Total Quality Management (TQM) – ZERO EFFECT ZERO DEFECT (ZED)

Recent Trends in Automation and Automobile Engineering Volume 2 Issue 3

Suhas S.D., Sharanabasappa C. Sajjan* Department of Mechanical Engineering, K.L.E Institute of Technology, Hubli, India *Corresponding Author E-Mail Id: [email protected]

ABSTRACT The concept of Zero Defect Zero Effect is addressed by Honorable Prime Minister on 68th Independence Day. This concept mainly focuses on Micro Small and Medium Enterprise (MSME) that the goods they manufacture in the country with “Zero Defects” and ensure that the produced goods must have “Zero Effect” on the environment. Zero Defect emphasis on the consumer, which has concern to zero non-conformances, noncompliance and zero waste. Zero Effect primarily emphases on society, and has emphasis on Air pollution, Solid Waste, Liquid Discharge (ZLD), Zero wastage of natural resources. This particular concept may be applied to all sectors of manufacturing and servicing industry.

Keywords: Zero defect, zero effect, customer, society, nonconformance, natural resources

INTRODUCTION (WHAT IS TQM?) TQM is put on to target producing these Firstly TQM stands for Total Quality specifications with zero defects. This Management. The total quality concept makes a commendable cycle of continual and the term “total quality management” enhancement for manufacture, customer was first introduced to the western contentment and profits. Total Quality business world by Armand Feigenbaum in Management (TQM) is not only accepted 1957, in the first edition of his book “Total by a single individual or an employee but Quality Control”. TQM has proved the all employees can become involved most persisting management theory in (including top management to shop floor industries and businesses. Quality management, in other ways entire or whole management is a part of management contribution, from now, Whole) for the meant at attaining quality goals via constant enhancement of the creation of planning, monitoring, promising and goods and services inside the framework refining quality. Comprising all of organizations to attempt for brilliance in participants of the organization brings us each thing they do to attain finest quality closer to total quality control (total quality standards (customer contentment to the management, TQM). Effective TQM quality) by its united well-managed system in organization can assist rapidly (quality need to be succeeded with best challenge in word market. Although many experienced system or tools) system of approaches exist for quality management, numerous best experienced principles, arguably, TQM is the most comprehensive methods. approach for quality management for all the sectors. Constant Improvement TQM contains an improved process Total Quality Management (TQM) is a thinking method. It identifies that entirety planned method for quality enhancement done at each level is part of a procedure along together with product and service not any additional burden, it also specifications to consumer performance. comprises how well every part of the

procedure works and the association of is definitely driven in TQM as shown in every part to the procedure for continuous fig (a) (b). According to the requirement, a perfection, e.g. The Plan-Do-Check-Act variety of approaches are implemented for cycle is a constant quest of quality, which TQM.

Figure a

Figure b Fig. 1(a,b): Continuous Improvement Consulting.

The Need of TQM competitive pricing, manufacturers though previously the idea of "mass requisite have to make nonstop changes. production" was existed in which whatsoever goods produced became MODERN INDUSTRY APPROACH required in market i.e. market style of FOR ZERO DEFECTS 'sales oriented' or 'product oriented', here a Due to financial changes the world has producer known as king , but totally the carried about problems and increasing day opposed scenario is seen today , the market to day level of competition in every single is turn out to be "customer oriented" or sector of industry. As a complete yield is 'demand oriented' where customer became one of the utmost significant criteria in a king. So, it is clear to cope up with the competitive market of every sector, several products demand with the great country or an industry. Quality fulfillment of products, ease of supply and productivity is a state of being capable to achieve in this competitive world. It is

correlated with the capability to produce  TQM Tools: external benchmarking defect free and trustworthy products. It is  ISO 9000 the degree to which a contemporary  Service quality measurement (SQM) industry can create goods and services  Six sigma quality with zero defects, which meet the test of International Markets i.e. it does not SIX SIGMA QUALITY respond (get rejected) from the world Six sigma is mainly a occupational process market In the early 1960s, the idea of zero development method that emphases on defects was revealed by Phil Crosby and achieving the final quality level or defect was executed at the Martin Company in level that is in parts per million, that is a Orlando, Florida. The numerous eminence very good level of quality. Six Sigma programs such as Total Quality attempts to eradicate the reasons of faults Management (TQM), statistical process and any mistakes that might be there in control (SPC) and ISO 9001 has occupied manufacturing service processes (fig c). It up all the oxygen, and currently the zero- emphases on the output and those specific defect method is followed by certain outputs that are critical consumers, and industries. tries to look for a clear financial return for the association. Thus the key objective of ZERO DEFECTS QUALITY TOOLS six sigma is to reach a fault level that is  Total quality management (TQM) only in parts per million.  Quality specifications and costs

Fig. 2: Six Sigma "Zero Defect" Thinking.

