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First Device Firm to Win Baldrige Award Finds Profit in Quality


Posted by mddiadmin on January 1, 1997

An MD&DI January 1997 Feature Article

Part II: TQM STRIKE TEAMS



The adoption of TQM was a voluntary extension of the company's search for
quality, and it has since become the cornerstone of the company's efforts to
improve. As implemented by ADAC, TQM has four basic building blocks--continuous
improvement, mutual learning, total participation, and focus on customers.
Continuous improvement became the focal point of ADAC's quality program--an
objective that, if achieved, would boost the company to ever new levels of
quality. The question was, how could this be achieved in a company with more
than 700 employees?



The key was to demonstrate clearly that the quality program being implemented
had the backing of executives at the highest level of ADAC, says Mosbarger. "When
the CEO is involved, it makes the process real--and that trickles down to all
of us and into all of our organizations. Without having the executive team buy
into the process, it will not work."



Lowe and the other top executives at the company decided to demonstrate their
support for the quality system by using two other building blocks of the TQM
system--mutual learning and total participation. Employees were initiated to TQM
in two-day seminars that not only taught the basic techniques of this management
approach, but also explained the tools and language that would be used. "Having
everyone speaking a common language transcends departments; it allows you to
understand where people are coming from," says Mosbarger.



With this common understanding established, ADAC executives began creating teams
charged with specific quality missions. In the early days of ADAC's pursuit of
quality, teams benchmarked different techniques and processes for improving
quality, building them into ADAC's own TQM system. They examined written
materials and visited other companies, some of which had won the Baldrige award
in the past. "We benchmarked and stole ideas shamelessly and adopted them
into our culture," says Mosbarger.



In early 1994, ADAC was able to expand its quality mission to helping other
companies. It cofounded the West Coast chapter of the Center for Quality
Management
, a consortium headquartered in Cambridge, MA, that shares experiences
and practices coming out of TQM. The idea behind the center was to mutually
improve and contribute to the collective success of the member companies, which
include Hewlett-Packard (Palo Alto, CA),
National Semiconductor (Santa Clara, CA),
Read-Rite Corp. (Milpitas, CA),
and Solectron (Milpitas), which had been a recipient of the Baldrige award in
1991.



ADAC also expanded its use of teams to include fixing the problems uncovered
during company self-assessments. The teams describe their progress at company
meetings. Progress is defined by executives as iterative improvements in
the vital areas that must be improved in order for the company to be successful,
such as product malfunctions in the first 30 days after installation,
unacceptable customer satisfaction scores obtained during surveys, inventory
shortages, or supplier rejects. The areas needing improvement are examined and
solutions are proposed along with a consensus on how those solutions will be
implemented. The company has established a variable bonus program called
Partners in Excellence, in which those involved in problem-solving teams are
rewarded financially.



QUALITY METRICS



Critical to this process is measuring the vital areas and defining them by
metrics, so that problems can be characterized and the effects of remedial
efforts judged. "The people providing metrics typically include staff who
have some ownership over a process, such as a lead inspector," says Kevin
Thorne, ADAC's director of materials. "But there are some exceptions; for
example, the master scheduler who reports on the performance of the organization
in terms of mass production stability. This metric shows how well we as a
company are able to forecast our customers' needs. It is nothing the scheduler
specifically controls, but he is a focal point for the collection of data and
will present those data."



According to Mosbarger, "Setting ever higher levels for these metrics not
only encourages stability, but lays the groundwork for steady improvement. I
have never seen a metric continue to go in the wrong direction when someone
measures it weekly and reports on it at meetings, because if a metric starts to
go out of control, we quickly react and keep trying corrective actions until it
turns around."



He continues, "Those corrective actions are based on trend analysis and
investigations into the root causes of the problems. Proposals are based on hard
data, not intuition. People are required to go get the data and report on them.
That leads you in the right direction and helps build consensus, because facts
are facts and you can't dispute them. When you stop accepting opinion, groups
reach consensus faster and more effectively."


Part III

Part I


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