How Has Quality Management Evolved Since its Inception?

Quality management (QM) first popped up as long ago as the Middle Ages, when guilds implemented inspections to maintain the quality of their products–and their reputations. Today, QM looks substantially different and can be expected to undergo even more significant evolutions as new technologies and data collections measures come into being.

Separate Inspection Departments

Frederick W. Taylor’s “The Principles of Scientific Management” was published in 1911, and was the first formally provided framework for the use of people in industrial organizations. Taylor’s concepts of clearly defined tasks and standard conditions included inspections.

These inspections were designed to:

  • Ensure no faulty product left the factory
  • Focus on the product and problem detection
  • Test every item
  • Be carried out at the end of the production process
  • Rely on specially trained inspectors

Taylor’s conception of inspections was one of the first formal corporate quality control procedures to be implemented. Thanks to his influence, business began to create separate inspection departments to focus solely on quality control.

Statistical Theory Speeds Up the Process

Thanks to statistical theory, the 1920’s saw the beginnings of faster inspections. In 1924, Shewhart made the first sketch of what would become a modern control chart. W. Edwards Deming (the father of modern quality management) expanded on Shewhart’s methods, applying them to war manufacturing during World War II to use statistical process control to enable faster manufacturing without the loss of quality.

Unfortunately, once the war ended Deming found American companies unresponsive to his ideas, so he went to Japan, which was desperate for help to rebuild its war torn economy. Thanks to Deming’s assistance and the studies of engineers such as Joseph Juran, Japanese manufacturing began to boom.

Growing consumer classes in the United States demanded higher quality and thanks to their advanced quality management, Japanese companies were able to produce more products at a lower price with higher customer satisfaction. American firms found themselves struggling to compete, and when Deming and Juran returned from Japan, the two men found new interest in their theories.

Fitness for Use Shifts How Quality is Defined

Joseph Juran published his book “Managerial Breakthrough” in the 1960’s. Using eastern philosophies her learned in Japan, he advocated what he called “fitness for use,” a concept later used extensively by management expert Peter Drucker. Juran believed that higher quality products had a greater number of features which fit with the requirements of the consumer–and also had fewer defects.

Deming also brought back lessons from Japan. His work “Out of Crisis” was published in 1982 and included his now-classic 14 points. Deming’s approach led to the creation of the theory of total quality management (TQM) and linked the concept of quality with efficient management.

Where Do We Go From Here?

Today, quality management has evolved to include these three most common theories: Six Sigma, Total Quality Management, and The Toyota Production System. Challenges to implementation remain, however. In a recent study, only 50% of business leaders said quality was at the heart of their organization, and even fewer (16%) claimed their quality was marketing-leading, despite over 80% claiming quality was critical or important.

As advances in technology improve manufacturing processes and the collection and integration of data, and as risk management is increasingly (and rightfully) seen as a vital component of quality, the practical use of quality management can only continue to grow.

Features You Should Be Targeting in Your Quality Management Software

New quality management software (QMS) implementation might be one of the most effective changes you can make–but it could also be your costliest. If your implementation goes wrong, you’ll be unlikely to receive a second chance. It’s absolutely imperative that you choose correctly the first time.

A good QMS can improve efficiency across the entire company, and provide lean solutions to assist in quality control management. A great system will help by providing the most relevant data in useable formats to the people who need it to the most. Especially in our day of lean initiatives, the right QMS is vital in streamlining operations among geographically dispersed locals.

What Truly Matters?

When evaluating your options, it’s important to consider whether you’ll want a system that’s Statistical Process Control (SPC) focused, or a fully integrated quality software solution that covers everything from quality planning to assurance to project management.

It’s also important to consider whether your new software will integrate well with existing Enterprise Resource Planning (ERP) systems and SAP or gaging/measuring equipment currently in place. Will there be tangible benefits to a software that seamlessly captures data from existing equipment and systems, or is this a feature you can afford to forgo?

How Does the Potential Software Company Relate?

It’s also worth investigating the potential software’s use within your industry and other industries. Is this company an innovator and a leader? Will they outlast their current software offering? Are they generic in their focus, or user-focused? Will this new QMS adapt to your needs, or will you need to adapt to it? Finally, pay close attention to the reporting capabilities of your new system. All the data in the world is useless if top management can’t quickly access real-time reporting.

Features to Look For

In addition to these important considerations, it’s also important to consider the features your new QMS will provide. These aren’t just bells and whistles; instead, they’re vital parts of the system you’ll be utilizing daily.

