SESSION – 7-

TOTAL
QUALITY
MANAGEMENT
By:
Zahid Hussain
Quality Trainer
MS-Total Quality Management
IRCA Lead Auditor ISO-9001-2000
B.Sc Engineering (Chemical)
PCBA–UCP
Leaders in Quality
Revolution Q in Descon Chemicals
Dr. Edward W. Deming

(Management Philosophy
and Systems) (1900-
1993) The Statistician Dr. Kaoru Ishikawa
USA Simple tools, QCC,
Dr. Joseph M.
Company-wide quality)
Juran
(Quality Trilogy)
(1915-1989) Age-74,
Japan, Mechanical
(1904-2008 -103 Engineer
years age)- USA-
industrial engineer
Dr. Philip Crosby Dr. Genichi Taguchi
Zero defects and Cost (Loss Function), 1924-
of quality) (1926 1989 65 years, Japan,
-2001) Age 75) USA. Textile Engineer
 Dr. Genichi Taguchi
 Mechanical Engineer – Won Deming award -4 times
 Taguchi methods emphasize consistency of
performance and reduced variation, (Cost, target &
Variation)
 Quality Loss function (deviation from target is a loss )
 Parameter design which is an application of Design of
Experiments (DOE).

 It is a structured and
Taguchi Definition of Quality:
organized method used to
– Stresses on engineering approach to Quality
determine the relationship
– between
Produce with minimum variation the different
to target goals
– factors (XS) effecting a
Focus on Design for Quality
– Quality is Loss function.process and the output of
process (Y).

The application of scientific and mathematical principles to practical ends

such as the design, manufacture, and operation of efficient and economical
structures, machines, processes, and systems
 TAGUCHI LOSS FUNCTION
Traditional Loss Function
Loss Incurred
Goal Post View

Upper
Specificatio
n Limit

No Loss Incurred

Lower
Specificatio
n Limit

Loss Incurred
TAGUCHI LOSS FUNCTION
 TAGUCHI LOSS FUNCTION
 Loss function; provides a process for
computing the cost of deviation
from the target value.

 Taguchi’s view was that any variation

from the expected value was a loss.
This places emphasis or reducing
process variation, not merely
accepting it.

 If process variation can be

reduced, then design tolerances can
be reduced. This increases quality of
manufacturing and quality of the
product. The ultimate aim of Taguchi
would be zero tolerance.
TAGUCHI LOSS FUNCTION
 TAGUCHI LOSS FUNCTION
– Quality is Loss function.
 Loss function measures quality
 Loss function establishes a financial measure of the
user dissatisfaction with product performance as it
deviate from a target value.
 Product quality is influenced by uncontrolled sources
of variance i.e. the noise factors.
 Concept of societal loss (failure to meet customer
requirements and ideal performance, harmful side
effects, toxic by product)
 Example of vinyl sheet thickness
 TAGUCHI LOSS FUNCTION
Sony Corporation- An
Example

• Sony uses the Taguchi model in managing the

television sets it produces.

• Quality characteristic=Color density of the

televisions.

• Color density measured between Upper and

lower tolerance level.

• The Taguchi model provides a good way to

analyze the costs associated with variability, even
within the limits.
 TAGUCHI LOSS FUNCTION
Sony Corporation- An
Activity Example
Plant 1 Plant 2
Color density uniformly distributed normal distribution with
measured televisions that fell an average near the set
between UTL & between the target.
LTL. specification limits.
Quality Control focusing on a defect rate focusing variation from
rather than a variation target rather than the
from the target. defect rate

Shipment shipped at a zero shipped at a zero

defect rate, the defect rate, the limits
specification limits were smaller and the
allowed for too much quality was more
variation consistent
Customer Lower level of higher level of
Response satisfaction satisfaction
 TAGUCHI LOSS FUNCTION
Sony Corporation- An
Example

LTL Target UTL LTL Target UTL

Conclusion
If companies want to remain competitive, they have to
provide quality products. To accomplish this, a
company must focus on the reduction of
variability of a product’s characteristics
around a specific target value. The traditional
approach is not enough. To remain a world competitor, a
company must consider the Taguchi QLF
 Dr. Joseph M. Juran
 “Fitness for Use”
 Seven Basic ways to improve
 Renowned for his quality trilogy.
– QUALITY TRILOGY:
 Quality Planning.
 Quality Control.
 Quality Improvement
 Seven basic ways to
Improve
 Optimize resources (Process- optimize resources,
Improve controls)
 Reduce Errors. (Better Control Reduce and eliminate
rework and wastes).
 Meet or exceed expectations of customer
 Register abnormalities (find root cause , do
corrective action, document for future)
 Use technical tools (like statistical process
Control, benchmarking etc)
 Education and training.
 Make the Process safer.
 Approaches towards
Continuous Improvements
 Juran’sTrilogy
 Shewhart’s Plan-Do-Study-Act Cycle
 Kaizen (Change +Good)
 Reengineering
(Rethinking , Redesign of business processes to
achieve dramatic improvements)
 Six Sigma
(Tool used to measure process capability)
 JURAN’S TRILOGY
Quality Planning.
Development Transferring
Determination Needs of Development
Of Product Plans to
of External External Of The
Or Services Operations.
Customers Customers Process
Features

Quality Control.
Measurement Comparison Act on the
Determination Of actual with
Set Goals Of Actual differences.
Of Items Goals
Performance

Quality Improvement.
 Allocate Resources, People to Pursue Quality
 Training
 Repair

Refinement

Renovation
Strategies
Improvement

Reinvention
 Improvement
Strategies
 Repair:
 “Anything broken must be fixed so that it functions
as designed.”
 Strategies divided into two levels:

1. Temporary or Short- term measure (Correction)

2. Permanent measure (Corrective action)
 Refinement:
 “Activities that continually improve a process that is
not broken.”
 Gradual change – face little resistance from
employees

 Improvement
Strategies
 Renovation:
 “This Strategy results in major or breakthrough
Improvement.”
 It look different from original but same. (Hole drilling
by hands and by drill machine)
 Innovation & technological advancement are key
factors in this approach. (Rechargeable drill machine
same as hand drill)
 Reinvention (Re-Engineering):
 “Reinvention begins by imagining that the current
approach can never satisfy customer requirements. (
Reinvention is done by understanding customer
requirement, such as process of drilling hole by laser.)
QUESTION
S