Quality Management and Safety Engineering (BSc) - MST 326 
    Definitions of Quality.  The Gurus of Quality. | 
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DEFINITIONS OF QUALITY
From the Concise Oxford Dictionary, 1979.
  - degree of excellence
 
  - faculty, skill, accomplishment
 
  - high rank or social standing
 
  - (logic) being affirmative or negative
 
  - distinctive character (of sound, voice etc.)
 
  - concerned with maintenance of high quality (quality control)
 
From the Quality Management discipline.
  - Taguchi & Wu, 1979: Quality, or rather non-quality, defined as “the 
losses to society caused by the product after its delivery”
 
  - Bergman and   Klefsjö, 1994: “The quality of a product (article or service) is its 
  ability to satisfy the needs and expectations of the customers”
 
  - ISO 8402/ISO 9000: “Quality is the totality of features and characteristics of 
  a product or service that bear on its ability to satisfy stated or implied 
  needs”
 
  THE GURUS OF QUALITY
First, consider the opening lines of Rudyard Kipling's poem
I Keep Six Honest Serving 
Men:
"I keep six honest serving-men
(They taught me all I knew);
Their names are What and Why and When 
And How and Where and Who" ....
The following is not an exhaustive list:
W Edwards Deming (1900-1993):
  - Electrical Engineering, University of Wyoming, 1921
 
  - PhD, Yale University
 
  - Western Electric Hawthorne, Chicago
 
  - US census statistician, 1939/40
 
  - Teaching Shewhart methods, 1942
 
  - invited to Japan after the war ....
 
  - Quality, Productivity and Competitive Position, 1982
 
  - Out of the Crisis, 1986/88
 
  - British Deming Association, Salisbury
 
  
  - regarded by the Japanese as the chief architect of their industrial 
  success
 
  - “all processes are vulnerable to loss of quality through variation: if 
  levels of variation are managed, they can be decreased and quality raised”
 
  - quality is about people, not products
 
  - Core element is the “management circle”
 
    - PDCA (or PISA) cycle
 :
    - plan
 
      - do/implement
 
      - check/study
 
      - action
 
    - Continuous improvement (Kaizen)
 - teamwork and competence in problem solving
 
  
  Out of the Crisis (1984) described by Sir John Egan (Jaguar Cars) in Director magazine, September 1988 as
  “required reading for every chief executive in British industry who is serious about ensuring the international competitiveness of his company” 
    - having a satisfied customer is not enough
 
    - profit in business comes from:
 
    - repeat customers
 
    - customers that boast about your product and service
 
    - customers that bring friends with them
 
    - and hence it is necessary to anticipate customer needs
 
Deming's fourteen points:
	- create constancy of purpose for continual improvement of products 
      and service
 - adopt the new philosophy created in Japan
 - 
      cease dependence on mass inspection build quality into the product
 - 
      end lowest tender contract: require meaningful quality along with price
 - 
      improve constantly and forever every process for planning, production and 
      service
 - institute modern methods of training on the job for all, 
      including management
 - adopt and institute leadership aimed at 
      helping people do a better job
 - drive out fear encourage effective 
      two-way communication
 - break down barriers between departments and 
      staff areas
 - eliminate exhortations for the workforce they only 
      create adversarial relationships
 - eliminate quotas and numerical 
      targets substitute aid and helpful leadership
 - remove barriers to 
      pride of workmanship including annual appraisals and management by 
      objectives
 - encourage education and self improvement for everyone
 - 
      define top management permanent commitment to ever improving quality and 
      productivity and their obligation to implement all these principles
 
	
 
 
   Reference
- WE Deming, Out of the crisis, MIT Press, Cambridge MA and London UK, 2000. PU CSH Library
 
 Joseph Juran (1904-2008):
 
  - Western Electric manufacturing, 1920s
 
  - AT&T manufacturing
 
  - Quality Control Handbook, 1951
 
  - Management of Quality courses
 
  - Juran on Planning for Quality, 1988
 
  - structured CWQM concept: Company-Wide Quality Management
 
  - essential for senior managers to
 
- involve themselves
 
  - define the goals
 
  - assign responsibilities
 
  - measure progress
 
  - empowerment of the workforce
 
  - quality linked to human relations 
    and teamwork
 
  - key elements:
 
- identifying customers and their needs
 
    - creating measurements of quality
 
    - planning processes to meet quality goals
 
    - continuous improvements
 
- died, aged 103, of natural causes.
 
