Total Quality Management (TQM) is a management philosophy that focuses on continuous improvement in all aspects of an organization. It involves creating a culture of quality that permeates every level of the organization, from the top management to the shop floor workers. In this blog post, we’ll explore the principles of TQM and how they can be applied to improve the quality of products and services in any organization.

6 Principles of Total Quality Management:

Customer Focus

The first principle of Total Quality Management is customer focus. The organization must understand the needs and expectations of its customers and strive to exceed them. This requires a deep understanding of the customer’s requirements and the ability to deliver on those requirements consistently.

Continuous Improvement

The second principle of TQM is continuous improvement. This involves a commitment to ongoing improvement in all aspects of the organization, from processes to products and services. It involves a willingness to identify and address problems as they arise, and to seek out opportunities for improvement.

Employee Involvement

The third principle of Total Quality Management is employee involvement. This involves engaging employees at all levels of the organization in the improvement process. Employees are encouraged to identify problems and suggest solutions, and their input is valued and acted upon.

Process Approach

The fourth principle of TQM is the process approach. This involves a focus on the processes that drive the organization, rather than individual tasks or activities. By improving processes, the organization can improve the quality of its products and services and reduce waste and inefficiencies.

Data-Driven Decision Making

The fifth principle of Total Quality Management is data-driven decision-making. This involves using data and analytics to drive decisions, rather than relying on intuition or guesswork. Data can provide insights into customer needs, process efficiency, and product quality, allowing the organization to make informed decisions that improve its performance.

Management Leadership

The final principle of TQM is management leadership. This involves a commitment from top management to lead by example and create a culture of quality throughout the organization. Leaders must set the tone for the organization and demonstrate their commitment to quality in all their actions.

Application of Total Quality Management

TQM can be applied to any organization, regardless of size or industry. The key is to start with a commitment to quality and a willingness to embrace the principles of Total Quality Management.

Here are some ways that TQM can be applied to improve the quality of products and services in an organization:

Identify and prioritise customer needs

Start by identifying the needs and expectations of your customers. Conduct surveys, focus groups, and other research to gather insights into what your customers want from your products and services. Once you have identified these needs, prioritize them based on their importance to your customers.

Implement continuous improvement processes

Create processes for identifying and addressing problems as they arise. Encourage employees to suggest solutions and implement changes that improve processes, products, and services. Continuously measure performance to ensure that improvements are making a positive impact.

Engage employees at all levels

Involve employees in the improvement process by providing training, support, and opportunities for input. Encourage a culture of open communication and collaboration that allows employees to share their ideas and expertise.

Use data to drive decisions

Implement systems for collecting and analyzing data that can provide insights into process efficiency, product quality, and customer needs. Use this data to make informed decisions that improve performance and drive continuous improvement.

Demonstrate leadership commitment

Demonstrate your commitment to quality by leading by example. Communicate the importance of quality to employees at all levels of the organization and create a culture of quality that is embraced by all.

In conclusion, Total Quality Management is a powerful management philosophy that can drive continuous improvement and improve the quality of products and services in any organization.

Have you ever had any experience with Total Quality Management? Leave a comment below!

Leave Paper Behind and Revolutionise Your Assembly Processes

Digital work instructions are an essential tool for the manufacturing industry, particularly for assembly operations.

Digital work instructions replace traditional paper-based work instructions with digital instructions that are accessible through a computer or mobile device. These instructions provide several benefits to manufacturers, including improved productivity, quality, and safety.

In this blog post, we’ll explore how Digital work instructions are revolutionising assembly manufacturing and why more manufacturers are adopting this technology.

Improve Productivity

Digital work instructions improve productivity by reducing the time it takes for operators to find the correct work instructions, reducing the number of errors made during assembly, and streamlining the assembly process. With paper-based work instructions, operators often spend a significant amount of time searching through stacks of papers for the correct instructions. With Digital, operators can quickly search for and find the instructions they need on their computer or mobile device.

Additionally, Digital work instructions provide operators with visual aids such as pictures, videos, and animations, which make it easier to understand complex assembly instructions. These visual aids are particularly helpful for new or temporary workers who may not have as much experience with the assembly process.

Reduce Errors

One of the biggest advantages of Digital work instructions is the reduced likelihood of errors during assembly. With traditional paper-based instructions, it’s easy for operators to miss a step or misinterpret an instruction, leading to costly rework and quality issues. With Digital, the instructions are clear, concise, and easy to follow, reducing the risk of errors.

Digital instructions also have built-in quality checks that ensure that each step of the assembly process is completed correctly before moving on to the next step. This reduces the likelihood of errors and ensures that the final product meets the required quality standards.

Quickly Identify Areas for Improvement

Digital work instructions can help streamline the assembly process by providing operators with real-time feedback on their progress. Operators can mark off completed steps as they go, and the system will automatically move them to the next step in the process. This eliminates the need for supervisors to physically check on each worker’s progress and ensures that the assembly process is running smoothly.

They can also help identify areas of the assembly process that are causing delays or bottlenecks. By analyzing data from them, manufacturers can identify areas for improvement and make changes to the assembly process to increase efficiency.

