DOES THE TOTAL QUALITY MANAGEMENT ENHANCE THE QUALITY? EVIDENCE FROM SELECTED MANUFACTURING UNITS; BRICKS

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1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 10, Issue 01, January 2019, pp , Article ID: IJMET_10_01_164 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed DOES THE TOTAL QUALITY MANAGEMENT ENHANCE THE QUALITY? EVIDENCE FROM SELECTED MANUFACTURING UNITS; BRICKS Department of Management and Commerce, Amrita School of Arts and Sciences, Mysuru, Amrita Vishwa Vidyapeetham, India ABSTRACT In the study an attempt was made to know the different total quality management practices adopted by the selected manufacturing brick units and effects of it on the process thinking, customer satisfaction, employee commitment, strategic thinking, integrated system, decision based on facts, continuous improvement and effective communication. The elements of total quality management has been studied about the quality enhancement, increase in customer base, profitability and sales. The data was collected through primary sources as company records and field observations. The study was conducted to know more about the TQM practices followed by the selected manufacturing units. In those days they used to take more time for manufacturing the bricks and now the time maintenance has been able to manage. The company s growth was realized only after adoption of TQM and it has been able to increase their customers. Dynamic thinking process was adopted wherein they were able to assess and give the changes that are happening in the market.so we can conclude by saying that total quality management has brought the considerable changes in the organization. Keywords: Bricks, Manufacturing, Total quality management, quality, sales, profitability Cite this Article:, Does the Total Quality Management Enhance the Quality? Evidence from Selected Manufacturing Units; Bricks, International Journal of Mechanical Engineering and Technology 10(1), 2019, pp INTRODUCTION In this competitive environment sustainability and growth to the manufacturing units is a challenge. Quality management and effective cost management along with innovations of the product and services is the only way to sustain. Cost can be varied to take care the needs of the customer but any change in quality will have long term adverse impact on the growth of organizations and retaining customer base. It is only through quality where they can enhance their goodwill. Consistent quality management can be done only on adoption of certain editor@iaeme.com

2 Does the Total Quality Management Enhance the Quality? Evidence from Selected Manufacturing Units; Bricks quality management techniques. TQM is one of the techniques that enhances the quality is what addressed through various researchers. The present paper tries to understand does really TQM enhances the quality. When it comes to TQM it helps the manufacturing units to upgrade the quality. 2. CONCEPT OF TOTAL QUALITY MANAGEMENT The TQM is geared to ensure consistency in quality of goods and services over a period of time and to meet customer requirements. This method is used to improve the quality and productivity in the business. TQM has also had an impact on quality enhancement, sales, increase in customer base and profitability. The key factors of TQM towards successful quality maintenance and management are: Process thinking Customer satisfaction Total employees commitment Strategic thinking Integrated system Decision based on facts Continuous improvement Effective communication. 3. STATEMENT OF PROBLEM The present study tries to understand whether TQM practices can be adopted in the brick manufacturing units and the impact of the same if adopted. 4. OBJECTIVES To understand the TQM practices followed in bricks manufacturing units. To understand how TQM practices had an impact on quality enhancement, sales, increase in customer base and profitability. 5. METHODOLOGY The present study is conducted on the basis of primary as well as secondary data.primary data was collected from the supervisors and the production department of the selected brick manufacturing units. Simultaneously observation was also used to collect more authentic data. The secondary data was collected towards understanding the quality process, quality management techniques and manufacturing process of bricks. Percentile method statistical tool is adopted for the study. 6. REVIEW OF LITERATURE Thomas C Powell (1995) in his article Total quality management as a competitive advantage: A review and empirical study. He says that TQM is a potential source to sustain for a longer period and he has done an empirical study on TQM performance. In his article he has suggested that the total quality management gives advantage on open culture, employee empowerment and executive commitment. He also says that the quality training, process editor@iaeme.com

