
Standards
 ISO 9000 series (Europe/EC)
 Common quality standards for products
sold in Europe (even if made in U.S.)
 2000 update places greater emphasis on
leadership and customer satisfaction
 ISO 14000 series (Europe/EC)

© 2008 Prentice Hall, Inc. 6 – 23

 ISO 14000
Environmental Standard
Core Elements:
 Environmental management
 Auditing
 Performance evaluation
 Labeling
 Life cycle assessment

© 2008 Prentice Hall, Inc. 6 – 24

 TQM

Encompasses entire organization,

from supplier to customer
Stresses a commitment by
management to have a continuing,
companywide drive toward
excellence in all aspects of products
and services that are important to
the customer

© 2008 Prentice Hall, Inc. 6 – 25

 Deming’s Fourteen Points
1. Create consistency of purpose
2. Lead to promote change
3. Build quality into the product; stop
depending on inspection
4. Build long-term relationships based on
performance, not price
5. Continuously improve product, quality,
and service
6. Start training
7. Emphasize leadership
Table 6.1
© 2008 Prentice Hall, Inc. 6 – 26
 Deming’s Fourteen Points
8. Drive out fear
9. Break down barriers between
departments
10. Stop haranguing workers
11. Support, help, improve
12. Remove barriers to pride in work
13. Institute a vigorous program of
education and self-improvement
14. Put everybody in the company to work
on the transformation
Table 6.1
© 2008 Prentice Hall, Inc. 6 – 27
 Seven Concepts of TQM
 Continuous improvement
 Six Sigma
 Employee empowerment
 Benchmarking
 Just-in-time (JIT)
 Taguchi concepts
 Knowledge of TQM tools
© 2008 Prentice Hall, Inc. 6 – 28
 Continuous Improvement

 Represents continual
improvement of all processes
 Involves all operations and work
centers including suppliers and
customers
 People, Equipment, Materials,
Procedures

© 2008 Prentice Hall, Inc. 6 – 29

 Shewhart’s PDCA Model

1.Plan
4. Act Identify the
Implement improvement
the plan and make
a plan

3. Check 2. Do
Is the plan Test the
working? plan

Figure 6.3

© 2008 Prentice Hall, Inc. 6 – 30

 Six Sigma
 Two meanings
 Statistical definition of a process that
is 99.9997% capable, 3.4 defects per
million opportunities (DPMO)
 A program designed to reduce
defects, lower costs, and improve
customer satisfaction

© 2008 Prentice Hall, Inc. 6 – 31

 Six Sigma
 Two meanings
Lower limits Upper limits

 Statistical definition of a process that

2,700 defects/million

is 99.9997% capable, 3.4 defects per

3.4 defects/million
million opportunities (DPMO)
 A program designed to reduce
defects, lower costs, and improve
customer satisfactionMean
±3
±6
Figure 6.4

© 2008 Prentice Hall, Inc. 6 – 32

 Six Sigma Program
 Originally developed by Motorola,
adopted and enhanced by
Honeywell and GE
 Highly structured approach to
process improvement

6
 A strategy
 A discipline - DMAIC

© 2008 Prentice Hall, Inc. 6 – 33

 Six Sigma
1. Define critical outputs
and identify gaps for DMAIC Approach
improvement
2. Measure the work and
collect process data
3. Analyze the data
4. Improve the process
5. Control the new process to
make sure new performance
is maintained
© 2008 Prentice Hall, Inc. 6 – 34
 Six Sigma Implementation
 Emphasize defects per million
opportunities as a standard metric
 Provide extensive training
 Focus on corporate sponsor support
(Champions)
 Create qualified process improvement
experts (Black Belts, Green Belts, etc.)
 Set stretch objectives
This cannot be accomplished without a major
commitment from top level management
© 2008 Prentice Hall, Inc. 6 – 35
 Employee Empowerment
 Getting employees involved in product
and process improvements
 85% of quality problems are due
to process and material
 Techniques
 Build communication networks
that include employees
 Develop open, supportive supervisors
 Move responsibility to employees
 Build a high-morale organization
 Create formal team structures
© 2008 Prentice Hall, Inc. 6 – 36
 Quality Circles
 Group of employees who meet
regularly to solve problems
 Trained in planning, problem
solving, and statistical methods
 Often led by a facilitator
 Very effective when done
properly

