If the cost of quality is high, looking through the Six Sigma glass the cost of poor quality is still higher. Companies bear a huge cost of about 9-16 percent of their revenues on problem solving. This is the cost of poor quality, or COPQ, as it is known. Motorola discovered this in the late 1970s at a huge price. General Electric has put the cost difference between 3 or 4 Sigma and Six Sigma at an astonishing $8-12 billion a year.
Anatomy Of COPQ
COPQ comprises costs which have generated as byproducts of defective and inconsistent manufacturing process. Six Sigma directly assigns a dollar value to cost of poor quality, meaning that the COPQ is measurable. The cost of poor quality originates at all places where the product or a part thereof is being made.
1.COPQ originating from suppliers
2.COPQ at the production points
3.COPQ at warehouse
4.COPQ at transportation and distribution
The cost effect due to poor quality from suppliers is defined at two levels. One is straight from the defective production of materials and the other is due to handling and delivery. The second and the third points are very much under the control of the manufacturer.
The following are the generally applicable consistent costs of poor quality:
1Wastage Or Under-Utilization: This is also referred to as spoilage in Six Sigma, arising out of raw material wasted due to inconsistent and inefficient processes.
2Cost Of Reworking: This cost includes the cost of repairing and replacing some parts. In addition, this also includes the cost labor to repair.
3Cost Of Additional Utilities: The overall cost of setting up the extra infrastructure and utilities consumed to run the recycling operation needs to be considered while calculating the COPQ.
4Lost Opportunities: The dissatisfaction triggered business loss can not be just the loss of margin. You have to include the capital to be invested to regaining the lost revenue and offset the cumulative revenue loss.
5Lost Revenue Due To Poor Quality: This cost refers to the potential loss of new business due to defective quality.
6Poor Customer Satisfaction: This is the mother of all costs of poor quality. This cost is compounded by the loss the customer suffers due to the defective product first and servicing second.
While Six Sigma provides for all labor, disposition and reworking costs, it does not permit inclusion of costs like that of inspection and prevention. But it is obvious that these efforts are only aimed at reducing the process variation and any resulting damage.
Quantifying The Cost Of Poor Quality And Six Sigma
The cost of poor quality is directly proportional to the level of Sigma. In other words, the COPQ is directly connected to the number of defects per million opportunities. Supposing your Sigma level is 4, and then across the industry, the standard cost of poor quality for you is 15%. It goes on decreasing with the increase in the Sigma level till it becomes equal to 6. At this point (Six Sigma) the cost of poor quality will be less than 5%. This means you have reduced the number of defects from around 60,000 to 3.4 per million opportunities.
Cost Of Poor Quality
Whatever may be the reports of the commercial agencies, it is poor management which causes the greatest percentage of business failures. Ill-luck - the unexpected crop failure or earthquake - may now and then wipe out a business, but mismanagement steadily and surely adds its enormous quota to the failure list.
Poor business management comes from lack of knowledge of the "how" of managerial methods. The man who does not know how to manage his business - or who does not get some one who knows how, to do it for him - is only baiting failure. Good management comes from an Intimate knowledge of a business, a knowledge of the principles of management and the ability and will to apply those principles.
Management is of two kinds, general and detail. A man may be a good general manager, and not know details. Another man may be an excellent detail manager, and still lack all knowledge necessary to general management. When a knowledge of general is combined with a knowledge of special management, then is seen a "captain of industry." These business leaders have been, by far the greater part, men who have the broad grasp of the big principles, and an intimate knowledge of the trade details of their proposition.
An illustration of good general management would be that of a man who has the broad grasp to know whether it would be feasible to run a railway from New York City to the Pacific coast. Such a man might not be able to swing a spike maul or tamp a tie, and yet possess a knowledge of general railway conditions which would enable him to manage a vast railway enterprise. The foreman of a construction gang on the other hand, would be obliged to know in detail all facts affecting construction; in order to be a competent manager he should be able to do everything which is required of his subordinates. In those super-rare cases where a manager has both general and special knowledge, the two kinds round out each other, making both better.
The opportunities which exist in the management field are outranked by perhaps only one other. Marketing a product - the ability to sell - commands at times a higher price in business than managerial ability. But either business management or sales ability commands - alike in direct salary returns or in the more indirect returns through increase in trade and profits - the most money to be made in business.
FINANCING A BUSINESS PROPOSITION
Money is the lifeblood of any business. An undersupply means under-development of the business; thinned down below a certain point, it means death. Whatever be the business, the first great factor to be reckoned with is financing the proposition; has it, or can it get money upon which to run?
The majority of businesses are underfinanced - not because they do not pay or because they afford a safe investment - but because the proprietor has not the time and sometimes has not the facility for financing his proposition.
There never was a time when financial backing was secured as easily as now. There never was such a vast amount of money available for legitimate financial purposes, as there is at the present time. How best to get it? is the question that every man in business is asking himself.
There are four ways - each having their various advantages - of getting money to finance a business. Each will be taken up in order.
The Cash Basis Plan. The first method of financing a business proposition is simplicity itself. It is that of financing it on a cash basis with your own funds or funds permanently in your trust. The percentage of business men who can do this is small indeed, perhaps less than one-tenth of one percent. But it is a method which many men have tried at least once in their business lite. Many men are trying it today, only to adopt other methods later.
When a man starts in business with the intention of financing himself either one of two condition exist. He either has sufficient funds to meet all contingencies or he has not. That is plain. The business man with sufficient funds who is financing himself has his problem as well as the man who is "wild-cutting." True, these problems are not disconcerting, but they are to be reckoned with.
Both Tony Jacowski & Liza Othman are contributors for EditorialToday. The above articles have been edited for relevancy and timeliness. All write-ups, reviews, tips and guides published by EditorialToday.com and its partners or affiliates are for informational purposes only. They should not be used for any legal or any other type of advice. We do not endorse any author, contributor, writer or article posted by our team.
Tony Jacowski has sinced written about articles on various topics from University, Six Sigma and Information Technology. Tony Jacowski is a quality analyst for The MBA Journal. Aveta Solution's Six Sigma Online offers online and certification classes for lean six sigm. Tony Jacowski's top article generates over 90500 views. to your Favourites.
Liza Othman has sinced written about articles on various topics from Eczema, Six Sigma and Marketing. . Liza Othman's top article generates over 8100 views. to your Favourites.
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