Documentos de Académico
Documentos de Profesional
Documentos de Cultura
as a Driver for
Continuous Improvement
Presented by
Roger E Olson
Partner
SYSTEMS Quality Consulting 1
Agenda
Crosby’s categories
• Price of Conformance (POC/COC)
– Prevention costs
– Appraisal costs
• Price of Nonconformance (PONC/CONC)
– Internal defect costs
– External defect costs
COPQ
Profits
Profit $400,660
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Prevention
Profit $400,660
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Appraisal
Profit $400,660
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Internal Failures
Profit $400,660
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Income Statement
Income
Sales $4,100,000
Returns ($105,000)
Income $3,995,000
over time
Failure
Appraisal
Costs
Prevention
Time
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In the Beginning COQ Category Maturity
~65% Failure <10%
~25% Appraisal <20%
<10% Prevention >70%
% of Total COQ
Failure
Appraisal
Prevention
How the Percentages Should Change Over Time
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Something to Think About…
External
$10 Final Inspection
Failure Costs
Internal
Subsystem/Assembly
Component
$1 Prevention
Process Time
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1. Linking Quality Improvement to Profits
2. Cost of Quality Definitions and Types
3. Understanding Cause and Effect in
COQ Measurements
4. Establishing COQ Baseline
5. Cost Driver Analysis
Increased Profitability
Which Leads to
Increased Competitiveness
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Any Similarity?
Higher Quality
Which Leads to
Increased Productivity
Which Leads to
Increased Profitability
Which Leads to
Increased Competitiveness
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The Problem Is…..
Increased Profitability
Which Leads to
Increased Competitiveness
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The Cause and Effect Framework
2. Fewer people to
1. Cut budget do same work-
false improvements!
3. More errors
5. Poor quality
And rework
4. Total
costs
increase
5. Improved quality
3. Fewer defects and rework
And profitability
4. Decrease
In
Total
costs
Pacific Bell Cost of Quality Handbook, 1992
• Two Approaches
• Advantages and Disadvantages of each
approach
• Getting started
• Advantages
– Can have report in two to four weeks
– Less cost than formal system
• Disadvantages
– Typically underestimates COPQ and does not
get managements attention
• Advantages
– Data is very accurate
– Root cause analysis and problem solving is
easier
• Disadvantages
– Slower to get first report
– Adds infrastructure (costs) although these will
be more than offset IF COQ projects are
successful
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Starting a COQ Program
• Definition
• Methodology
• Root Cause Analysis
• Percent Allocation and Cost
• Add Common Root Cause Costs
What is it?
A powerful technique that integrates the
problem solving tools of the quality
process with the poor-quality cost
assessment.
Late shipments
80%
Partial
Shipments
$198,714
15%
Penalties
5%
90%
Excessive
Downtime
80%
Partial
Shipments
$198,714
15% 10%
Penalties
5%
Root Cause of
Poor Quality Hard Spots in
Raw Material
Poor-Quality- Tool
Cost Element Breakage
Excessive
Downtime
Partial
Shipments
Penalties
Examples:
• Disruption of operations due to out of
conformance purchases and production
• Excessive inventory levels maintained to
accommodate poor quality
• Poor quality related schedule changes
• Opportunity costs of lost consumer goodwill
1. Commitment
2. COQ Team
3. Gather data (COQ assessment)
4. Pareto analysis
5. Determine cost drivers Typically
6. Process Improvement Teams Missing
7. Monitor and measure
8. Go back to step 3
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