Examples of additional important features include:

  • Mobile & Fixed Station. Are there full plant data collection options available, including fixed station and mobile collection? What is the flexibility to capture data from any location on the plant floor or remote sites?
  • Local Cache. Will there be uninterrupted data collection and the ability to collect data when the network or database server is down?
  • Flexible Row/Column Data Collection. Can you create data collection setups based on most efficient methods? Is there flexibility to set up data collection for optimal efficiency?
  • Drill Down Reporting (Analysis). Can you filter data to a specific data set and gain new visibility into your data with specialized data filters? Are you able to analyze specific details in the report data at any point in the hierarchy (collector, setup, labels, or time)?

Conclusion

The implementation of a new QMS is important enough that considerable time should be spent analyzing your company’s needs and objectives, as well as the potentials benefits and features of your new software. Careful attention to detail here will result in the most favorable outcome–increased quality and better profits overall.

Understanding the Continuous Improvement Process (CiP) as it Relates to Quality Management

For a quality manager or engineer, nothing matters more than preventing a fire before it happens. The continuous improvement process (CiP) can address these concerns, helping the organization find new and better ways to cut costs without sacrificing quality.

The continuous improvement model is at the heart of all quality management (QM) systems, including the most common Six Sigma, Toyota Production System, and Total Quality Management theories. In fact, it is a leading tenant in the overarching study of QM and one of six factors that result in more competitive companies that are customer focused and therefore more profitable.

Where Continuous Improvement Process Began

CiP is as much about tactics as it is about shifting organizational culture over time to value improvement.

In the 1960’s, Edward Deming pioneered the use of CiP as part of the quality management process, relying heavily on feedback. Later, Imai introduced the concept of kaizen (“good change” or “improvement”) in his 1986 work, “Kaizen: The Key to Japan’s Competitive Success.”

Kaizen focuses even more heavily on system feedback than Deming, especially from employees, who can make more, smaller changes over time that are less expensive and more effective long term.

Four Step Action Plan for Implementing CiP

The plan-do-check-act (PDCA) cycle is also known as the Deming Cycle or Shewhart Cycle and is the most widely used tool for continuous improvement. Popularized by Edward Deming, this cycle is a repetitive four-stage model designed to enhance continuous improvement efforts within a QM program.

The plan has four stages:

  1. Plan (identify an opportunity and plan for change)
  2. Do (implement the change on a small scale)
  3. Check (use data to analyze the results of the change)
  4. Act (if the change was successful, implement on wider scale and continually reassess)

The PDCA cycle is simple, yet profound, and emphasizes the small changes that are at the heart of CiP. Proponents of QA have long understood that incremental changes made over time have a much greater impact than larger changes made at great cost.

Other methods of continuous improvement (which include Six Sigma, Lean or the Toyota Production System, and Total Quality Management), emphasize employee engagement, measuring and systemizing processes, and reducing variations, defects, and cycle times, but all rely heavily on the CiP.

Benefits to CiP

One of the deepest benefits to CiP is that the identification of opportunities for improvement comes not from top management, but from employees. The bottom-up system of improvement means that those closest to the problems–the employees–are the ones truly equipped to solve the organization’s quality problems.

Further, since employees are most likely to recommend smaller, easy-to-implement changes (or sometimes eliminating processes) improvements are generally extremely cost effective. Organizations find employees take greater ownership, which decreases turnover, and an organization that experiences high rates of turnover is an organization constantly reacting to fires–not preventing them.

Tips for Making it Work

Four factors can greatly impact CiP success. Those include:

  • Focused, consistent leadership
  • Focus on prevention (and not reaction)
  • Unrelenting commitment to QM
  • Long term mindset

While CiP relies on employee engagement at the bottom level, engagement and support at the top level are also crucial. Inadequate support from organization leadership will ultimately stymie efforts toward improvement.

A focus on risk management and the prevention of issues (instead of reacting to issues that have already happened) is also vital. Organization incentives must be carefully scrutinized to ensure that employees that put out fires aren’t being more heavily rewarded than employees who prevent fires.

Finally, an unrelenting, constant focus and a long term mindset must be adopted to ensure the benefits of CiP in an organization. The beating heart of any QM system, continuous improvement well actualized will result in the best possible results for the long term competitive advantage of the organization.

What Does A PDCA Cycle Entail and Why Is It Part Of QM?

Do you have a go-to plan to solve problems at work? Let’s look at the PDCA cycle, a no-frill approach to identifying problems, fixing them and monitoring your results.

Add the PDCA cycle to your business intelligence tool belt to seamlessly manage your different business processes and achieve continuous improvement.

What Does PDCA Stand For?

