Manufacturing Performance Enhancement Through Total Quality Management And Total Productive Maintenance Paradigms

QUESTIONNAIRE
GENERAL ORGANIZATIONAL INFORMATION Organizations Name Organizations Address

Respondents Name and Designation

Respondents E-Mail Address Respondents Contact No. / Fax No. i. Product(s) of the Organization (Please Specify) ii. iii. iv. v. vi. vii. viii ix Main Areas of Business Activity of the Organization Present Turnover (In Crores of Rupees) Number of Employees Number of Maintenance Planners Number of Maintenance Operators Market Share How do you evaluate your Organizational Culture? What is your employee profile? Production Unit < 25 Crores < 250
No Maintenance Planners

Distribution Unit 25 75 Crores 251 750 < 2% 5 10 % 10 25 % Good Good

Service Unit 75 200 Crores 751 1500 25% 25% 25 40 % Very Good Very Good

Others > 200 Crores > 1500 <5% <2% > 40 % Excellent Excellent

> 10 % < 10 % Poor Poor

Please tick mark () the most appropriate choice.

A: Please indicate the Status of Quality initiatives in your Organization.

QUERY
1 Who initiated TQM program in your company? Top management Not at all Rarely Not at all Consultant Staff others

Others (please specify). 2 3 4 Whether the organization has effectively demonstrated commitment and customer focus for TQM initiatives? Whether the organization is keen on providing reliable quality at Competitive Price? Whether the organization is committed to planning and improvement of Quality? To some extent Sometimes To some extent
To large extent To full extent

Normally
To large extent

Always
To full extent

B: Please indicate to what extent you agree with the following statements concerning the top management involvement and employees contribution in your Organization.

(i) Top Management of your organization: Page 1

Manufacturing Performance Enhancement Through Total Quality Management And Total Productive Maintenance Paradigms

1 2 3 4 5

Has a written quality policy and communicates the quality policy to all employees? Defines quality, taking the view-point of customers? Always encourage employees to improve quality? Take feedback from customers and follow up the suggestions? Leaders of your organization Create an environment for empowerment and employee learning?

Disagree 1

Neutral 2

Agree 3

Strongly agree 4

1 1 1 Poorly 1

2 2 2 Averagely 2

3 3 3 Good way 3

4 4 4 Excellent way 4

(ii) Employee Empowerment

1 2 3 4 What percentage of companys employee is involved in education and training programs? What type of training programs workers/operators in your organization? are organized for <20%
Individual training

20-50% Class room training To some extent Occasiona lly 2 2 2

To some extent 2

50-80% On job training

To large extent

>80%
Combinat ion of all

Whether organization encourages & empowers employees to make decisions regarding continuous quality improvements? Whether the operators are credited responsibility for the following activities? with

Not at all Not at all 1 1 1

To full extent To a great extent 4 4 4

To full extent 4

Usually 3 3 3

1. Setting machines?
2. 3. Doing first level maintenance? Participating into project teams?

5 6 7

Does every employee of your organization believe that quality improvement is his or her responsibility? Whether employees are rewarded according to objective and measurable criteria for good work done? Whether your organization gives moral rewards to wellperforming employees by means of a thank-you note, oral praise, or award ceremony?

Not at all 1

To large extent 3

1 1

2 2

3 3

4 4

C: Please specify the importance of the following Total Quality Management (TQM) issues in your organization. (i) 1 2 3 4 STRATEGIC QUALITY PLANNING Does every employee of the company is concerned with the need for quality? Are they aware of how their jobs contribute to the realization of organizational goals? Whether the top management communicates and educates its employees about mission statement and strategy? Whether your company has long-term goals concerning quality improvements?
Not at all 1 To some extent 2 To large extent 3 To full extent 4

1 1 1

2 2 2

3 3 3

4 4 4

(ii) PROCESS MANAGEMENT

1 2 3 4 5 6 Whether you calculate, control and improve process capability during the shift? Whether job being produced is acceptable (quality-wise) & usually finished without delay without wastage of material? Whether you conduct breakdown and preventive equipment maintenance in the shop floor? Do you conduct effective incoming, in-process, and final inspection and use information to seek quality improvements? Whether the key processes in the company are regularly measured and audited? Whether you have relevant information from your competitors and best-in-class organizations? 1 1 1 1 1 1 2 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4 4 4

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7 8

Do you benchmark the competitors? Whether your company recognizes its social responsibilities such as public health/safety, environmental protections and waste management by including these in their quality policy?

