TQM Webinar and Quality Failures Case Studies
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Questions and Answers

What is a key outcome of effective Daily Management?

  • Increased complexity in monitoring parameters
  • Maintaining stability and consistency in outputs (correct)
  • Delivering unreliable outputs
  • Ability to ignore performance deviations

What does the trend line in management indicate?

  • Historical performance only
  • Potential future performance if targets are set (correct)
  • Current performance levels without deviations
  • Unchanging processes for all future years

What should all members commit to for successful Daily Management?

  • Permanent implementation of existing processes
  • Consistent, long-term commitment (correct)
  • Avoidance of performance monitoring
  • Short-term results and immediate fixes

What can a lack of Daily Management lead to?

<p>Failure to achieve improvement objectives (B)</p> Signup and view all the answers

What is a primary focus of Policy Management?

<p>Achieving set targets through structured methods (C)</p> Signup and view all the answers

Which of the following is NOT a focus area of Daily Management?

<p>Creating rigid processes (B)</p> Signup and view all the answers

Why is understanding 'what' is needed to keep parameters stable important?

<p>To make informed decisions about performance (A)</p> Signup and view all the answers

What is a consequence of setting 'stretched' targets by management?

<p>Need for increased performance levels (B)</p> Signup and view all the answers

What is a key challenge in the steel recycling business regarding suppliers?

<p>Ensuring Quality as Zero-day Requirement (A)</p> Signup and view all the answers

Which methodology is specifically mentioned as a part of the Integrated TQM Framework?

<p>Theory of Constraints (TOC, CCPM) (B)</p> Signup and view all the answers

What does the guiding principle of SII stand for?

<p>Standardise, Improve, Innovate (B)</p> Signup and view all the answers

In the context of Daily Management, what is the primary goal?

<p>To stabilize regular jobs for consistent outcomes (C)</p> Signup and view all the answers

What does capability building of suppliers relate to?

<p>Aligning with Tata Steel’s growth plans (C)</p> Signup and view all the answers

Which aspect is NOT a part of the Integrated TQM Framework's review & assessment?

<p>Ad hoc audits (D)</p> Signup and view all the answers

What is the primary purpose of the PDCA cycle within the improvement framework?

<p>To promote continuous improvement processes (A)</p> Signup and view all the answers

What is the primary focus of Retail Value Management within the TQM framework?

<p>Enhancing customer interactions and sales (C)</p> Signup and view all the answers

Which committee is primarily responsible for overseeing reviews related to quality, safety, and environmental concerns?

<p>Apex Review Committee (D)</p> Signup and view all the answers

What is a common misconception about sustainability in the context of logistics?

<p>It only involves reducing transportation costs (C)</p> Signup and view all the answers

How are departmental reviews structured according to the governance mechanism?

<p>Led by department heads or chiefs (A)</p> Signup and view all the answers

What role does the suggestion box play in the governance mechanism for quality improvement?

<p>To provide a channel for employee feedback (A)</p> Signup and view all the answers

Which of the following is NOT a key deliverable outlined in the governance mechanism?

<p>Conducting external audits (B)</p> Signup and view all the answers

Which committee is dedicated to support functions like facilitation and reviews of TQM plans?

<p>Central TQM Committee (B)</p> Signup and view all the answers

In the context of the improvement cycle, which statement about SDCA is correct?

<p>It is aimed at sustaining improvements already achieved. (B)</p> Signup and view all the answers

Who typically chairs the divisional reviews within the governance structure?

<p>Vice Presidents (C)</p> Signup and view all the answers

What is the primary role of the VP TQM in Tata Steel?

<p>Overseeing TQM and supply chain initiatives (D)</p> Signup and view all the answers

Which initiative focuses on daily management and employee involvement?

<p>TPM (D)</p> Signup and view all the answers

Who is responsible for driving improvements through analytics at Tata Steel?

<p>Avinash Kumar (B)</p> Signup and view all the answers

What does the DATOM stand for in the context of Tata Steel?

<p>Data and Analytics Target Operating Model (B)</p> Signup and view all the answers

Which role focuses on the implementation of quality assurance across the value chain?

<p>Chief TQM &amp; CQA (D)</p> Signup and view all the answers

What is the purpose of the Tata Education Excellence Programme (TEEP)?

<p>To deploy TQM and CQA at TSK (A)</p> Signup and view all the answers

Which model is associated with enhancing customer value management?