PDCA either stands for Plan Do Check Act or Plan Do Check Adjust. This cycle is ideal for organizations that implement ISO 9001 standards or rely on the Total Quality Management approach.

What Do the Four Steps of The PDCA Cycle Entail?

  1. Plan

Start by answering these three questions:

  • What is the issue?
  • What data is relevant to collect to document the issue?
  • What is causing the issue?
  1.  Do

The second phase of the PDCA cycle consists of developing a solution for the problem identified during the first step. Ideally, you should develop a step-by-step plan to implement your solution and set some precise goals so you can determine whether your solution worked.

  1. Check

Did your solution work as expected? Typically, organizations compare data collected before and after implementing the solution to measure its efficiency. You should also use data to determine if the solution met (and ideally exceed) the goals set during the second phase.

  1. Act or Adjust

There are two courses of action you can take depending on the outcome of the third phase:

  • If the solution didn’t work as expected, go back to the first step. You will have more data available to develop a plan of action this time.
  • If the solution was a success, develop and implement a new set of best practices. Consider going back through the PDCA cycle again to optimize your solution and make sure you can get consistent results.

Why Is PDCA A Part Of QM?

Adopting PDCA means you will have a clearly-defined course of action whenever a quality issue arises. Here is why the PDCA is particularly adapted to address quality issues:

  • It’s a simple 4-step plan. There is no need for an overly complicated system that would slow things down.
  • Everyone knows what their role is thanks to the clearly-defined steps.
  • The PDCA cycle is result-oriented so you can find a solution quickly, reduce costs and prevent more quality issues.
  • This approach is a cycle, which means it allows you to continuously improve the quality of your products and services while drawing on data collected each time you implement a new solution.
  • This simple system makes you more reactive whenever you need to implement new industry standards or whenever you roll out a new product.

The PDCA cycle is a model that you can use to develop your Quality Management process itself. The cycle approach allows you to get a picture of your QM process in relation to your other processes. It also gives you the possibility to use data to continuously improve how you monitor quality and how you fix problems.

The PDCA cycle is a comprehensive four step plan that breaks things down into more manageable tasks. This approach allows you to stay on track, get results and learn from your mistakes. Consider replacing an outdated or overly-complicated system with this cycle or think about adopting the PDCA cycle if you currently don’t have a clearly-defined course of action to address issues.

How Companies Can Get Ahead By Utilizing QM Software

The benefits of relying on QM software include reducing waste and costs, developing more efficient processes and setting a general direction for an entire organization. Companies can also easily implement new standards.

These are the obvious benefits – but there are other ways in which QM software helps companies get ahead.

Traceability in Case of Audit

Going through an external audit means your organization will have to make relevant data available. The data collected by your QM software will speed up the auditing process and making this data available shows you are cooperating with the auditing agency.

Using a QM solution provides additional benefits if the auditor finds a problem:

  • Develop and implement a solution before the deadline set by the auditing agency.
  • Show that you are taking a pro-active attitude towards fixing the problem.
  • Prove that you have taken the necessary steps to address the issue if a follow-up audit takes place.

Catching Eventual Quality Issues Before the Fact

Defective products can endanger your customers. At the very least, distributing a faulty product will damage your brand reputation. It can also lead to costs linked to legal problems, recalls and repairs.

Relying on QM software makes you more reactive. You will be able to take action before a quality issue costs you money and can quickly roll out a solution and automate specific actions to implement your new quality plan.

Reducing Reworks, Scraps, Recalls, And Associated Costs

What are the top causes behind reworks and scraps in your manufacturing process? One of the purposes of QM software is to gather data so you can precisely answer this question and take steps to address the problem.

Here is how QM software helps reduce costs associated with reworks and waste:

  • Red flags go up whenever there is a change of pattern detected with the testing process.
  • Catching problems early means you can address it before it spreads to an entire batch of products.
  • Gathering data on faulty products allows you to improve your processes on the long-term.
  • Determine where the issue is coming from so you can address it without causing any downtime.
  • Follow industry standards or internal best practices to address problems in a compliant manner.

Ability to Identify Issues That Need to Be Reported Back to Design

Some quality issues are more serious than others. QM software can recognize these quality issues and let you know when a product should go back to the drawing board.

Distributing a product with a design flaw can put customers’ safety at risk and have disastrous consequences for your brand image. Because redesigning a product takes time, it is crucial to have a reactive solution you can rely on to detect these major quality problems.

You can automate different responses from your QM system. If a design flaw is detected, your QM software can alert key individuals. Your QM solution can also automatically schedule a check for a machine if testing indicates a potential problem with this part of the assembly line.