1 1

2 2

3 3

4 4

(iii)CUSTOMER SATISTFACTION
1 2 3 Whether your company collects customers extensively and treats them with top priorities? complaints 1 1 1 2 2 2 3 3 3 4 4 4

Do you provide a quality warranty on products sold to customers? Do you store various data related to customers (e.g., satisfaction surveys, their needs and expectations)?

D: Please indicate to what extent you agree with the following statements concerning the General Maintenance Issues in your organization.

QUERY
1 Does your company recognize effective maintenance as a fundamental driver of improved business results? Do you have a well planned and structured maintenance policy? What percentage of the plant equipment is covered by the Preventive Maintenance program? Do operators help with minor PMs such as cleaning, lubricating, adjusting and inspecting? Whether the maintenance program includes procedures, practices to maintain and correct equipment deficiencies? Whether your organization has Maintenance (PdM.) program? an effective Predictive
Strongly disagree 1 Disagree 2 Agree 3 Strongly agree 4

2 3 4 5

1
< 10%

2
10 30%

3
30 65%

4
65 100%

1 Not at all 1 Not at all 1 1

2 To some extent 2 To some extent 2 2

3
To large extent 3 To large extent 3

4
To full extent

4 To full extent 4 4

Does your company use PdM, like vibration, oil analysis, infrared or, ultrasonic, or optical or laser alignment?

E: Please mark () to the appropriate boxes for issues related to Total Productive Maintenance in your organization.

(i) TPM Implementation Issues

1 2 How long your organization has been implementing TPM?? What is the current status of TPM implementation? < 1 year
Early stages of introduction

1 3 years
Approximately midway

3 5 years
Completed majority, continuing
Proactively analyze critical equipment

> 5 years
Program successfull y completed
Proactively analyze all equipment

In what way your company implement maintenance initiative at workplace? (ii) Continuous improvement issues

Training only

Analyze/assess equipment failures after they occur

Whether the cleaning, lubrication, tightening standards implemented in the organization?

(C-L-T)

Not at all 1

To some extent 2

To large extent 3

To full extent 4

2 3 4 5 6

Whether the machine adjustment / readjustment, inspection is carried by the productive operators? How far efforts are being made to track the root cause of all the losses affecting the equipment performance? Whether the equipment bottlenecks identified and tackled effectively in the organization? Whether every machine failure monitored, analyzed and action taken to prevent recurrence? Whether the safe operating procedures (SOP) developed and adequately deployed at all levels in the organization?

1 1 1 1 1

2 2 2 2 2

3 3 3 3 3

4 4 4 4 4

(iii)Product quality Maintenance issues

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Manufacturing Performance Enhancement Through Total Quality Management And Total Productive Maintenance Paradigms

Whether employee skills consistently evaluated and efforts made to improve the skills from time to time? Whether emphasis laid on achieving multi-skilling of employees in the organization? Whether 7 QC tools (Old/New) effectively deployed for addressing quality defects and customer complaints? Whether the 5S principles and standards are extensively employed in the organization? How often your organization use a computerized system to analyse / record / improve maintenance activities? Has your company deployed continuous improvement philosophy in maintenance and quality activities throughout the organization? Does your company carry out in-process inspection and or selfinspection according to maintenance quality procedures? Does your company carryout a complete annual audit inspection on maintenance & quality improvement activities? Whether the employees are made aware of the basic principles of maintenance and quality in the program? To what extent the maintenance quality circles are helpful in solving the production and maintenance related problems? To what extent the maintenance quality circles are helpful in discussing about the essential points of TQM and TPM? Are cross-functional (production and maintenance) teams used to identify and resolve issues that affect both departments? Has your company utilized contractors for maintenance and quality services over the past 24 months?

