QUALITY AND

JAPANESE SUCCESS

BY- Achintya Agarwal

101303007

COE-1

THAPAR UNIVERSITY

Juran’s statement in a

conference in Sweden…

The Japanese are headed for World

quality leadership and it will attain it

in the next two decades because no

one else is moving at the same pace

What is Quality?

Quality is defined as excellence in the product or service that fulfils or exceeds the expectations of the customer.

It is the degree to which a set of inherent characteristics fulfils requirements.

BIRTH OF TOTAL QUALITY

MANAGEMENT

TOTAL QUALITY MANAGEMENT

TOTAL: Made up of the whole

QUALITY: Degree of Excellence attached with the product

MANAGEMENT: An act or art of understanding, analysing

and applying through Conceptual and Statistical Tools

Basically, it covers SWOT matrix (Strengths, Weaknesses, Opportunities

and Threats) analysis

HISTORY BEHIND JAPAN’S QUALITY

MOVEMENT

Began in 1946 with US Occupational Force’s Mission

Two important organization behind Japanese post war

miracle:

* JUSE- Japanese's Union Scientists and

Engineers

* MITI- Ministry of international trade and industry

J.U.S.E.

Organized by Ichiro Ishikawa in 1946.

Invited Deming in July 1950 (an eight day quality control seminar)

Invited Juran in 1954 and 1960( focused on quality ).

In July 1956 ,started broadcasting a quality control course on Japan’s short wave radio.

JUSE started Deming’s prize for major advances in quality improvement in 1951

ROLE OF DEMING

In 1947 Douglas MacArthur and the U.S. State Department sent Deming to war devastated Japan. His concept of employees working toward quality fit well into their personal ideas.

Deming developed the chain reaction: as quality improves, costs go

down and productivity goes up; this leads to more jobs, greater

market share, and long-term survival.

Quality circles, a central Deming theme, are based on the importance of employees meeting regularly in groups to comprehensively discuss product quality.

The GDP in Japan rose rapidly from 1960s by more than 10 percent

per year

ROLE OF JURAN

Joseph M. Juran in 1954 went to Japan.

He emphasized customer satisfaction more than Deming did and

focused on management and technical methods rather than worker

satisfaction.

Juran developed basic steps that companies must take, however he

believed there was a point of diminishing return, a point at which

quality goes beyond the consumer needs.

The Pareto Principle, or the Juran 80/20 rule: 80 percent of the

trouble comes from 20 percent of the problems.

JURAN’S TRIOLOGY

Quality planning (determine customer needs, develop product in response to needs).

Quality control (assess performance, compare performance with goals, act on differences between performance and goals).

Quality improvement (develop infrastructure, identify areas of improvement and implement projects, establish project team, provide teams with what they need).

IMPORTANT CONCEPTS BEHIND THE

QUALITY SUCCESS OF JAPAN

5-S

KAIZEN

LEAN MANUFACTURING

KAIZEN

KAIZEN means “ continuous improvement“.

Kaizen strategy calls for never-ending efforts for

improvement involving everyone in the

organization – managers and workers alike.

Kaizen and Management has two major

components:

1. Maintenance

2. Improvement

5-S

SEIRI-Sorting: Keep only essential items. Everything else is stored or discarded

SEITON-Straighten: Everything should be placed in a order

SEISO: Keep the workplace clean as well as neat

SEIKETSU-Standardizing: Work practices should be consistent and standardized.

SHITSUKE: Sustaining the discipline Maintain and review standards

Safety (sometimes taken as a sixth phase)

LEAN PRODUCTION SYSTEM

Lean production system is the western term for Toyota Production

System

Doing more with less:

less time

less inventory

less space,

less labour

less money i.e. Maximum Output

A shorthand for a commitment to eliminating waste, simplifying

procedures and speeding up production

Five areas drive lean production: Cost, Quality, Delivery, Safety

and Morale.

CASE STUDY-

-:TOYOTA:-

SEISO: Keep the workplace clean as well as neat

SEITON-Straighten: Everything should be placed in a order

SHITSUKE: Sustaining the discipline Maintain and review standards

Other Miracles Fortune 500 global companies report 2009: No. of companies

of Japan-68.

Best rank in top 10 : Rank 3 , Toyota(only automobile

industry)

Tokyo – center of 51 fortune 50 companies

1950: Japanese economy (4.2% of USA and 1/3 of UK).

1980:40% of USA and two times of UK.

…AND

ENDLESS

SERIES

MOVING

TOWARDS

QUALITY…