Chapter 2 Quality Theory PDF

Chapter 2 Quality Theory Copyright © 2017 Pearson Education, Inc. 2-2 Chapter Objectives 1. Integrate theories and concepts from key thought leaders in quality management. 2. Discuss differing ideas from quality management thought leaders to determine the best methods for managing qual...

Chapter 2 Quality Theory Copyright © 2017 Pearson Education, Inc. 2-2 Chapter Objectives 1. Integrate theories and concepts from key thought leaders in quality management. 2. Discuss differing ideas from quality management thought leaders to determine the best methods for managing quality. 3. Discuss key quality improvement variables and how they combine to create a quality management system. 4. Assess a quality management system using the theoretical framework for quality management. Copyright © 2017 Pearson Education, Inc. 2-3 What is Theory? Theory: “A coherent group of general propositions used as principles of explanation for a class of phenomena” Random House Webster’s College Dictionary 2011. Figure 2-1 Copyright © 2017 Pearson Education, Inc. 2-4 What is Theory? For a theory to be complete, it must have four elements: What – Involves what variables or factors are included in the model How – Involves the nature, direction, and extent of the relationship among the variables Why – The theoretical glue that holds the model together Who-Where-WhenDavis,– J.,The Methods,” aspects Academy of Management that Review 32,place contextual Eisenhardt, K., and Bingham, C., “Developing Theory through Simulation 2(2007): 480–499. boundaries on the theory Copyright © 2017 Pearson Education, Inc. 2-5 What is Theory? Theories are established in one of two ways: Induction – A theory generated by observation and description Deduction – Researchers propose a model based on prior research, and design an experiment to test the theoretical model Deduction moves from idea to observation, while induction movesCopyright from observation © 2017 Pearson Education, Inc. to idea. 2-6 What is Theory? So, is the below hypothesis Inductive or Deductive? Random House Webster’s College Dictionary 2011. Figure 2-1 Copyright © 2017 Pearson Education, Inc. 2-7 Inductive Reasoning Copyright © 2017 Pearson Education, Inc. 2-8 History of Quality Copyright © 2017 Pearson Education, Inc. Table 2-1 2-9 Deming Interview https:// www.youtube.com/ watch?v=tsF-8u-V4j4 Copyright © 2017 Pearson Education, Inc. 2-10 W. Edwards Deming Gained credibility because of his influence on Japanese and American industry Best known for his emphasis on the management of a system for quality His thinking was based on the use of statistics for continual improvement. He provided lectures on statistical quality control to the Japanese Union of Scientists and Engineers after World War II. The United States hired him when they realized that they were lagging behind Japan in quality. Copyright © 2017 Pearson Education, Inc. 2-11 Deming 14 Points of Management Deming believed that the historic approach to quality used by American management was wrong in one fundamental aspect: Poor quality was not the fault of labor. It resulted from poor management of the system for continual improvement. Copyright © 2017 Pearson Education, Inc. 2-12 Deming 14 Points of Management 1. Create constancy of purpose toward improvement of product and service with the aim to become competitive, stay in business, and provide jobs. 2. Adopt a new philosophy. We are in a new economic age. 3. Cease dependence on mass inspection to improve quality. 4. End the practice of awarding business on the basis of price tag alone. Copyright © 2017 Pearson Education, Inc. 2-13 Deming 14 Points of Management (cont’d) 5. Improve constantly and forever the system of production and service to improve quality and productivity, and thus constantly decrease cost. 6. Institute training on the job. 7. Improve leadership. Copyright © 2017 Pearson Education, Inc. 2-14 Deming 14 Points of Management (cont’d) 8. Drive out fear so that everyone may work effectively for the company. 9. Break down barriers between departments. 10. Eliminate slogans, exhortations, and targets for the workforce that ask for zero defects and new levels of productivity. 11. Eliminate work standards on the factory floor. Copyright © 2017 Pearson Education, Inc. 2-15 Deming 14 Points of Management (cont’d) 12. Remove barriers that rob workers of their right to pride in the quality of their work. 13. Institute a vigorous program of education and self-improvement. 