Not at all

To some extent

To large extent

To full extent

1 2 3 4 5 1 1 1 Rarely 1

2 2 2 2 Sometimes 2

3 3 3 3 Normally 3

4 4 4 4 Always 4

F: To what extent you agree with the following statement related to Transfusion of TQM and TPM in your organization. 1
Not at all 1 To some extent 2 To large extent 3
To full extent 4

2 3 4 5 6 7 8

1 1 1 1 1 1 1

2 2 2 2 2 2 2

3 3 3 3 3 3 3

4 4 4 4 4 4 4

G: Please indicate how far have you been able to achieve the following goals related to the upkeeps of business performance and benefits of implementing TQM and TPM quality derives in your organization (i) Strategic Business Performance
Nominal Gain (< 10%) 1 Reasonable Gain (10 30 %) 2 Remained the same High Gain (30 45 %) 3 Decreased by 10%) High Gain (> 45 %) 4 Decreased by 20%)

Product Cost

Increased (upto 10%)

2 3 1 2 3

Competitive image of the organization. Market share of the organization.

1 1 1 1 Before TQM & TPM

< 10% 10 -30% 3045% > 45%

2 2 2 2

3 3 3 3 After TQM & TPM

< 10% 10 -30% 3045%

4 4 4 4

(ii) Employees Empowerment

Broader job perspectives and employee empowerment. Flexible and Multi skilled workers.

What percentage of production workers in your firm participate in teams or groups of the following?
>4 5%

i ii iii

Autonomous Work Team (AWT) Problem Solving Groups (PSG) Project Teams(PRT) (iii) Quality and Operational Results Manufacturing Quality Reduction in number of customer warranty problems.

1 1 1

2 2 2 1 1

3 3 3

4 4 4 2 2

1 1 1

2 2 2 3 3

3 3 3 4 4

4 4 4

1 2

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3 1 2 3 4 5 6 1 2 1 2 3 4 5

Reduction in total process defects and rejections.

1 1 1 1 1 1 1 1 1 1 1 1 1 1

2 2 2 2 2 2 2 2 2 2 2 2 2 2

3 3 3 3 3 3 3 3 3 3 3 3 3 3

4 4 4 4 4 4 4 4 4 4 4 4 4 4

(iv)

Production and Cost

Improvement in equipment Availability. Improvement in Man-power Productivity. Improvement in Overall Equipment Effectiveness (OEE). Reduction in setup times. Reduction in additional capital investment. Reduction in operating cost.

(v) Flexibility and delivery

Faster and Dependable deliveries. Reduction in new product development lead-times

(vi)

Safety and employee morale

Better health and safety of employees. Improvement in visual controls in employees workplace Reduction in number of accidents and injuries reported. Improved employee motivation and morale. Increase in employees involvement in Quality circles.

H: As a concluding remark, please specify what type of Quality derives, a company should have, for better achievement of following objectives. 1-Least Required, 2-Moderately Required, 3-Highly Required, 4-Fully Required OBJECTIVES 1 2 3 4 5 6 7 8 9 10 1 2 Steps taken for Resolving these Problems (Please Specify) 1 2 Excellent sales. Enhanced profit. Competitive product cost. Enhanced market share. Enhanced competitive image. Increased productivity. Excellent product quality. Enhanced customer satisfaction. Total employee involvement. Excellent work culture. Barriers to TQM & TPM Implementation (Please Specify) TQM TPM JIT 5S

Signature of the Respondent with Seal

THANKS FOR YOUR COOPERATION

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