The maturity in an industrial allowing the industry to improve manufacturing process is described by the competitiveness. It will benefit the rating of sigma which indicates the industry in the zones like reverse percentage of zero defect products that it engineering, manufacturing technology, creates and its yield. and Quality Management Systems comprising Environment Management Centre for Total Quality Management & System, Occupational Health and Safety Zero Effect Zero Defect (TQM & ZED) Management System, Information Security has been association in 2015 later entering Management System, Information into a MoU with Quality Council of India. Technology Service Management Systems The main objective of this MoU is that and process improvements via lean six equally PEC and QCI will upkeep each sigma. other‟s activities in providing academic programs and research actions mainly in Six Sigma methods follow the two project the areas of quality management standards procedures and use of statistical quality tools,

1. DMAIC objects to progress the increasing and becoming full scale prevailing business procedures (figure 3). industries, the extent of injurious and This is expressed as "duh-may-icky”. detrimental effect that their manufactured 2.DMADV objects at emerging new constituents are causing to the procedure designs and fresh product environment is increasing at a frightening (figure 4). This is expressed as "duh-mad- rate. vie”. Mostly nations facing fast and unexpected growth of such number of industries and are verdict it to be a very serious problem that has to be taken under control instantly. The foremost matters concerning with the environmental influence of constituents is the use of volatile organic compounds, heavy metals and non-renewable oils that laid a contrary effect on the surroundings. This Issue can only be controlled if the Fig. 3: Six Sigma. manufacturing industries create such products which have a zero consequence on the surroundings that is by carrying zero effect i9approach into preparation. On India‟s 68th Independence Day make a speech with the nation, our honorable Prime Minister Shri Narendra Modi Spoke this mostly to the micro, small and medium enterprise that to manufacture Fig. 4: Phases of DMADV. goods in the country with "zero defects" and to make sure that the goods have "zero MODERN INDUSTRY APPROACH effect" on the environment. The zero effect FOR ZERO EFFECT zero defects, also recognized as the ZED Developing nations have less effective Maturity model campaign, the government manufacturing practices than that of is basically highlighting on quality (by developed nations. It means the developing means of clean technology) over quantity, countries discarded their income and thus allowing Brand India to get capitals by taking more water, energy, prominence in the manufacturing center resources than necessary in addition to stage of the world. [1] providing damage to the environment. However due to improvement in the [2] Logo is striding lion made of cogs that manufacturing procedures, there are symbolize strength & manufacturing, plentiful of openings to save money, different lions made of different things to resources and in turn a reduced amount of symbolize different sectors, designed by harm to the environment. the agency Wieden & Kennedy. [1] As of the industrial revolution, humans have progressive a lot. Earlier, the amount The slogan “Zero Defect Zero Effect” was of industries was very less, because of that given by Prime Minister Narendra Modi the amount of environmental pollution and and it signifies two things: degradation initiated by their manufactured 1. Production mechanisms wherein constituents was also very less. But products have no defects nowadays, as the number of industries are

2. Production process which has zero and people management. The government adverse environmental and ecological will too rope several companies and effects. compartments of commerce to promote the model between vendors and dealers. Thus, the ZED model targets to attain high quality manufacturing that‟s also green. What is the significance of the model? The probability of the model is spans India perceives extraordinary through all sectors of manufacturing and technological progress in several fields service industry with a special attention on like farming, industry, business or amenity micro, small and medium enterprises sectors. But most these technical advances (MSME). The ZED model is intended to have caused some method of ecological elevate the quality levels in the degradation. It is essential to develop new unregulated MSME sector. The MSME ways to diminish the consumption of sector is the engine of Indian economic natural capitals and develop clarifications growth. The MSME sector donates 38% of leading to sustainability of energy use and the country‟s GDP and around 110 million security of universal environment. The Indians are employed in the sector. „Zero defect, zero effect‟ concept looks like theoretical idea but its significance to Questions to Analyze Indian manufacturing and let down the What ground work was done to promote impression on environment cannot be the ZED model? overstated. Questions are elevated on how What is the importance of the model? growth can be attained without affecting the environment. Production and What ground work was complete to surroundings protection can, and must, co- encourage the ZED model? exist. Simple steps like decline of After the model was theorized in discharge can improve the environmental September 2014, the Quality Council of sensitivity of our processes and can have India (QCI) articulated the first draft of the far-reaching influence. model. Later in 2015, trial of the model was launched in certain enterprises. ZED (ZERO EFFECT AND ZERO Attentiveness campaigns are launched in DEFECTS) 30 cities of India. Ten ZED cells that It aims to build sustainable competitive implement the model have been launched. advantage for MSMEs across India by Quality Council of India (QCI) will play a focusing on zero defects (quality) and zero very vital role in implementation of the effects (environment). The ZED model is model. an integrated certification and capability building model, encompassing quality led In the model, the manufacturing units will process and product design, productivity, be measured and awarded ratings of production, and postproduction bronze, silver, gold, diamond and maintenance, enhanced „product and platinum. A ZED platinum rating denotes process‟ compliance with environmental that the manufacturer is of international standards, financial prudence including standard and follows global finest financial discipline, human resource practices. The assessing rest on the development and dissemination of MSME manufacturing selected, and the numerous innovations. quality and environment evaluating factors comprise process automation, process Global, MSMEs have been recognized as capability, design, safety and hygiene engine of economic growth particularly concerns, waste management, fault rate that of manufacturing growth with