<p>RVM (D)</p> Signup and view all the answers

Who leads the initiatives related to Learning & Innovation at Tata Steel?

<p>Ankur Gandotra (C)</p> Signup and view all the answers

What is the primary focus of employee engagement in Quality Circles?

<p>Team-based activities addressing local problems (D)</p> Signup and view all the answers

Which of the following roles are primarily involved full-time in facilitating TQM deployment?

<p>Improvement Managers (A)</p> Signup and view all the answers

In the framework for people involvement, what does KPI stand for?

<p>Key Performance Indicator (C)</p> Signup and view all the answers

Which of the following is NOT a key performance indicator (KPI) related to employee engagement?

<p>Rate of Employee Turnover (C)</p> Signup and view all the answers

What type of teams are formed temporarily to address specific tasks related to employee development?

<p>Temporary Task Forces (D)</p> Signup and view all the answers

Which method focuses on managing organizational improvement through systematic approaches?

<p>Total Quality Management (TQM) (D)</p> Signup and view all the answers

Which of the following is a distinguishing feature of the SGA activity in people involvement?

<p>Focus on local workplace problems (B)</p> Signup and view all the answers

What does the focus on 'Suggestions' in employee engagement primarily aim to achieve?

<p>Foster innovative ideas from employees (C)</p> Signup and view all the answers

What does TQM primarily focus on as a vehicle for improvement?

<p>Driving business excellence (B)</p> Signup and view all the answers

Which project is aimed at accelerating EBITDA improvement?

<p>Shikhar25 (D)</p> Signup and view all the answers

Which year did the launch of ASPIRE-6 Sigma occur?

<p>2005 (A)</p> Signup and view all the answers

What is the primary objective of the TQM Diagnosis mentioned?

<p>Improving customer delight (A)</p> Signup and view all the answers

The term 'Digital Value Acceleration' refers to which aspect of TQM?

<p>Enhancing customer experience (B)</p> Signup and view all the answers

Which of the following is a key component of the Total Operational Performance (TOP)?

<p>Employee involvement (D)</p> Signup and view all the answers

What characterizes the 'KVHS' approach in TQM practices?

<p>A focused problem-solving approach (C)</p> Signup and view all the answers

During which period was the emphasis on standardization in TQM established?

<p>1988 - 1991 (A)</p> Signup and view all the answers

What accolade did the organization receive in 2012 related to TQM?

<p>Deming Grand Prize (A)</p> Signup and view all the answers

Which initiative aims to promote internal talent exchange?

<p>StepUP (A)</p> Signup and view all the answers

The concept of Cross Functional Approach in TQM mainly targets which aspect?

<p>Solving complex problems (C)</p> Signup and view all the answers

Which initiative contributed to the rise of innovation through market-led strategies?

<p>Innovent (D)</p> Signup and view all the answers

What does the term 'Awareness to Delight' primarily imply in TQM?

<p>Transforming customer experiences (A)</p> Signup and view all the answers

Which award recognizes advancements in quality in the field of operational performance?

<p>JRD QV Award (C)</p> Signup and view all the answers

Flashcards

Multi-sourcing

Obtaining raw materials from multiple sources.

Green Steel

Steel produced with sustainable practices.

Green Warehousing

Warehousing that minimizes environmental impact.

Integrated TQM

A framework that links quality across the entire production process.

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Daily Management

Managing routine tasks to ensure consistent and predictable outputs aligning with customer needs.

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Zero-day Requirement

Quality standards required immediately during production.

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Supplier Relationship Management (SRM)

Managing relationships with suppliers.

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Standardization

Creating consistent systems and processes.

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Daily Management (DM)

Managing routine tasks to ensure consistent and predictable output, aligning with customer needs.

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Performance Monitoring

Systematically tracking key performance indicators (KPIs) to understand current performance levels.

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Policy Management (PM)

High-level approach to setting objectives and strategies for consistent results.

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Stable Output

Consistent and predictable results meeting customer expectations.

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Deviation Handling

Strategies and actions for dealing with unexpected issues to maintain control.

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Long-Term Commitment

Continuous effort and dedication from all team members to achieve goals.

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Target Setting

Defining specific performance metrics to evaluate and guide action plans.

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Trend Line Performance

Visual representation of expected performance levels based on current processes.

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PDCA Cycle

A cyclical process for continuous improvement, involving Plan, Do, Check, and Act.

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SDCA Cycle

A cyclical process for sustaining improvements, building on the PDCA cycle.