  References
  
  
    - JM Juran with FM Gryna and RS Bingham., Quality control handbook - third 
    edition, McGraw-Hill, New York and London, 1974.  ISBN 0-07-033175-8.  PU CSH Library.
 
    - JM Juran, Juran on planning for quality, Free Press, 1988. Third edition, 1993: ISBN 0-07-112992-8.   PU CSH Library.
 
    - JM Juran and FM Gryna, Quality planning and analysis: from product 
    development through use - third edition, McGraw-Hill, New York, 1993.  PU CSH Library.
 
  
Philip Crosby (1926-2001):
    - Martin missiles
 
    - QM at ITT, then corporate VP
 
    - 1979: Quality is Free
 
    - Philip Crosby Associates Inc.
 
    - 1984: Quality without Tears ... “do it right first time” ... “zero 
    defects”
 
Crosby's Absolutes of Quality Management include the following:
      - Quality means conformance to requirements, not “elegance” or 
      “goodness” 
 
      - There is no such thing as a quality problem
 
      - There is no such thing as the economics of quality: doing the job 
      right first time is always cheaper
 
      - The system for creating quality is prevention, not appraisal
 
      - The only performance standard is "Zero Defects", not “that’s close enough”
 
      - The only performance measurement is the cost of quality, which is the 
      expense of nonconformance
 
Manufacturing companies spend around 20% of revenue doing things wrong, then doing them over again.
Service companies may spend 35% of operating expenses in a similar way.
The Costs of Quality can be classified as:
- Prevention costs
 
    - design reviews
 
		- product qualification
 
		- drawing checking
 
		- engineering quality orientation
 
		- supplier evaluations
 
		- supplier quality seminars
 
		- specification review
 
		- process capability studies
 
		- tool control
 
		- operation training
 
		- quality orientation
 
		- acceptance planning
 
		- zero defects programme
 
		- Quality Audits
 
		- preventative maintenance
 
	- Appraisal costs
 
	- prototype inspection and test
 
		- production specification conformance analysis
 
		- supplier surveillance
 
		- receiving inspection and test
 
		- product acceptance
 
		- process control acceptance
 
		- packaging inspection
 
		- status measurement and reporting
 
	- Failure costs
 
	- consumer affairs
 
		- redesign
 
		- engineering change order
 
		- purchasing change order
 
		- corrective action costs
 
		- rework
 
		- scrap
 
		- warranty
 
		- service
 
		- after service
 
		- product liability
 
1992: “Quality, meaning getting everyone to do what they have agreed to do 
and to do it right first time is the skeletal structure of an organisation, 
finance is the nourishment and relationships are the soul.”
References
  - PB Crosby, Quality is free: the art of making quality certain, New 
  American Library, 1979.  PU CSH Library.
 
  - PB Crosby, Quality without tears: the art of hassle-free management, 
  McGraw Hill, 1984.  PU CSH Library.
 
  - PB Crosby, Quality is still free: making quality certain in uncertain 
  times, McGraw-Hill, c1996.  PU CSH Library.
 
Shigeo Shingo (1909-1990):
- 1930: ME degree from Yamanashi Tech
 
- Taipei Railway Factory, Taiwan
 
- consultant with Japan Management Assn
 
- 1955: training at Toyota Motor Company
 
- 1959: Institute of Management Improvement
 
- 1961-64: concept of Poka-Yoke
 
Poka-Yoke: mistake-proofing
  - identify errors before they become defects
 
  - stop the process whenever a defect occurs, define the source and prevent recurrence
 
1967: source inspection and improved Poka-Yoke
- prevented the worker from making errors so that defects could not occur
 
- Zero Quality Control
 
  References
- Shigeo Shingō (translated by AP Dillon), A revolution in manufacturing: 
  the SMED system, Productivity Press, 1985.  ISBN 0-915299-03-8.  PU CSH Library.
 
  - Shigeo Shingō (translated by AP Dillon), Zero quality control: source 
  inspection and the Poka-yoke system, Productivity Press, 1986.  ISBN 0-915299-07-0.  PU CSH Library.
 
  - Shigeo Shingō (translated by AP Dillon), The sayings of Shigeo Shingo: key 
  strategies for plant improvement, Productivity Press, 1987.  ISBN 0-915299-15-1.  PU CSH Library.
 
  - Shigeo Shingō, Non-stock production: the Shingo system for continuous 
  improvement, Productivity Press, 1989.ISBN 0-915299-30-5.  PU CSH Library.
 