MSMEs establishing over 90% of total exports. The top 10 MSME subsectors by enterprises in many of the economics and their contribution to the Indian being recognized with generating the manufacturing output are summarized in maximum rates of employment growth and the exhibit below (figure 5).

Fig. 5: The Indian MSME Sector: An Epitome of Vigor and Vitality.

Zed was sponsored by  IPR (Intellectual Property Rights) in  Department of Industrial policy & both products and processes promotion (DIPP)  Ministry of commerce & industry of Main Aim India  Promote Make In India campaign  Under Quality counsel of India (QCI)  Creating employment  By Government of INDIA  Creating a self –sustained eco system for zed The ZED scheme is an integrated and  Zed focuses on health ,safety & holistic certification system that will welfare of country account for  quality Companies will be allotted star ratings on  Productivity a scale of 1 to 5 centered on their levels of  energy efficiency capability, technology and quality on 61  pollution mitigation parameters. There will be categories for  financial status each parameter ranging from bronze,  human resource silver, gold, platinum, diamond. A bronze  Technological depth including design one star will be the lowest rating, and diamond five stars the highest (figure 6).

Fig. 6: ZED Rating.

APPLICATIONS manufacturing does not have an contrary ZED in Water Treatment Plants effect on our environment" - Prime The water treatment plants which make Minister Narendra Modi use of RO filters for purification and treating of water for the use of drinking With this strong vision, the Indian mainly, the chemicals whatever they use manufacturing companies is set to expand must go according to ZED. Usually in the the “Zero Effect and Zero Defect” process of purification, some amount of movement. The industry will be improved water is used for drinking and some dignified to rise as we start manufacturing amount of water carries waste through it. quality products that will not get This waste accumulated water consists of harmful chemicals which are left to disallowed from the worldwide market, penetrate into ground. This can cause and simultaneously, have zero (contrary) increase in acidic nature of soil. Therefore, consequence on the environment. To align as per government rules of having zero with the government‟s vision, the industry effect on nature, these chemicals that are is already taking potential initiatives. carried by water are treated by making it There is a continuous effort to attain zero flow through series of RO water filtering defects, zero waste and zero denials via systems where from each setup of series inventiveness like smart design, and by put clear (purified) water is taken out, and at on several Total Productive Maintenance the end of RO water series system, the and Total Quality Management amount of water containing harmful techniques.[3] chemicals will be reduced as in each time it leaves back the chemicals in form of 3D printing, improver manufacturing, precipitate. Now again the precipitate is automation, and IOT are certain of the treated with heat in order to remove technical developments that will lead to entirely the water content it is holding in smart manufacturing, even though order to obtain only the solid confirming „zero defect‟ and „zero effect‟. (amorphous/crystalline) form of chemicals Besides, aspects such as productivity, price which are collected and given to respective and logistics get incorporated on real time government officials. In this way the chemicals penetration into ground is basis by executing smart technology. reduced effectively. In count, manufacturers can also put on Total Productive Maintenance (TPM) and ZED in Industry Manufacturing Total Quality Management (TQM) Processes methods to upkeep government‟s vision. "Let's think about creating products which With the help of TPM‟s holistic method to have 'zero defect’ and 'zero effect' so that equipment upkeep that tries to attain

exactness in production, manufacturers can National Handloom Day on 7th August eradicate breakdowns, small pause or slow 2015 for branding of high quality running, and most significantly the faults. handloom products, authentic designs with TPM is an abundant tool for refining zero defects and zero effect on efficiency by enhancing up time, environment. shortening down on cycle times, and eradicating faults. INTEGRATED PROCESSING DEVELOPMENT SCHEME (IPDS) When both the government and the The scheme has been extended and manufacturers comprehend their part and notified for the period from 2017 to 2020. involvement, we will be capable to achieve Six projects have been approved during the the dream of being a world-class last 4 years, providing relief to about 1400 manufacturing center with „zero defects‟ SME units and promoting „zero effect‟ in and „zero effects.‟[4]. textile processing.[5]

