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CONCEPT
Joseph Juran first discussed cost of quality analysis in 1951 in the first edition of Quality Control Handbook It was first described by Armand V. Feigenbaum in a 1956. In Process improvement efforts, the concept of quality costs or cost of quality is a means to quantify the total cost of quality related efforts and deficiencies. Definition:Quality costs are alll those costs that arise from not performing a task the right way the first time. In short it is cost of poor products or services.
Classification
Non conformance
conformance
Conformance Costs
A. Prevention costs: Costs associated with all activities designed to prevent defects in product or service. These include : The direct and indirect costs related to quality training and education, pilot studies, quality circles, quality engineering, etc. These costs are used to build awareness of the quality program and to keep the costs of appraisal and failure to a minimum. Prevention costs are all costs incurred in an effort to make it right the first time.
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Conformance Costs
B. Appraisal costs The costs associated with measuring and evaluating the product or service quality to ensure conformance. These include the cost of inspection, test or audit of purchases, manufacturing or process operations and finished goods or services. The direct and indirect costs of the various tests & inspections to determine the degree of conformity are included in this category.
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Non-Conformance Costs
These are associated with products or services that do not conform the customer's requirement. They are often referred to as failure costs and consist of two types. Internal failure costs: costs incurred prior to the shipment of the product or the delivery of the service. These costs are associated with defects that are found prior to customer delivery. These include the net cost of scrap, re-inspection and retest, downtime due to quality problems, opportunity cost of product classified as seconds, or other product downgrades. These costs would disappear if there were no defects in the product.
A.
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5. Downgrading cost: The price differential between the normal selling price and any selling price that might be obtained for a product that does not meet the customers requirements. Downgrading is common in the textile, apparel goods, electronics, and carpet industries. 14
B.
The costs of discovered defects occurring after product shipment or service delivery. These costs include warranty charges, customer complaint adjustments, returned merchandise, product recalls, allowances, and product liability. They also include the direct and indirect costs such as labor and travel associated with the investigation of customer complaints, warranty field inspection, tests and repairs. These costs would disappear if every unit of product conforme to requirements and specifications.
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3. 4.
Complaint adjustment: all cost of investigation and adjustment of justified complaints attribute to the nonconforming product. Returned product & material: all costs associated with receipt, handling, and replacement of the nonconforming product or material returned from the field. Also recalls of defective product. Warranty charges: all costs involved in service to customers under warranty contracts. Includes repair and replacement of product or parts. Indirect costs: in addition to direct operating costs of external failures, there are some indirect costs. Customer dissatisfaction with the level of quality Loss of good-will; loss of business reputation; loss of future business; loss of market share.
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Cost of Quality =
Cost of Prevention+Cost of Appraisal +Cost of Failure
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QUALITY IMPROVEMENT
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Failure costs
Quality of conformance %
100
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