© 2008 Prentice Hall, Inc. 6 – 37

 Benchmarking
Selecting best practices to use as a
standard for performance rnal
e i nt king
e
Us hmar ig
 Determine what to c re b
be n ’
benchmark o u
if y nough
e
 Form a benchmark team
 Identify benchmarking partners
 Collect and analyze benchmarking
information
 Take action to match or exceed the
benchmark
© 2008 Prentice Hall, Inc. 6 – 38
 Benchmarking Factors for
Web Sites
Use of meta tags Yes: 70%, No: 30%
Meaningful homepage title Yes: 97%, No: 3%
Unique domain name Yes: 91%, No: 9%
Search engine registration Above 96%
Average loading speed 28K: 19.31, 56K:
10.88, T1: 2.59
Average number of spelling errors 0.16
Visibility of contact information Yes: 74%, No: 26%
Presence of search engine Yes: 59%, No: 41%
Translation to multiple languages Yes: 11%, No: 89%

Table 6.3
© 2008 Prentice Hall, Inc. 6 – 39
 Best Practices for Resolving
Customer Complaints
 Make it easy for clients to complain
 Respond quickly to complaints
 Resolve complaints on first contact
 Use computers to manage
complaints
 Recruit the best for customer
service jobs
© 2008 Prentice Hall, Inc. 6 – 40
 Just-in-Time (JIT)
Relationship to quality:

 JIT cuts the cost of quality

 JIT improves quality
 Better quality means less
inventory and better, easier-to-
employ JIT system

© 2008 Prentice Hall, Inc. 6 – 41

 Just-in-Time (JIT)

 ‘Pull’ system of production scheduling

including supply management
 Production only when signaled
 Allows reduced inventory levels
 Inventory costs money and hides process
and material problems
 Encourages improved process and
product quality

© 2008 Prentice Hall, Inc. 6 – 42

 Just-In-Time (JIT) Example

Work in process
inventory level
(hides problems)

Unreliable Capacity
Vendors Scrap
Imbalances

© 2008 Prentice Hall, Inc. 6 – 43

 Just-In-Time (JIT) Example
Reducing inventory reveals
problems so they can be solved

Unreliable Capacity
Vendors Scrap
Imbalances

© 2008 Prentice Hall, Inc. 6 – 44

 Taguchi Concepts
 Engineering and experimental
design methods to improve product
and process design
 Identify key component and process
variables affecting product variation
 Taguchi Concepts
 Quality robustness
 Quality loss function
 Target-oriented quality
© 2008 Prentice Hall, Inc. 6 – 45
 Quality Robustness

 Ability to produce products

uniformly in adverse manufacturing
and environmental conditions
 Remove the effects of adverse
conditions
 Small variations in materials and
process do not destroy product
quality

© 2008 Prentice Hall, Inc. 6 – 46

 Quality Loss Function
 Shows that costs increase as the
product moves away from what
the customer wants
Target-
 Costs include customer oriented
dissatisfaction, warranty quality
and service, internal
scrap and repair, and costs to
society
 Traditional conformance
specifications are too simplistic
© 2008 Prentice Hall, Inc. 6 – 47
 Quality Loss Function
High loss L = D2 C
Unacceptable where
Loss (to L = loss to
producing Poor society
organization,
customer, Fair D = distance from
and society) target value
Good
C = cost of
Best deviation
Low loss Target-oriented quality
yields more product in
the “best” category
Target-oriented quality
brings product toward
Frequency the target value
Conformance-oriented
quality keeps products
within 3 standard
deviations
Lower Target Upper
Specification Figure 6.5
© 2008 Prentice Hall, Inc. 6 – 48
 Tools of TQM
 Tools for Generating Ideas
Check sheets
Scatter diagrams
Cause-and-effect diagrams
 Tools to Organize the Data
Pareto charts
Flowcharts
 Tools for Identifying Problems
Histogram
Statistical process control chart
© 2008 Prentice Hall, Inc. 6 – 49
 Seven Tools of TQM
(a) Check Sheet: An organized method of
recording data

