David Hutchins International Quality College

Published Articles by David Hutchins

This section will be re-organised from time to time to add fresh material. You will find articles on Six Sigma, Lean Manufacture, Problem Solving Tools, History of Quality and many other Business performance Improvement topics relevant to the CQI level 3 Certificate in Quality management and the CQI Level 5 Diploma in Quality Management. They are also useful for quality training purposes

This paper has been reprinted several times by magazines around the world and other web sites and discusses the impact of Dr Deming's 14 Points on British Industry since they were published in his book 'Out of the Crisis'.
Demings 14 points how are we doing IQA version August 2005.doc

Are we prepared for what might be the worst calamity to confront our business? Companies spend small fortunes on advertising the usefulness of their products. If a product recall is required, they may end up spending even more explaining why their product might cause injusy or even death. Do we have a stragey to deal with this?
Product Recall.doc

How complete industries have been wiped out by systematic Japanese competition. In the West, the idea of exploiting a weakness in the opposition is referred to as 'finding the achilles heel'. In Japan it is referred to as 'finding the loose brick'. Some Japanese companies have exploited this idea with ruthless efficiency.
In search of the loose brick.doc

Sometimes also referred to as 'Business Intelligence', Benchmarking is the means by which successful organisations make sure that they do not lose ground to their competitors. An overview of all aspects of this important topic.
Competitive Benchmarking.DOC
Quality Function Deployment - also known as Concept engineering - is the name given to a collection of tools that can very effectively enable the smooth introduction of a wide range of initiatives including new product developmentAn explanation of the tools of QFD.
IQA Conf 2002 QFD in Supply.PDF
Involving the people in business performance improvement is critical to success and this paper explores some of the issues.
Human factors in Six Sigma.doc

An overview of this fascinating and controversial subject. David Hutchins has researched Japanese Management approaches over several decades and this article provides an insight into this experience.
Japanese Quality Management.doc
Huge improvements to Plant performance have been achieved through the use of this concept. In some examples, even 30 year old machines have been able to cmpete with the latest. What it is and how it can be mplemented.
Total Productive Maintenance QMA Nov 2004.doc
In 997, Mobarakeh Steel in Iran was just a run of the mill steel producer. Now, after 5 years of developement based on the concepts of Total Quality, this papaer shows how the Steel Plant was transformed into a world leader.
IAQ 05 Tokyo Paper mod August 2005.doc

A comment which was written by David Hutchins 30/12/2005 in response to discussion on Radio 4 that morning.
UK Industry Dec 2005.doc

 

History of Quality 

This was Dr Juran's last trip outside the USA and we made it a rather special occasion.
Quality Review Juran good bye Nov 1990.pdf
The first Total Quality event in in the UK and Professor Ishikawa's first and only visit to Europe
Quality Circle Review

Cost of "Poor Quality"

They say: According to Guardian Unlimited 6 December 2005

"Government departments are wasting billions of pounds in public money each year as they fail to heed lessons to improve value for money, according to a hard-hitting report by MPs today.

The Commons public accounts committee, responsible for scrutinizing the use of public funds across government departments, today blamed poor leadership and management for the failure to take on board MPs' recommendations.

Departments were failing to learn from each other and made the same mistakes time and again, the report said, resulting in a colossal waste of money.

The conclusion follows a report on the committee's work over the past decade, which has generated a number of practical recommendations in achieving better value for money for the taxpayer, such as careful planning and developing staff capabilities in a range of skills.

Given the scale of government spending, a 2% improvement in the use of resources could generate savings of £8bn a year, equivalent to the purchase of 15 large hospitals, he claimed.

"Of course, no one should underestimate the difficulty of making large-scale and lasting improvements to public services," he said.

"We say"

This is probably a gross underestimate of the real levels of waste.

It is a well known and proven fact that in Industry, 'Quality related Costs' are at least the equivalent of 20% of sales revenue! Some find this statistic hard to believe but it has been proven over and over. In most cases it is a fact that the true cost can be as high as 50% of sales believe it or not. We at DHI have frequently participated in assessments where it has been acknowledged to be more than 30% of sales.

Generally speaking, these costs are higher in non manufacture than in manufacture, the reason being that in manufacture, they are more visible. For example, in one large high volume food production company we saw finished goods stocks at £36M with just 6% turnover. As a consequence of a company wide improvement programme this was reduced to less than £10M in little more than one year and with significantly shorter lead times! In contrast, the equivalent  costs in non manufacturing and service industries are not visible and are therefore not appreciated.

If this statistic is applied to the GDP (Gross Domestic Product) then the following astonishing statistics would result:

In 2004 the UK GDP was in the order of £1000bn. At 20%, the Cost of Poor Quality (COPQ) would be at a conservative estimate in excess of £200bn.

Experience from Industry indicates that a well designed Business wide improvement programme can result in halving these costs. If this could be applied nationally, the saving would be in the order of £100bn but probably more!

In that year, the total cost of running the Health Service was £69bn.
Income from VAT £100bn and the cost of pensions £48bn.

It is a bit sick to think that we could cut out VAT altogether and if we really worked at it, get the Health Service and Pensions for free?????? Food for thought for, David Cameron Nick Clegg and the Coalition Government we think.

 
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