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Governance Mechanism

A system of committees and reviews to manage and monitor TQM implementation.

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Joint Committees

Groups of union and management representatives working toward quality goals.

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Apex Review

A high-level review of quality, safety, and environmental performance.

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Divisional Reviews

Reviews of TQM at the level of business sections.

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Departmental Reviews

Reviews for quality in individual departments

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Key Deliverables (TQM)

The clear outcomes and outcomes of TQM processes.

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TPM

Total Productive Maintenance, a structured approach to maximize equipment uptime and efficiency.

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TBEM

Tata Business Excellence Model, a framework for organizational excellence and best practices.

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Head TQM - DM

Driving Daily Management, Quality Management Systems and Employee Involvement, specifically at a division level.

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Head TQM – Analytics

Driving improvements in initiatives through focused methodologies.

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Head CQA

Implementation of quality assurance requirements throughout the value chain.

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Head TQM-Org.

Driving innovation and learning.

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ASPIRE

Aspirational Initiative to Retain Excellence, a program aimed at upholding high quality standards.

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TQM Organizational Structure

Tata Steel India's structure for implementing Total Quality Management, showcasing key roles and responsibilities.

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Quality Circles

Employee-led teams focused on quality improvements within a specific workplace.

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DMAIC/DMADC/TOC/CCPM

Methods for improving business processes, encompassing problem-solving, lean methodologies, project management for quality, strategic planning etc.

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Employee Involvement KPI

Measures the percentage of employees actively participating in quality improvement initiatives.

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Improvement Managers

Full-time employees dedicated to driving quality improvements within their divisions or profit centers.

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TQM Coordinators

Part-time employees facilitating quality efforts within various departments.

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Apex Review

High-level quality, safety, and environmental performance evaluation.

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Framework for People Involvement

Structure and processes for employee engagement in quality improvement initiatives.

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Knowledge Management

System for collecting, sharing, and retaining valuable information about a company.

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TQM Practices

Total Quality Management practices involve a focus on improving quality across all areas of a business

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Prioritization of Focus Areas

Identifying key areas that need the most attention for quality improvement

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Cross-functional Approach

Working together across different departments to solve problems and improve quality

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Triggers for Change

Events or factors that lead to changes in quality improvement efforts.

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TQM Response

How a company reacts to quality improvement triggers.

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Agility (AWOW)

Ability to adapt and change quickly, often used in quality projects

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Customer Delight

Going beyond customer expectations to ensure complete satisfaction.

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Value Discovery

Finding and recognizing the worth of any aspect of an operation.

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Deming Prize

A prestigious award for quality improvement, often recognized globally.

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Digital Value Acceleration

Using technology to boost the value of a company's outputs.

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Corporate Quality Assurance

Ensuring consistent quality standards across a company

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Integrated TQM Framework

A system that ties various quality improvement approaches into one plan.

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TBEM

Tata Business Excellence Model, a framework for measuring business excellence.

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Cost Competitiveness

Focus on reducing costs while maintaining quality.

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Operational Efficiency

Performing tasks with minimal resources and maximum output

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Study Notes

SAKSHAM: IL6 Webinar for Logistics - Overview of TQM

  • Webinar focused on Total Quality Management (TQM) for logistics.
  • Presented by Tata Steel.

Ignoring Quality - A Recipe for Catastrophe (Case 1) - Chernobyl Disaster (1986)

  • Quality failures contributed to the Chernobyl disaster.
  • Safety test mishandlings and inadequate training were cited as quality failures.
  • Reactor design flaws and a lack of safety culture/emergency preparedness contributed to the disaster.
  • Significant release of radioactive materials, immediate deaths, and long-term health effects resulted.
  • Design flaws, deviations from operational procedures, insufficient operator training, and poor communication were identified as quality rule violations.

Ignoring Quality - A Recipe for Catastrophe (Case 2) - Samsung Galaxy Note 7 Recall (2016)

  • Samsung Galaxy Note 7 was recalled due to widespread battery overheating and fire issues.
  • Quality failures included battery design flaws, manufacturing defects, and inadequate quality control.
  • Financial losses, customer safety concerns, and damage to consumer trust resulted from the recall and discontinuation.
  • Insufficient testing, rapid production, and design flaws were among the main issues.

