How to achieve 100% conformance or Zero non - conformance status by TQM? - Mechstudytips

 How to achieve 100% conformance or Zero non - conformance status? 

 Here are some steps which can be successfully adopted to achieve zero status on non - conformance.

 (1) Standard operating procedures (SOP): 

Make SOPs simple and easy to follow.  Use flow charts to explain the steps.  Use local language to clarify the activities required.  As far as possible, use pictures and drawings to convey the requirements.  Lesser the words used, the better.  Pictures get etched in the mind and are retained for a longer period of time.  Use SOPs to communicate, educate and train.  Involve users in the preparation of SOP.  Form teams for this purpose.  If we do so, then SOPs will become user-friendly and will be followed voluntarily.

According to Professor Yasutoshi Washio, the widespread weakness of Indian industries is the absence of effective usage of Standards.  Professor Washio feels that the Standards in India, in general, do not pay sufficient attention to the aspect of 'how to do' - that is, the step - by - step details of the dos & don'ts of an activity.  

(2) The 3D principal: 

The users should adopt an attitude of adhering to Standards with 3Ds - dedication, diligence, and discipline.  Dedication gives the humble attitude of respect to standards on the part of the users.  Diligence is the unfailing practice of the standards.  Discipline is what makes standardization a way of life.  The 3D - the principle is to be imbibed and followed by the users of the standards.  

(3) Poka-Yoke: 

Poka-Yoke which is a Japanese term for mistake - prevention can be used to prevent non - confirming products being produced in the first place or at the most, are not passed on to the next customer.  Mechanical, electronic devices, and information technology can be used to ensure mistake prevention.  

However, it should be kept in mind that all the activities required to be carried out might not be 'mistake - preventable'.  Hence Poka-Yoke is not a panacea.  It is only by following the 3D - principle, as explained in (2) above, we can ensure 100% conformance.  Poka - Yoke, at best, can be an effective antidote in preventing mistakes in certain key parameters only. 

 (4) Audits: 

Periodical audits by internal and external teams could facilitate improvement of conformance.  Trained auditors can conduct audits systematically, according to a pre-planned schedule.  They can audit and issue Non-Conformance Reports (NCRs), whenever any non - adherence to standards are observed.  The NCRs are to be prompted by the process owners by taking Immediate Action, Corrective Action and Preventive Action Immediate actions are for putting out the fire with a short-term perspective in mind.  Corrective actions are systemic actions resulting in improvement in the methods, practice, and standards.  Preventive actions are those which are carried out in similar areas to prevent the occurrence of non - conformance in those areas as well.  This is known as Horizontal deployment

 (5) Culture of conformance:

 A continuous improvement would be possible only if a conformance culture is in place.  If not, a company will be swinging in the same place without moving forward.  Therefore it is important to foster a culture of conformance.  Top management can institute suitable awards and recognition for the zero non-conformance departments and individuals.  The best conforming persons can be awarded in the monthly meetings.  Any other innovative methods of motivation, suitable to the company, can be employed to foster the culture of the conformance.  The best way to inculcate the culture is for the top management team to become role models in walking the talk. 

(6) The PDCA of Conformance

This will help to improve the conformance by rotating the issues..