14. Put everybody in the company to work to accomplish the transformation. Copyright © 2017 Pearson Education, Inc. 2-16 Joseph Juran Was responsible for the growth of quality in the past half- century Took a more strategic and planning-based approach to improvement than Deming Promotes the view that organizational quality problems are largely the result of insufficient and ineffective planning for quality Argues that companies must revise strategic planning processes and achieve mastery over these processes Copyright © 2017 Pearson Education, Inc. 2-17 The Juran Trilogy Planning Providing the operating forces with the means of producing products that can meet the customer’s needs Control A process-related activity that ensures processes are stable and provides a relatively consistent outcome Improvement Must be accomplished on a project-by-project basis Copyright © 2017 Pearson Education, Inc. 2-18 Juran’s Pareto Law Called the 80/20 Rule Using Pareto’s law, the majority of quality problems are the result of relatively few causes. Compare the “vital few” to the “trivial, but useful, many” Copyright © 2017 Pearson Education, Inc. 2-19 Kaoru Ishikawa Great believer in training with major contribution on the total involvement of the operating employees in improving quality Developed the basic seven tools of quality (B7) Credited with democratizing statistics Coined the term company-wide quality control Copyright © 2017 Pearson Education, Inc. 2-20 Ishikawa’s 11 Points Adapted from K. Ishikawa, Guide to Quality Control (White Plains, NY: Quality Resources, 1968). Table 2-3 Copyright © 2017 Pearson Education, Inc. 2-21 Armand Feigenbaum Three-step process to improving quality Quality leadership Quality technology Organizational commitment Major impediments to improving quality Hothouse quality Wishful thinking Producing overseas Confining quality to the factory Copyright © 2017 Pearson Education, Inc. 2-22 Feigenbaum’s 19 Steps Based on A. Feigenbaum, Total Quality Control (New York: McGraw-Hill, 1991; original 1951). Table 2-4 Copyright © 2017 Pearson Education, Inc. 2-23 Philip Crosby Became well known for the authorship of his book, Quality is Free Emphasized the zero-defects approach and the behavioral and motivational aspects of quality improvement rather than statistical approaches Adopted a human resource approach similar to Deming Copyright © 2017 Pearson Education, Inc. 2-24 Crosby’s 14 Steps Based on P. Crosby, Quality Is Free: The Art of Making Quality Certain (New York: Mentor Executive Library, 1979). Reproduced with permission of The McGraw-Hill Companies. Table 2-5 Copyright © 2017 Pearson Education, Inc. 2-25 Genichi Taguchi The Taguchi method provides: A basis for determining the functional relationship between controllable product or service design factors and the outcomes of a process A method for adjusting the mean of a process by optimizing controllable variables A procedure for examining the relationship between random noise in the process and product or service variability Copyright © 2017 Pearson Education, Inc. 2-26 Genichi Taguchi Unique aspects of the Taguchi method include: Definition of quality Quality loss function Concept of robust design Copyright © 2017 Pearson Education, Inc. 2-27 Other Quality Contributors Robert C. Camp - Benchmarking 1. Sharpen the saw. 2. Be proactive. 3. Begin with an end in Stephen R. Covey – 7 Habits mind. 4. Put first things first. 5. Think win-win. Michael Hammer - Reengineering 6. Seek first to understand, then to be understood. James Champy - Reengineering 7. Synergize. Copyright © 2017 Pearson Education, Inc. 2-28 Group Activity – Guru’s Philosophical Outlook Time – 10 mins, in your groups discuss the tools and principles of your assigned guru and consider how they viewed the world philosophically. Nominate a member of the group to do a 2 min presentation of your guru to the class. Group 1 W Edwards Deming Group 2 Joseph Juran Group 3 Philip Crosby Group 4 Genichi Taguchi Group 5 Kaoru Ishikawa Group 6 Armand Feigenbaum Group 7 Robert Camp Group 8 Stephen Covey Group 9 Michael Hammer Copyright © 2017 Pearson Education, Inc. 2-29 Viewing Quality from a Contingency Perspective There is a mass of contradictory information, therefore it is best to focus on fundamental questions: What are our strengths? What are our competencies? In what areas do we need to improve? What are our competitors doing to improve? What is our organizational structure? Contingency perspective – Successful firms adopt aspects of each of the various approaches that help them improve. Copyright © 2017 Pearson Education, Inc. 2-30 Resolving the Differences in Quality Approaches: An Integrative View Core variables: Leadership Role of quality department Information analysis Environmental characteristics Strategic planning and constraints Employee improvement Philosophy driven Quality assurance of Quality breakthrough products and services Project/team-based Customer role in quality improvement Copyright © 2017 Pearson Education, Inc. 2-31 Quality Improvement Content Variables Table 2-7 Copyright © 2017 Pearson Education, Inc. 2-32 Theoretical Framework for Quality Management Figure 2-6 Copyright © 2017 Pearson Education, Inc. 2-33 Copyright © 2017 Pearson Education, Inc. 2-34