TQM Definition

  • Total Quality Management (TQM) comprises systematic activities carried out by the entire organization to achieve company objectives.
  • Goal is to provide products/services with quality that meets customer needs on time and at the correct price.
  • TQM is a complete management system encompassing philosophy, principles, methods, and tools.
  • Successful implementation requires a comprehensive approach rather than standalone components or cherry-picking.

Steel Making at Tata Steel India: Long and Complex Value Chain

  • Crude steel production at Tata Steel has doubled since 2015.
  • Number of dealers and Steel Processing Centers have increased significantly.
  • Tata Steel is focused on sustainability, evidenced by developments in recycling, green steel, and green warehousing.

Key Challenges

  • Multi-sourcing/variation in raw material quality is a key challenge.
  • Logistics and transportation pose further challenges due to increasing demand and volume.
  • Expanding to newly-acquired units & contract manufacturing raises new challenges for quality assurance.
  • Setting quality as a zero-day requirement demands high implementation standards and capability building of suppliers/partners.

Integrated TQM Framework

  • Framework integrates various methodologies to bind the process from mining to finished products.
  • Components include focused methodologies, TQM vehicles, and review & assessment mechanisms.
  • Focused methodologies focus on problem-solving, achievments through the Shikar 25, TOC(CCPM), Knowledge Management, Retail Value Management, & Supplier Relationships.
  • TQM Vehicles include Policy Management, Daily Management, Cross-functional Management, Small Group Activities, & Suggestion Management.
  • Review & Assessment mechanism track performance through tracking and periodic assessments.
  • Standardization (Systems and Processes) forms the core of the framework.
  • Education & Training play a vital role in the success of the framework.
  • Guiding Principle: Standardize, Improve, Innovate.

SII - Key Dimensions of Improvement

  • Adaptation of a Buddhist motif illustrating the interconnectedness of past, present, and future, with the elements of Innovation, Improvement, and Standardization.

What is Daily Management?

  • Focuses on stabilizing routine jobs to provide consistent and predictable outcomes that match customer needs.
  • Enables a systematic approach to monitoring performance parameters.
  • Understanding and managing deviations is crucial for maintaining stability.
  • Emphasis is placed on delivering consistent and stable outcomes.

Policy Management (PM) and Daily Management (DM)

  • Policy Management sets targets for performance.
  • Daily Management ensures stability to achieve targets.
  • Trend line analysis reveals performance levels under both scenarios (setting targets vs. continuing processes).

Why Daily Management is important

  • Leads to big improvements through effective policy management, problem-solving, and task achievement.
  • Stability is necessary for progress via continuous, long-term commitment.

PDCA and SDCA

  • PDCA (Plan-Do-Check-Act) and SDCA (Standardize-Do-Check-Act) are iterative improvement cycles used for cyclical process improvement.
  • The cycle includes analyzing the process to identify root causes of recurrence, implementing remedies, checking the process against the plan, and achieving targets.

Governance Mechanism

  • System of management committees and joint committees for monitoring and reviewing TQM methodologies.

Triggers for change addressed through unwavering focus on Quality

  • Company seeks various strategic changes including agility, organizational responsiveness, talent engagement, and market-leading practices.
  • TQM emphasizes a variety of approaches including digitalization, internal talent development, market-led innovation, and problem-solving frameworks.
  • Focus is on developing customer awareness, measuring effectiveness, and enhancing efficiency/effectiveness.

Tata Steel India: TQM Organizational Structure

  • Organizational diagram outlines the leadership and key personnel responsible for different TQM-related functions, including roles for quality and supply chain management.

Framework for People Involvement

  • Emphasizes employee involvement through Small Group Activities (SGA) and Manthan Ab Shopfloor Se+ (MASS+).
  • Employee participation is incentivized through various types of team-based activities and suggestion management approaches.

TQM Means Understanding

  • TQM involves understanding job objectives, client needs, the complexities of processes, the importance of measurement (Control charts/trend charts), and the role of standardized operations.
  • Dealing with deviations, complaints, and implementing corrective actions is critical for successful TQM.

Overall

  • The presentation highlights the importance of consistent TQM practices to achieve sustainable business excellence. -TQM principles and methodologies are highlighted throughout the presentation.

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TQM Overview PDF

Description

This quiz covers an overview of Total Quality Management (TQM) presented in a Tata Steel webinar, focusing on its application in logistics. It also explores critical quality failures through case studies of the Chernobyl disaster and the Samsung Galaxy Note 7 recall, emphasizing the consequences of ignoring quality standards.

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