3 improvement and benchmarking does not generally produce advantage. He concludes that the organization can acquire the competitors with or without TQM ideology. Ismail Sila and Maling Embrahimpour (2000) An investigation of total quality management. His study focus on factors of total quality management and he also says that TQM factors are classified into 25 categories. TQM is an important factor to be considered in a manufacturing process and managing helps in better development of quality. Ozden Bayazit, Birsen Karpak (January 2007) An analytical network process-based framework for successful total quality management: An assessment of manufacturing industry. In his study he has done an analytic network process to identify the impact of different factors on TQM. Lisbeth M Ottosen (November 2007) Salt-related problems in brick masonry and electro kinetic removal of salts. In his study he had said that if the newly plastered brick shows the dark area at certain the height, it means that there is a problem in the salt content. He also says that the salt content can be removed by applying the electric DC field to the bricks. Alaa.A.Shakir, Siva Kumar Naganathan, Kamal Nasharuddin Bin Mustapha (January 2013) Development of bricks from waste material: A review paper. This paper reviewed recycling various waste material in bricks manufacturing. The effects of wastes on the bricks as physical, mechanical properties will be reviewed and recommendations for future research as out comings of this review will be given. This reviewed approach on bricks manufacturing from waste is useful to provide potential and sustainable solution to improve their business and they recycled the raw materials. Mohamed Ismail Mohideen Bawa (January 2011) Quality control in small and medium brick industry : In his study he has identified the causes for the quality defects and has suggested about the quality improvements. He has attempted to find out the length quality of brick and has been able to improve the quality by continuous improvement. Piotr Matysek and Michal Witkowski (October 2015) A Comparative Study on the Compressive Strength of Bricks from Different Historical Periods. This was conducted based on the hand model and mechanically formed bricks and the strength was determined on rectangular premises and on cylindrical cut out from the bricks. Shikhar Shrimali (January 2017) Bricks from waste plastic. In this paper the author has studied about the all scenario and she has developed the effective way for utilizing the soft plastic waste and recycling into plastic bricks which are very light in weight and can resist high amount of pressure as compared to standard modular bricks. 7. ANALYSIS AND INTERPRETATION 7.1. Objective To understand the TQM practices followed in bricks manufacturing units. The present study reviles that the TQM practices have been adopted in the selected brick manufacturing units. It was observed that TQM practices have brought in considerable changes towards the approach of modern business techniques, quality consciousness and changes accordingly in the TQM variables studied about. Process Thinking From past to years there is a change in the process of manufacturing of the bricks. Before they used to do the soft mud process and now they have change to more quality bricks. The hand work has reduced and they also have checking the bricks in each process by pressure check. In those days they used to take more time for manufacturing the bricks and now the time maintenance has been able to manage editor@iaeme.com

4 Does the Total Quality Management Enhance the Quality? Evidence from Selected Manufacturing Units; Bricks Table 1 Shows about customer satisfaction in terms of sales increase on adoption of TQM practice Increase in sales Years Increase in units units units units units [Source: company records] It can be observed from the Tale 2.1 that customer satisfaction towards the product and servicing is increasing year by year that can be witnessed from increase in sales. Respondent stated this growth was realized only after adoption of TQM practice in manufacturing the units. Financial years Table 2 Shows about Employee commitment Total no of employees joined the organization Cumulative strength Total no of employees left the organization Cumulative strength The block of financial year from shows an increase of 8 employee s average increase of 1.2 employees in the block of 2 years. The increase in the employees was to fill the production labor gap for the increased production demand. The attrition rate is almost negligible which shows which high lights the employee consistency in their commitment. Strategic Thinking The respondent stated about strategic thinking process adopted that helped effective decision making for the growth of organization. Dynamic thinking process was adopted wherein they were able to assess and give the changes that are happening in the market. Looked into SWOT analysis of the concern and developed futuristic development plans for themselves. Result of which could be noticed in the form of effective advertisement, change in approach of employment where in an employment mix was developed including skilled, semi-skilled, unskilled strategically in requirement of the work force in relation to production demand. Change In the investment pattern including different capital mixes, change in procurement pattern, credit management where some of them. Integrated system Adoption of 4 P s can be seen in this company responded explained about the changes in the product processing method adopted (Pressure check). Further he explained about the promotion methods adopted to increase the market share (marketing promotional methods). The price change adoption also has been taken into consideration as and when price change has been observed in the market. The new three agents covering 3 untapped areas of Mysore (Bogadi, Vijaynagara, and Saraswathipuram) and one outlet yet (Hebbal) where demand is growing up is opened editor@iaeme.com

