コンセプトは ”どうしたら面白くなるか?” Profit by Quality/品質でもうけなさいin English drawn & written by Isao Hirasawa
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2.6 Level of quality control Profit by Quality《Contents》
 Prologue
T.Way of thinking quality and cost
Although it becomes little bit a conceptual talk, if we grasp what kind of composition
quality cost has and compare with some cases, it will become the reference
that evaluates a management level.
1. Company without problem cannot profit
2. Good or bad quality is known at cost
2.1 Let’s think over the meaning of quality
2.2 Is quality "goodness"?
2.3 If quality is good, productivity is also high.
2.4 Quality is not visible by the number of cases.
2.5 Grasp quality with cost.
2.6 Level of quality control

[Level 0]
This is the condition that defectives occur frequently and customers' trust loses in this situation.

The condition that you’re all busy with settlement of defectives, like the example
of the beginning of this section,
is also this level.

The quality control of Japan is said to be
the number one in the world,
but there are a lot of companies
struggling at this level.

What about your company?
The top priority problem at this level is that
we never trouble for customers anyhow.
It’s most urgent to think out a solution that stop defectives outflow right away,
even if we lose the present profits.
3. What is quality assurance?
U.Way of solution quality problem
4. Make problem solving efficient.
5. Shares a problem by visualization
6. Dig into, and get clue of solution
7. Don't take unprofitable measure
V.Consultation example of quality problem
8. Consultation example of quality problem
9. Necessary way of thinking to raise level

 Epilogue
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改善提案名人に挑戦! Dの問題…デリバリー/生産管理の問題について考えてみましょう
[Level 1]
This is the condition that complaints from customers decreased but appraisal cost is pressing profits.
Although only defectives outflow is barely prevented by inspection of the water's edge,
at the process, defectives are occurring frequently as usual.

I mention it later, but the inspection of this case cannot be said a true inspection,
so level 1 is not different from level 0 substantially.
The top priority problem in this level is not to make trouble for following processes.
It means not to pass defectives thinking following processes as customers.

Some people criticize that it’s like spiritualism, but it is an important problem
because even such morals are often exhausted in the workplace of a low level
such as 0 and 1.
[Level 2]
This is the condition that appraisal cost is reduced by carrying out the maintenance of facilities and the education training to workers to some extent and consequently the whole cost is reduced.

Generally quality is said to be stable in this level.

However, in fact,
the quality is not improved at all because failure cost
can hardly be reducing.

The problem of this level is
defective reduction by all the members' participation.

We can arrive at level 2 relatively easily even if we advance
improvement activities with only much enthusiasm.
However, many companies stagnate here and are easy to get into a rut,
so I think the following level 3 is a wall for improvement.
[Level 3]

This is the condition that defective is reduced by having strengthened a quality improvement and process control and also inspection man-hour is reduced, so consequently the whole cost is reduced.
The reason why accomplishing level 3 is difficult is we need a substantial reform
that is not with only enthusiasm as before.
We must convert the way of thinking and invest in reform drastically,
but we are apt to hesitate in such an epoch because management is
conservative generally.

The problem in level 3 is reliability improvement, efficient control,
new technology development etc. as items to list,
but I think management power reinforcement and independent reform
are more important.
[Level 4]
This is the ideal condition that prevention cost is enriched furthermore
and failure cost becomes almost zero
by carrying out the thorough quality improvement.



There are problems still more even if it becomes level 4.

Can’t we put a squeeze on preventive cost and appraisal cost more?
… If the company is in this level, it should solve problems rationally not abstractedly.

When it has been realized, your company may be said the true excellent company.
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