Increase Safety

Digital work instructions can help improve safety in the assembly process by providing operators with clear instructions on how to use equipment safely and how to perform assembly tasks without injury. They can also provide operators with information on potential hazards and how to avoid them, reducing the risk of accidents and injuries.

In conclusion, Digital work instructions are transforming the assembly manufacturing industry by improving productivity, reducing errors, streamlining the assembly process, and improving safety. With the benefits of going digital becoming increasingly apparent, it’s no surprise that more manufacturers are adopting this technology to stay competitive in the ever-evolving manufacturing landscape.

We regularly post on our YouTube channel, where you can find out more about digital manufacturing.

Hey, it’s Martin from Metis Automation here.  I’m going to talk about non conformance reports in the manufacturing processes.  And the NCR or the non conformance report. More importantly, I am going to show you how Tascus can help and improve this process.

The Current Situation

The reason this occurs is when you are going through the manufacturing process, you do an inspection or a check on what you’re creating.  You may not be doing a specific test or a failure test.  You may, however, find something about the product that means it does not conform to the correct standards that it should.

So it may be things like a visual imperfection such as a scratch or rust.  Or another fault that means it doesn’t meet the specification.  But it is something that you know you cannot pass on to the customer.

How Non Conformance Reports and Currently Documented

So what do you do in that situation? Usually you would create a non conformance report.  The non conformance processes and documentation has been around for a long time.  The documentation has either been paper based, database based or an Excel based system.

How Tascus Can Help Non Conformance in Manufacturing

What I’m going to do today is show you what tools we’ve included into the Tascus manufacturing execution system to let you handle the non conformance report process within Tascus.

Watch the video below to show you further how Tascus can help and improve the non conformance reports within manufacturing.  Even more, I show you how simple this process is to set up. Please get in touch if you would like to know more.

Hi, Martin here from Metis Automation. In my video, I am going to talk about how to configure our Manufacturing Execution System – Tascus.  You can use this fantastic tool to capture and record some of the downtime that you might experience in your manufacturing process. Most importantly Tascus will help you avoid downtime.

Maximise Your Manufacturing Productivity

As we all know, it is key and extremely important to capture the reasons for downtime and measure manufacturing downtime effectively.   It is also crucial to record the periods of time that are consumed with downtime.  These records will enable you to make continuous improvements towards optimising your manufacturing productivity.

Avoid Parts Shortage and Avoid Waiting Time in the Manufacturing Process

Parts shortages can lead to your employees unable to continue their work. Additionally parts shortages may lead to unexpected breakdowns on machinery. The first thing to do, before you can resolve those problems is categorise them.  If you can figure out what they are with 80 / 20 analysis.  Ideally use the Pareto principle to split out the problems which are causing the most impact and causing the most disruption.  Then systematically go through and resolve the issues one by one. By doing this, you’ll end up with a more productive process.

How Tascus Can Help You

So bearing that in mind, in Tascus, we’ve added some tools to enable the capturing of that downtime and make it easier to resolve.  

Watch the video below to see how Tascus can help you.  We use a simple traffic light system, green for fully functional,  amber means that there is some kind of delay and red means aligned stoppage.

Tool Traceability

When manual tools are used in the manufacturing process, it is very important for quality standards to record exactly which tool reference number has been used. It is also important to keep that aligned with its calibration records and its service records. If this is recorded you know, as well as all the components that have gone into building of a manufacturing product are correct, that also all of the manual tools used are also the correct tools.

How Metis Can Help You

Historically, most manufacturers use paper or Excel spreadsheets of what tools have been used and whether they’re up to date or not. Alternatively, we’ve added a new feature into the Tascus Manufacturing Execution System to automatically let you scan the tool and attach it to a workstation. With this exciting new feature, you can easily check if it is the right tool that has been used for the process.

So take a look at the video below which explains how to set this process up. When you have watched the video, please let us know if this looks like it will help with your traceability of using tools in the manufacturing process.

It is important to note that we have added this new process in order to make it easy and expandable. This means you do not have to put specific tool names into a production sequence, which would quickly make maintenance of the system difficult. We’ve added it in an easy way and in an expandable way so that you can add tools which can then be used at multiple different workstations across your factory.

Visual work instructions for a manufacturing process. What are they and why are they useful?

Firstly, having things explained in a clear visual way, can speed up the training process, reduce errors and help to standardise processes across a manufacturing company. Secondly, this can lead to improved productivity, efficiency and quality.

Visual work instructions mean taking photographs and videos of how the ideal manufacturing process should be performed. The aim is to make it easier for new hires and the team to replicate that process more closely.

They say a picture’s worth a thousand words. Having one video or image makes it clearer for people than having text instructions explaining how something should be done. In the past, generating those instructions would have meant taking pictures, printing them out on paper and putting them into a folder or on a work cell somewhere. However, these days using tablets and screens across the factory creates a great solution for digital visual work instructions. An operator can just scan a barcode, it presents it to them and walks them through the process.

This video covers the principles of visual work instructions and the easiest ways to get them used across your business. So, watch the video to see how this works with the key features in our Tascus manufacturing execution system.