5 Table 3 Shows about the Decision based on facts Years Increase in investment Increase in production quantity Development of production units units units units 1 production unit units 1 outlet It can be observed from the table that decisions has been taken appropriately based on the need of the hour and market facts. Increase in investment can be observed as and when the demand for and production of bricks manufacturing has increased. In order to meet the increased production and sales one production unit at (Vijaynagara) and one outlet at (Hebbal) has been expanded. Effective Communication The adoption of effective communication channels has been witnessed. Initially it was word of mouth, pleasant interaction with the customer base followed by adoption of new advertising techniques like print media, multi-media is observed as change in the adoption of effective communication methods by the manufacturing unit. Continues Improvement The respondent stated about continues improvement has been able to notice after adoption of TQM. The quality of bricks has improved and they also change in the bricks. The continuous improvement of technology, training the staff has helped the company to increase their sales and quality Objective To understand how TQM practices had an impact on quality enhancement, sales improvements, increase in customer base and profitability. Table 1 Shows about the Quality enhancement Parameters Before adoption of TQM After adoption of TQM Time consumption in manufacturing per unit minutes minutes wastage Solid wastage of some 300 Solid waste of some 162 grams per unit grams per unit Durability 20 years 28 years Concrete mix consumption(plastering) 7.29 bags of cement for 1 cubic meter of concrete 6 bags of cement for one cubic meter of concrete It can be observed from the table that there is improvement in the quality enhancement of the company. We can see that there is a change in all the parameters after adopting TQM. The consumption of time in manufacturing per unit of the bricks has reduced. Further there is also decrease in wastage and has been able to utilize the resources properly. The durability of bricks has almost extended to 28 years than before the adoption of TQM. The decrease in the concrete consumption can be seen and they have now decrease to 6 bags of cement for one cubic meter of concrete editor@iaeme.com

6 Does the Total Quality Management Enhance the Quality? Evidence from Selected Manufacturing Units; Bricks Table 2 Shows about the Sales improvements Years Improvements units units units units It can be observed from the table that sales improvements towards the product and servicing is increasing year by year that can be witnessed from sales improvements. Respondent stated this growth was realized only after adoption of TQM practice in manufacturing the units. Table 3 Shows about the Increase in the customer base Years Increase in customer It can be observed from the table that there is increase in the customer base. The customers are the contractors that are constantly purchasing from the selected manufacturing units. The company has been able to maintain their customers year by year after adoption of TQM practices. Table 4 Shows about the profitability Year profitability Rs Rs Rs Rs It can be observed from the above table that there is increase in the profit of the company by adoption of the total quality management. The company has able to meet their company targets. We can see that there is constant increase of profit in the and There is a small amount off decrease in the and again there was a decrease in the year We can able see the increase in profit year by year. 8. KEY FINDINGS It was found that the selected manufacturing unit of brick has adopted all 8 TQM parameters as their TQM practices. The study shows that on the adoption of TQM practices has impacted positively on quality enhancement, sales improvement, increase in customer base and profitability editor@iaeme.com

7 9. CONCLUSIONS The study started with the investigating questions of TQM practices adoption in selected brick manufacturing units. On the observation made through the field study and the records of the manufacturing units it was found that TQM practices have brought in considerable change in the organizational growth. The growth is observed in quality enhancement of bricks, effective employment management, modern communicative adoption increase in sales and customer base and ultimately an enhancement in goodwill and profit of the organization. REFFRERENCES [1] Thomas C Powell (1995) in his article Total quality management as a competitive advantage: A review and empirical study. [2] Ozden Bayazit, Birsen Karpak (January 2007) An analytical network process-based framework for successful total quality management: An assessment of manufacturing industry. [3] Ismail Sila and Maling Embrahimpour (2000) An investigation of total quality management. [4] Mohamed Ismail Mohideen Bawa (January 2011) Quality control in small and medium brick industry. [5] Development of bricks from waste material: A review paper. [6] Shikhar Shrimali (January 2017) Bricks from waste plastic. [7] Piotr Matysek and Michal Witkowski (October 2015) A Comparative Study on the Compressive Strength of Bricks from Different Historical Periods. [8] Lisbeth M Ottosen (November 2007) Salt-related problems in brick masonry and electro kinetic removal of salts. [9] Dusko Pavletic, Micro Sokovic classification development model by manufacturing preparation, [10] Alexandra Kraemer, song Lli, Daniel Brabandt, Thomas Bohlke, Gisela lanza et al., standard dominance in the manufacture operation of the SMC insubstantial material. [11] Ms. Sindhu N, Mr. Aashish C I (2019) A study on manufacturing process of customized doors at G9 company in Mysuru city. [12] Dr. A. Bunglowala and Dr. Nidhi Asthana, A Total Quality Management Approach in Teaching and Learning Process. International Journal of Management, 7(5), 2016, pp [13] Vasantharayalu and Dr. Surajit Pal, An Empirical Study of Total Quality Management (TQM) Practices on Operational Performance of Indian Manufacturing and Service Firms. International Journal of Management, 7(6), 2016, pp [14] Dr. K.V.S. Prasad, An Empirical Study of Total Quality Management in Engineering Education Institutions: Perspective of Management, International Journal of Mechanical Engineering and Technology 9(2), pp [15] Akshara Mahesh and Vidya D Avadhani, An Empirical Study on the Influence of Total Quality Management on Quality of Construction in Construction Industry, International Journal of Civil Engineering and Technology, 9(11), 2018, pp editor@iaeme.com