Quality Management Software allows you to take full control of your quality process while using less manpower, fewer hours and getting better results. These tools make you more reactive and allow you to address issues before they affect customers. The best part is that you can use data to gradually improve your processes and run into fewer quality issues on the long-term.

The 4 Main Components of Quality Management Explained

What makes a good quality management system? Ideally, a quality management solution should have some basic qualities such as simplicity, efficiency, and flexibility. Here are four building blocks for a strong basis, but your QM system should also meet the unique needs and challenges of your industry.

Establish A General Direction

Link your QM system to the mission and values of your organization. Create an action plan that reflects these values through monthly, weekly and daily tasks to ensure that different processes and teams meet quality goals.

Define what your quality goals are, set some deadlines if you are rolling out a new strategy and plan on reviewing your general direction on a regular basis.

Quality should be a priority and should be part of your company culture. This means you might have some work to do to get management involved and to get every employee to see quality as one of their responsibilities.

Identify Relevant Quality Control Strategies

You need to establish a set of practices to test products and make sure your organization meets quality goals.

Here are a few common ways to make sure products and services meet quality standards:

  • Develop a set of relevant tests and determine how often employees will perform tests.
  • Schedule internal quality audits.
  • Provide additional training to employees.
  • Delegate tasks so everyone has a clear role.
  • Gather data on products returned for quality issues.
  • Set some objectives for supervising the assembly line.
  • Develop a company culture that encourages employees to feel personally responsible for quality at their workstation.

Let Everyone Know About Your QM System

Quality assurance is one of the elements that allow you to develop a positive image for your brand. Customers and shareholders want to know that quality matters to you and which actions you are taking to implement quality standards.

Make your ongoing QM effort a part of the story and values you share with your customers via different marketing campaigns. Talking about your testing process in more details would make sense for a B2B company.

Shareholders and partners will need more information. Document the entire QM process for transparency purposes and talk about how you resolved known issues.

Aim For Continuous Improvement

There is always room for improvement. This applies to your products and services as well as to your different processes.

Improve your QM system by looking at past solutions. Assess how much each quality problem cost your organization to get an idea of how efficient your QM system is.

Gathering data about the quality issues you run into will help you continuously improve your finished products. Schedule regular reviews of your findings and focus on addressing the root cause behind detected quality problems – whether you need to rethink the design of a product, find a new supplier for your materials or make a few adjustments to the assembly line.

You also need a dedicated quality team behind your QM system. The right QM software is another valuable building block for your QM system since it will allow you to implement your plan, gather data and help you make the right decisions for continuous improvement while improving communication.

How Does QM Hardware Differ from QM Software?

Generally speaking, software refers to code while hardware refers to physical equipment. The programs you run on your computer and the apps downloaded to your phone fall in the software category. On the other hand, your Smartphone, computer and Wi-Fi router belong to the hardware category.

The same distinction exists in the world of quality management tools. Quality Management Software allows companies to gather data and to streamline the decision-making process when an issue arises. Quality Management Hardware allows manufacturers to perform physical tests on products and on the assembly line.

What Do Businesses Use QM Software For?

QM software helps businesses implement a quality management system. Features typically include:

  • Gathering data from different processes to get a clear picture.
  • Integration with other systems (such as ERP solutions).
  • Automatically schedule tasks, reminders, and training linked to quality control.
  • Analyzes data to detect trends and issues with quality.
  • Turns QM into a seamless process and allows businesses to achieve continuous improvement.
  • Improves collaboration and communication, especially for companies that manage assembly lines remotely.

What Are the Uses of QM Hardware?

QM hardware mostly encompasses testing equipment. This field is rapidly evolving thanks to the Internet of Things. It is now possible to have connected objects on the plant floor. These smart objects can send data to a cloud-based system and receive instructions.

This is a game-changer for Quality Management. A smart machine can share data about each product in real time. Some businesses are also using portable data collectors to have employees perform checks at different steps of the assembly line.

Smart tools are another noteworthy innovation. ASI DATAMYTE has developed a digital wrench that accurately takes torque measurement and makes this data available in an accessible format.

What Is Industry 4.0?

Industry 4.0 is the missing piece of the puzzle. This approach blurs the lines between QM software and QM hardware by developing integrated solutions for the smart factory of tomorrow.

Industry 4.0 tools allow businesses to collect data on their plant floor thanks to the Internet of Things. An advanced QM software solution can then analyze data from smart machines, connected tools, and portable data collectors.