Hour
Defect 1 2 3 4 5 6 7 8
A /// / / / / /// /
B // / / / // ///
C / // // ////

Figure 6.6

© 2008 Prentice Hall, Inc. 6 – 50

 Seven Tools of TQM
(b) Scatter Diagram: A graph of the value
of one variable vs. another variable
Productivity

Absenteeism

Figure 6.6

© 2008 Prentice Hall, Inc. 6 – 51

 Seven Tools of TQM
(c) Cause-and-Effect Diagram: A tool that
identifies process elements (causes) that
might effect an outcome

Cause
Materials Methods
Effect

Manpower Machinery
Figure 6.6

© 2008 Prentice Hall, Inc. 6 – 52

 Seven Tools of TQM
(d) Pareto Chart: A graph to identify and plot
problems or defects in descending order of
frequency
Frequency

Percent
A B C D E
Figure 6.6

© 2008 Prentice Hall, Inc. 6 – 53

 Seven Tools of TQM
(e) Flowchart (Process Diagram): A chart that
describes the steps in a process

Figure 6.6

© 2008 Prentice Hall, Inc. 6 – 54

 Seven Tools of TQM
(f) Histogram: A distribution showing the
frequency of occurrences of a variable
Distribution
Frequency

Repair time (minutes)

Figure 6.6

© 2008 Prentice Hall, Inc. 6 – 55

 Seven Tools of TQM
(g) Statistical Process Control Chart: A chart with
time on the horizontal axis to plot values of a
statistic

Upper control limit

Target value

Lower control limit

Time
Figure 6.6

© 2008 Prentice Hall, Inc. 6 – 56

 Cause-and-Effect Diagrams
Material Method
(ball) (shooting process)
Grain/Feel Aiming point
(grip)
Size of ball
Air pressure Bend knees
Hand position
Balance
Lopsidedness
Follow-through
Missed
Training
free-throws
Rim size

Conditioning Motivation Rim height

Consistency Rim alignment Backboard

stability
Concentration

Machine
Manpower
(hoop & Figure 6.7
(shooter)
backboard)
© 2008 Prentice Hall, Inc. 6 – 57
 Pareto Charts
Data for October
– 100
70 – – 93
– 88
60 – 54
Frequency (number)

Cumulative percent
– 72
50 –
40 –
Number of
30 – occurrences
20 –
12
10 –
4 3 2
0 –
Room svc Check-in Pool hours Minibar Misc.
72% 16% 5% 4% 3%
Causes and percent of the total

© 2008 Prentice Hall, Inc. 6 – 58

 Flow Charts
MRI Flowchart
1. Physician schedules MRI 7. If unsatisfactory, repeat
2. Patient taken to MRI 8. Patient taken back to room
3. Patient signs in 9. MRI read by radiologist
4. Patient is prepped 10. MRI report transferred to
5. Technician carries out MRI physician
6. Technician inspects film 11. Patient and physician discuss

8
80%
1 2 3 4 5 6 7 11
9 10
20%

© 2008 Prentice Hall, Inc. 6 – 59

 Statistical Process Control
(SPC)
 Uses statistics and control charts to
tell when to take corrective action
 Drives process improvement
 Four key steps
 Measure the process
 When a change is indicated, find the
assignable cause
 Eliminate or incorporate the cause
 Restart the revised process
© 2008 Prentice Hall, Inc. 6 – 60
 An SPC Chart
Plots the percent of free throws missed

