These points may be all too
familiar to you, but as Dr. Samuel Johnson used to say, "What we need is
not so much to be taught new truths as to be reminded of old
truths we already know." So let's look at what this all means.
TQM looks at
quality through the eyes of the customer.
The business
pursuing TQM must determine what qualities its customers want and find
ways to build those qualities into their products.
TQM
stresses communication.
People have to
share information and ideas.
TQM
relies on teamwork.
Internal competition discourages quality. As my friend, Charles Dygert,
points out, "In cooperative situations, others are depending on you to
succeed. In competitive situations, others hope to see you fail."
TQM calls
for empowerment.
Give your employees the authority to make spot decisions without
constantly checking with supervisors.
TQM uses
fact-based decision-making.
When things go wrong, the emphasis shifts from "who did it" to "what
happened and why?" TQM looks at the process. What are the steps in the
process, and at which step did the problem occur?
TQM
requires feedback.
Management lets
employees know in what areas they're doing well and in what areas they
need to improve. It finds ways to reward productive, quality-oriented
behavior and provides disincentives for unproductive behavior that
inhibits quality.
TQM is a
long-range, never-ending process.
It takes time to make the changes necessary to achieve superb quality.
That quality can vanish overnight if you don't institutionalize the
process.
To adopt TQM, you must
establish a
qualilty
culture, with
employee involvement as a key ingredient. This requires more than
training employees in mechanical and statistical techniques. It means
educating your work force in the new way of doing things.
Employees must learn to see
their jobs not as machine operators or order processors, but as
value
adders. They
must adopt an attitude that puts quality first and refuses to accept
second-rate results.
This calls for developing,
teaching and nurturing quality-oriented values. When Levi Strauss
embarked on its quality-improvement course, it adopted an Aspirations
Statement as an authoritative guide for new behaviors. Then it developed
a comprehensive educational program to teach its people to practice the
behavior outlined in the Aspirations Statement.
When Xerox embarked on its
program of "Leadership Through Quality," each of its employees received
at least a basic 28-hour course in the new culture.
One of my clients, Duke
Power Company in the Carolinas, adopted a set of "Guiding Principles"
and made sure that each of its employees became familiar with them.
Among other things, it printed them on wallet-size cards so that
employees could use them as a checklist.
If you study successful TQM
efforts, you'll find that they share a number of characteristics. Here
are some keys to success I have observed:
TQM stresses
prevention instead of inspection and correction.
Studies show that one dollar spent on prevention is worth ten dollars
spent on inspection and correction. One IBM division discovered that it
was processing 96% of its orders perfectly, but fixing the remaining 4%
was occupying 58% of the people and hardware.
TQM
emphasizes incremental improvements, not major breakthroughs. In baseball language, this means relying on lots of singles
instead of the occasional grand slam. Look for ways to make small
improvements. The cumulative effect will amaze you.
TQM links
quality efforts to the bottom line.
Some executives confuse the means with the ends. It's meaningless to say
"We've trained 1,000 employees in TQM." What matters is the effect this
training has on your company's performance.
Iomega Corporation of Roy,
Utah, which manufactures disk drives for computers, cut the production
cycle for its product from 28 days to 1-1/2 days, but that wasn't the
ultimate benefit. The real benefit was going from a $36 million net loss
in 1986 to a $14 million profit in 1991. Look for things that have a
measurable effect on performance, as measured by return on assets and
value added per employee.
Quality
comes from practicing the fundamentals.
Look for the things that add value, look for ways to simplify, and look
for ways to move faster.
Some quality-enhancing ideas
are amazingly simple. L.L. Bean, which sells paraphernalia for outdoors
people, found that it could significantly improve the speed and accuracy
of its shipping department by stocking high-volume items close to
packing stations. The idea came from the workers themselves. They
periodically plot flow charts to look for bottlenecks and impediments to
quality.
Iomega cut the production
cycle on its product by attacking bottlenecks. One of the steps it took
was to group its equipment in clustters of related operations. This
enabled it to assemble its products in one continuous operation without
having to store parts for days at a time in holding zones.
BENCHMARKING
CAN BE A POWERFUL TOOL FOR ACHIEVING TQM
Benchmarking means examining
the methods of another business that is doing things right and
establishing its methods as your minimum standard.
Xerox carried benchmarking
one step further. It looked at other companies in search of the best
practices. Based on these practices, it projected what the highest
standards would be in the future. Then it developed strategies for
matching the future standards.
A word of caution:
Don't
undertake benchmarking until you have a comprehensive quality program in
place. If you're
a small business, don't use world-class enterprises as your benchmarks.
Instead, look at your competitors and find ways to improve on their
methods.
Implementing Total Quality Management requires change. That's
a scary thought for many people. Not everybody relishes change and
challenge. Most people want to achieve comfortable plateaus and remain
there. They'd rather be comfortable than excellent.
But you and I know that we
don't stay in business by staying comfortable. We stay in business by
achieving excellence -- and then improving on it.
Total
Quality Management
is a system for
institutionalizing excellence.