Combining cloud computing and cognitive computing means that a QM system could make simple decisions on its own based on the data collected on the plant floor.

This approach considerably reduces the need for manpower and makes organizations more reactive, even if a business manages a plant remotely. This type of QM system will become more common as more manufacturing plants upgrade to connected machines and tools.

QM software allows organizations to get a global picture of their quality system and to respond to issues quickly. QM hardware is typically one of the solutions used to monitor quality, mainly through the use of testing equipment. The role of QM hardware will probably change in the near future as the Internet of Things and cognitive computing offer a new way to monitor what is happening on the plant floor.

ASI DATAMYTE Sold German Division and QDA Software Solution

PLYMOUTH, Minnesota, July 14, 2017 /PRNewswire/ — ASI DATAMYTE, the global standard in enterprise quality software and hardware solutions, today announced the sale of its QDA software platform and related operations to Alpina Partners (ALPINA), a private equity group located in London, UK and Munich, Germany. As a part of this transaction ASI DATAMYTE will transfer substantially all of the QDA related customer contracts, assets, vendor contracts and its related operations. The two companies will continue a deep bi-directional partnership to resell, support and service each other’s products worldwide.

ASI DATAMYTE will continue to support its global customers with data collectors, torque solutions, dimensional gages, quality management software as well as support and services for QDA. In addition, they are innovating a new line of products and service offerings.

“This transaction will allow both organizations to focus on their core businesses while also providing capital, resources and investment which will accelerate and deepen its position as the global standard for enterprise quality management,” said ASI DATAMYTE Chairman Joel Ronning.

ALPINA’s new company, QDA Solutions, will provide “Industrie 4.0” platform software integration with Enterprise Resource Planning (ERP), Computer-aided Quality (CAQ), Manufacturing Execution Systems (MES) and Product Lifecycle Management (PLM) systems.

“This new strategic direction positions both of our organizations to offer leading-edge manufacturing solutions to advance the quality goals and efficiencies of our customers worldwide,” said ASI DATAMYTE president Rick Bump.

Raymond James acted as corporate finance advisor to ASI DATAMYTE with Winthrop & Weinstine providing legal advice.

About Alpina Partners
Alpina Partners (ALPINA) is an owner-managed, independent investment firm with approximately € 300 million in assets under management. With proven industry, technology and international business expertise, ALPINA focuses on helping small- and mid-sized businesses in Europe to implement growth strategies. ALPINA is supported by the European Union through the Competitiveness and Innovation Framework Program (CIP). For more information, visit http://www.alpinapartners.com.

About ASI DATAMYTE
ASI DATAMYTE is the global leader in providing world-class software and hardware solutions and services for quality management and quality improvement. For decades, they’ve been serving assembly, manufacturing and laboratory operations worldwide in a broad range of industries, including automotive, aerospace, consumer products, defense, food and beverage, medical device, industrial, pharmaceutical, wind power and others. Headquartered in Plymouth, Minn., U.S.A., ASI DATAMYTE has offices in Belgium, Brazil, Canada, China, France, Italy, Singapore, and India. For more information, visit www.asidatamyte.com.

Combat FMEA Fatigue: Discover the Top 3 FMEA Issues and their Solutions

FMEA WHITEPAPER:

As an original equipment manufacturer (OEM), you’re well aware: your success depends on mitigating risk of product failure. So it’s critical to integrate Failure Modes and Effects Analysis (FMEA) at the product design and process stages.

Creating a comprehensive FMEA can be a grueling and tedious task. Yet failing to do so puts product quality at risk.

The Missing Link in Quality Improvement: Integrating Design and Process FMEAs covers the top three FMEA issues that face OEMs like you. You’ll also find out about solutions that close the loop to continuous quality so you can align your FMEA processes with today’s automated manufacturing environments.

Discover how to combat FMEA fatigue and move your FEMA process, quality and efficiency forward. Simply click on the download whitepaper button below.

Harness the Power of Industrie 4.0 and IIoT

Harness the Power of Industrie 4.0 and IIoT

Industrie 4.0 is a network-based approach to industrialization. In manufacturing, it applies the “Industrial Internet of Things” (IIoT) to achieve ultimate smart control of factory lines. Implementing pervasive intelligence throughout your factory can push your automation to new heights, enabling autonomous machines and smart products to interact and achieve blazing efficiencies, on-the-fly “batch of one” customizing, ultra-transparent quality assurance, integrated communications and more.

Discover how implementing Industrie 4.0 can help you improve what might currently seem to be your “maxed out” production speed, accuracy, quality and flexibility to boost your output — and your bottom line.