Upper control limit

20%

10%
Coach’s target value

| | | | | | | | | Lower control limit

0% 1 2 3 4 5 6 7 8 9

Game number
Figure 6.8

© 2008 Prentice Hall, Inc. 6 – 61

 Inspection
 Involves examining items to see if
an item is good or defective
 Detect a defective product
 Does not correct deficiencies in
process or product
 It is expensive
 Issues
 When to inspect
 Where in process to inspect
© 2008 Prentice Hall, Inc. 6 – 62
 When and Where to Inspect
1. At the supplier’s plant while the supplier is
producing
2. At your facility upon receipt of goods from
the supplier
3. Before costly or irreversible processes
4. During the step-by-step production
process
5. When production or service is complete
6. Before delivery to your customer
7. At the point of customer contact
© 2008 Prentice Hall, Inc. 6 – 63
 Inspection
 Many problems
 Worker fatigue
 Measurement error
 Process variability
 Cannot inspect quality into a
product
 Robust design, empowered
employees, and sound processes
are better solutions
© 2008 Prentice Hall, Inc. 6 – 64
 Source Inspection
 Also known as source control
 The next step in the process is
your customer
 Ensure perfect product
to your customer

Poka-yoke is the concept of foolproof devices

or techniques designed to pass only
acceptable product

© 2008 Prentice Hall, Inc. 6 – 65

 Service Industry Inspection
What is
Organization Standard
Inspected
Jones Law Office Receptionist Is phone answered by the
performance second ring
Billing Accurate, timely, and
correct format
Attorney Promptness in returning
calls

Table 6.5

© 2008 Prentice Hall, Inc. 6 – 66

 Service Industry Inspection
What is
Organization Standard
Inspected
Hard Rock Hotel Reception Use customer’s name
desk
Doorman Greet guest in less than 30
seconds
Room All lights working, spotless
bathroom
Minibar Restocked and charges
accurately posted to bill

Table 6.5

© 2008 Prentice Hall, Inc. 6 – 67

 Service Industry Inspection
What is
Organization Standard
Inspected
Arnold Palmer Billing Accurate, timely, and
Hospital correct format
Pharmacy Prescription accuracy,
inventory accuracy
Lab Audit for lab-test accuracy
Nurses Charts immediately
updated
Admissions Data entered correctly and
completely

Table 6.5

© 2008 Prentice Hall, Inc. 6 – 68

 Service Industry Inspection
What is
Organization Standard
Inspected
Olive Garden Busboy Serves water and bread
Restaurant within 1 minute
Busboy Clears all entrée items and
crumbs prior to dessert
Waiter Knows and suggest
specials, desserts

Table 6.5

© 2008 Prentice Hall, Inc. 6 – 69

 Service Industry Inspection
What is
Organization Standard
Inspected
Nordstrom Display areas Attractive, well-organized,
Department stocked, good lighting
Store
Stockrooms Rotation of goods,
organized, clean
Salesclerks Neat, courteous, very
knowledgeable

Table 6.5

© 2008 Prentice Hall, Inc. 6 – 70

 Attributes Versus Variables
 Attributes
 Items are either good or bad,
acceptable or unacceptable
 Does not address degree of failure
 Variables
 Measures dimensions such as weight,
speed, height, or strength
 Falls within an acceptable range
 Use different statistical techniques

© 2008 Prentice Hall, Inc. 6 – 71

 TQM In Services
 Service quality is more difficult to
measure than the quality of goods
 Service quality perceptions depend
on
 Intangible differences between
products
 Intangible expectations customers
have of those products

© 2008 Prentice Hall, Inc. 6 – 72

 Service Quality
The Operations Manager must
recognize:
1. The tangible component of
services is important
2. The service process is important
3. The service is judged against the
customer’s expectations
4. Exceptions will occur

© 2008 Prentice Hall, Inc. 6 – 73

 Service
Specifications
at UPS

© 2008 Prentice Hall, Inc. 6 – 74

 Determinants of Service
Quality
 Reliability  Credibility
 Responsiveness  Security
 Competence  Understanding/
 Access knowing the
customer
 Courtesy
 Tangibles
 Communication

© 2008 Prentice Hall, Inc. 6 – 75

 Service Recovery Strategy
 Managers should have a plan for
when services fail
 Marriott’s LEARN routine
 Listen
 Empathize
 Apologize
 React
 Notify

© 2008 Prentice Hall, Inc. 6 – 76