Introduction

TQM is not new, it is a tried and tested Management discipline that has had remarkable success in the past, it has the potential to improve company performance to a remarkable degree. It involves every-one in the company, all have to commit to an attitude focussed on improving performance in all aspects of the business. Without this commitment the system will not produce the anticipated results.

With our considerable experience in the Garment Industry we have developed a set of training courses slanted towards TQM, concentrating our knowledge to achieve the maximum results from this exciting set of management principles.

Commitment must come from the top, directors can no longer just “Blame” they must commit to an ongoing drive to improve performance, the important word here is commit.

We in South Africa MUST improve our approach to export; we can no longer approach the customer without a total commitment to serve them to the utmost of our ability. There are more than 10,000,000 people involved in garment production in the world, and all of them want each others orders. We are competing against the whole world, and if we can’t perform, there are plenty of our competitors who will “go the extra mile” to obtain the order.

What is TQM ?

Continually meeting agreed customer requirements, at the lowest cost, and by releasing the potential of all employees.

The Motive

“The only survivors in the next10 years will be those companies with a consistency of purpose for Quality, Productivity and Service." (W. Edwards Deming)

Who do you need to involve ?

Everyone in the business, from the Directors down, this means that all attend training courses and commit to the concept; unless all are involved it will fail.

The first steps.

Create a TQM board, this will involve some of the directors and a specially designated TQM MANAGER whose function is to oversee all the projects going on in the organisation. He is there to plan and facilitate all the current projects.

His job is to work with, and help to appoint Project Owners and to plan, control, and monitor all of the projects that the company decides to embark on. Project Owners need to build project teams to help them in their chosen projects, in many cases these teams will include operators from the factory floor who want to contribute to the success of the project.

What are projects?

The projects are all of the procedures within the organisation where we believe we will be able to save money, for example:

Recuts—Repairs—Loose threads---Lost Time ---Absenteeism ---Fabric analysis--and many more.

In an average factory more than 30 projects can easily be identified. To achieve results we will need the Co-operation, involvement, and encouragement of all levels of management. It is the function of the TQM manager to properly plan and monitor the projects as they progress, and to report the progress to the TQM board on a regular basis. It is also part of his job to devise Incentives to ensure the continued participation of all concerned, these incentives to be applied in such a way as to give the people involved the recognition they deserve for the success of their projects, and for the recognition of those who contribute exceptionally well. Projects will be monitored against Pre-Determined Measurements and the participating teams will work out their progress against target on a continual basis. Display boards will be strategically placed so that all participating group members will be able to see them easily.

No Blame

The company need to embrace “No Blame” policy, blame only attempts to shift responsibility,it does nothing to help to solve problems, and therefore “Blame” is not acceptable.

What’s First?

Perhaps a competition throughout the factory to name the overall concept, getting all to participate finding a name that everyone can identify with for the overall project. This competition will have a reward for the winner, and is the first step in involving everyone.

Will it be easy?

TQM is NOT a quick fix; it will take a lot of hard work. Everyone working together towards continuous improvement will achieve success.

The Principles.

TQM has 9 basic principles, they are:
1. Agree customer requirements. (A customer can be internal or external)
2. Understand Customer-Supplier chains. (Everyone depends on the quality of work they
receive from others)
3. Do things right. (The aim is to deliver customer satisfaction at the lowest cost)
4. Right first time. (Its no good to think it will come right in time)
5. Measure for success. (Unless you can measure you don’t know where you are going)
6. Continuous Improvement. (Not short term but for always)
7. Management must lead. (No success unless it is backed 100% from the top)
8. Training is essential. (You can only understand the process if you have been trained in it)
9. Communicate, communicate, and communicate. (As you have never done before.)