  - Shigeo Shingō (translated by AP Dillon), A study of the Toyota production 
  system from an industrial engineering viewpoint, Productivity Press, 1989.  ISBN 0-915299-17-8.  PU CSH Library.
 
Kaoru Ishikawa (1915-1989)
  - 1939: engineering graduate of Tokyo Univ
 
  - 1947: Assistant Professor
 
  - 1955-60: Company-wide QC movement
 
  - 1960: Professor (still at Tokyo!)
 
  
    - “quality does not only mean
    the quality of the product, 
    but also of after sales service,
    quality of management,
    the company itself
    and human life”. 
  Ishikawa's fifteen points
  
    - product quality is improved and becomes uniform: defects are reduced
 
    - reliability of goods is improved
 
    - cost is reduced
 
    - quantity of production is increased, rational production schedules are 
    possible
 
    - wasteful work and rework are reduced
 
    - technique is established and improved
 
    - inspection and testing costs are reduced
 
    - rational contracts between vendor/vendee
 
    - sales market is enlarged
 
    - better relationships between departments
 
    - false data and reports are reduced
 
    - freer, more democratic discussions
 
    - smoother operation of meetings
 
    - more rational repairs and installation
 
    - improved human relations
 
  
  References
  - Kaoru Ishikawa, Guide to quality control (translation of Genba no QC Shuho), 
  Asian Productivity Organization, Tokyo, 1982.  ISBN 92-8331035-7.  PU CSH Library.
 
  - Kaoru Ishikawa, What is total quality control?: the Japanese way, 
  Prentice-Hall, 1985.  ISBN 0-13-952441-x. PU CSH Library.
 
Yoshio Kondo (b.1924)
  - 1945: graduated from Kyoto University
 
  - 1961: doctorate in engineering & Prof
 
  - 1987 Emeritus Professor
 
  - 1989: Human Motivation
  - a key factor for management 
  - 1993: CompanyWide Quality Control
  - leadership is central to implementation of TQM 
Human work should include:
  - creativity
    - the joy of thinking 
  - physical activity
    - the joy of working with sweat on the forehead 
- sociality
    - the joy of sharing pleasure and pain with colleagues 
  Four points of action to support motivation
- when giving work instruction, clarify the true aims of the work
 
  - see that people have a strong sense of responsibility towards their work
 
  - give time for the creation of ideas
 
  - nurture ideas and bring them to fruition
 
  Leaders must have:
- a dream (vision and shared goals)
 
- strength of will and tenacity of purpose
 
- ability to win the support of followers
 
- ability to do more than their followers, without interfering when they can do it alone
 - successes
 
- ability to give the right advice
 
Taiichi Ohno (1912-1990)
  - regarded as the father of Just-In-Time (JIT) at Toyota.
 
  - graduated with a mechanical engineering degree from Nogoya Technical High 
  School
 
  - worked for the Toyoda Weaving Company
 
  - 1939: transferred to Toyota Motor Company as a machine shop manager
 
  - 1988: two books Workplace Management describing just-in-time 
  and Toyota Production System (later known as Lean Manufacturing).
 
Identified seven forms of waste:
  - overproduction 
 
  - waiting
 
  - transportation
 
  - motion
 
  - inventory
 
  - defects
 
  - overprocessing
 
  
References
      - Taiichi Ohno, Workplace Management, Productivity Press, Portland OR, 
      1988. ISBN 
      0-915299-19-4.
      
 
      - Taiichi Ohno, Toyota Production system: beyond large-scale production, 
      Productivity Press, Portland OR, 1988.  ISBN 0-915299-14-3.  UOP Library.
 
And finally, note what Sheldon and Yoxon have to say: "people who don't know vote no"
  Reference
Complementary teaching support materials:
  RECOMMENDED TEXTS:
- James Evans and William Lindsay, The Management and Control of Quality - Fifth 
Edition,
South-Western/Thomson Learning, Cincinnati OH, 2001.  ISBN 0-324-06680-5.  PU CSH Library.
inc. CD-ROM with QuickTimeTM videos, web links and spreadsheets. ISBN 
0-324-06682-1.
 
For this lecture:
- Tony Bendell, The Quality Gurus: what can they do for your company?, Department of Trade and Industry, London, October 1991.  PU CSH Library.
 
- Carol Kennedy: Guide to the Management Gurus: the best guide to business 
thinkers, Random House Business Books, 
London, 1998. ISBN 0-7126-7950-2.  Fourth edition, 2002: ISBN 0-7126-2072-9.  PU CSH Library.
 
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Updated by John Summerscales on 
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