ZED in Textile Industry ZED in Health care sector Textiles industry in India is one of the The medical sector is gratified to strive for biggest in the world with a vast raw matter anything but final brilliance in quality base and manufacturing asset across all delivery, raising its mantra of “Zero worth chains. The strength of India‟s Defects Goal”. The first problem when fabrics industry lies both in the handmade talking quality in medical sector is its very sector as well as industrial sector. definition. Quality has been well-defined Traditional sectors like handloom, as the degree to which a product or service handicrafts and small scale power loom are meets or go beyond customer´s desires and the major source of occupation for millions potentials. of persons in rural and semi-urban areas. This manufacturing donates to 7% of Conformance quality, well-defined as the industrial productivity in value terms, 2% degree to which a merchandise or service‟s of India‟s GDP and 15% of the country‟s design comes across customary standards, export wages. can be interpreted into the level of devotion to disease-specific standards of India Handloom Brand care in the medical sector. Sales of handloom merchandises to the tune of Rs. 582.93 crore have been made Professor David Garvin (as in figure 7) as on 31.10.2018. 1185 registrations have recognized types of characteristics named been allotted under 122 product dimensions of quality: Core Performance, groups. The India Handloom Brand was Features, Convenience, Reliability & launched by the Prime Minister on First Durability, and Serviceability.

Fig. 7: Garvin's Dimensions of Quality.

The WHO suggests that a health system skills and resources are suitable to should seek to make improvements in therapeutic need six areas or dimensions of quality. These 4. Acceptable/patient-centered, dimensions require that health care be: delivering health care which proceeds 1. Effective, delivering health care that into account the preferences and is adherent to an evidence base and objectives of specific service users results in improved health outcomes and the values of their societies; for individuals and communities, 5. Equitable, delivering health care based on need; which does not be different in quality 2. Efficient, delivering health care in a since of particular features such as way which exploits resource use and gender, race, ethnicity, geographical prevent waste; location, or socioeconomic status; 3. Accessible, delivering health care that 6. Safe, delivering health care which is well-timed, geologically reasonable, diminishes risks and damage to and providing in a situation where service users.

Fig. 8: WHO's Dimensions of Quality for Healthcare.

Nevertheless, the only true measures of of the manufacturing life cycle so as to quality are those attribute that attar to manage and assess the possible potential patients. And patients are concerned about risks. The inputs to and outputs from each so much more than mortality rates and stage of the manufacturing life cycle conformance quality.[6] should be analyzed to assess their impact on the environment and surroundings. CONCLUSION It must be clear that the businesspersons REFERENCES should certainly not compromise primarily 1. Societal Economic Technology on two points i.e. first is the Zero defect Environment Wants and Needs and, second, Zero effect. It is advised that Modifying Factors Demand Corporate the products must be manufactured in such Plans Product Designs Product Policy a method that they bear zero defects and if Instrument Reconstructing Plans. exported, the merchandises should not get International Journal of Engineering rejected in the international markets. These Research and General Science. goods produced by manufacturing Volume 3, Issue 2, March-April, industries should also have zero effect that 2015. ISSN 2091-2730 323 they should not produce any sort of www.ijergs.org detrimental or negative impact on the 2. Parashar S., Parashar A.K. Goal of environment. Considerations towards Modern Industries: Zero Defects, Zero environment should be taken at every stage Effect. B. Tech, Mechanical

engineering (3rd year), Krishna Limited (NEIL). Institute of Engg & Tech., Ghaziabad, https://auto.economictimes.indiatimes. Uttar Pradesh. com/autologue/building-a-world- 3. TIAG Alliance, International Alliance class-manufacturing-hub-by-focusing- of Independent Accounting Firms. on-zero-effect-and-zero-defect/2076 https://www.slideshare.net/TIAG_Alli 6. Press Information, Bureau ance/make-in-india-february-2015- Government of India Ministry of 44458223?qid=04ebe1dc-f31e-4ba2- Textiles, 20-December-2018 17:21 abc3- IST Year End Review-2018: Ministry a7852646bcd8&v=&b=&from_search of Textiles Zero defect, Zero Effect - =1 Mantra of Textiles Ministry. Ministry 4. ZED (Zero Defect-Zero Effect). of Textiles Striving to Promote pilot_report 31 Mar 2015, National Production, Employment and Exports pilot project report 2016. Ministry Working on Promotion of https://zed.org.in Technical Textiles. 5. Saboo R. The writer is the President & https://pib.gov.in/newsite/PrintRelease CEO of CK Birla Group-owned .aspx?relid=186673 National Engineering Industries