D.5. Business Process Improvement and Quality Flashcards

Learn methods for improving operations through value chain analysis, process reengineering, benchmarking, and quality initiatives. (45 cards)

1
Q

What is a business process?

A

A related group of activities encompassing several functions that produces a specific product or service of value to a customer or customers.

A business process is also activities that result in higher quality or lowered costs of a product or service.

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2
Q

Who introduced the concept of the value chain?

A

Michael Porter

In his 1985 book, Competitive Advantage: Creating and Sustaining Superior Performance.

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3
Q

What is competitive advantage?

A

An advantage that a company has over its competitors by offering consumers greater value than they can get from its competitors.

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4
Q

Fill in the blanks:

___________ _________ makes the difference between a company that succeeds and a company that fails.

A

Competitive advantage

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5
Q

What two things must a company have or create if it is to have a competitive advantage?

A
  1. Distinctive competencies and the superior efficiency, quality, innovation, and customer responsiveness that result.
  2. The profitability that is derived from the value customers place on its products, the price that it charges for its products, and the costs of creating those products.
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6
Q

What are the four generic distinctive competencies that give a company competitive advantage?

A
  • Superior efficiency
  • Superior quality
  • Superior innovation
  • Superior customer responsiveness
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7
Q

What is a value chain?

A

A business unit’s chain of activities for transforming inputs into the outputs that customers will value.

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8
Q

Define:

Primary activities

(in the value chain)

A

Activities essential for adding value to the product or service and creating competitive advantage.

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9
Q

Define:

Support activities

(in the value chain)

A

Activities that support the primary activities and add value indirectly to the product or service.

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10
Q

What is the purpose of value chain analysis?

A

To identify the ways in which the organization creates value for its customers and to maximize value by increasing benefits or reducing non-value-adding activities, thereby gaining competitive advantage.

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11
Q

What are the steps in value chain analysis?

A
  1. Identify the activities that add value to the finished product.
  2. Identify the cost driver or cost drivers for each activity.
  3. Develop a competitive advantage by increasing the value to the customer or reducing the costs of the activity.
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12
Q

What is business process reengineering?

A

The restructuring of organizational processes brought about by rapidly changing technology and today’s competitive economy.

In business process reengineering, management redesigns processes to accomplish its objectives. Operations that have become obsolete are discarded.

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13
Q

What does business process reengineering involve?

A

It involves analyzing and radically redesigning the workflow to achieve significant improvements in performance.

It focuses on making quantum leaps rather than incremental improvements by starting with a clean sheet of paper to redesign processes.

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14
Q

Who are the key figures involved in a reengineering project?

A
  • A reengineering project leader
  • The process owner, the manager responsible for the process being reengineered
  • The reengineering team, who diagnose the current process and oversee its redesign and the redesign implementation
  • A reengineering steering committee, a group of senior managers who determine the organization’s overall reengineering strategy and oversee it
  • A reengineering czar, who is responsible for developing reengineering techniques to be used throughout the organization and for coordinating the company’s various reengineering projects
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15
Q

What are the criteria for prioritizing processes for reengineering?

A
  • Most dysfunctional processes
  • Greatest impact on customers
  • Most feasible for reengineering

These criteria help determine which processes should be reengineered first to maximize benefits.

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16
Q

What is the primary focus when beginning the reengineering process?

A

It begins with the customer, focusing on reorganizing work to provide the best quality and lowest-cost goods and services.

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17
Q

What is benchmarking?

A

The process of measuring an organization against the products, practices, and services of its most efficient global competitors or other segments of the company, in order to identify and adopt best practices.

It aims to identify and adopt best practices to improve efficiency, quality, and customer satisfaction.

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18
Q

The first thing a company should do when benchmarking is identify the critical success factors for its business and the processes it needs to benchmark.

What are critical success factors?

A

These are the actions an organization needs to take to achieve its goals and objectives, that are essential to its competitive advantage and therefore to its success.

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19
Q

What are the benefits of benchmarking?

A
  1. Helps a business establish standards for continuous improvement
  2. Identifies areas needing improvement
  3. Leads to increased efficiency and reduced costs
  4. Focuses on practices that promote customer satisfaction
  5. Provides data needed for effective change management
20
Q

Define:

Kaizen

A

A Japanese term meaning “continuous improvement,” focusing on slow but constant incremental improvements in business operations.

21
Q

What are the costs of quality?

A

They include costs of conformance (prevention and appraisal costs) and costs of nonconformance (internal and external failure costs).

22
Q

What are the prevention costs of quality?

A

Costs incurred to prevent a defect from occurring in the first place, including:

  • Design and process engineering costs
  • Quality training
  • Preventive maintenance
  • Supplier selection and evaluation
  • Evaluation and testing of materials
  • Information systems costs
  • Quality improvement program costs
23
Q

What are the appraisal costs of quality?

A

Costs incurred to monitor production processes and individual products and services before delivery to determine whether all units of the product or service meet customer requirements, including:

  • Testing and inspection costs
  • Equipment and instrument costs for testing
  • Quality audit costs
24
Q

What are the nonconformance costs of quality?

A

Costs incurred after a defective product has been produced. They include:

  • Internal failure costs - when a problem is detected before a product’s shipment to the customer
  • External failure costs - when a defect is not detected until after the product is already with the consumer
25
What are internal failure costs?
These are a type of nonconformance cost of quality. They occur when a problem is detected before a product’s shipment to the customer. They include: * Spoilage and scrap costs * Rework and reinspection costs * Tooling changes to correct a defective product and the necessary downtime to do the tooling changes * Machine repairs * Engineering costs for redesign to correct quality problems when the problem is detected before the product is in the customer's hands * Lost contribution margin * Expediting costs of rushing to complete an order in time because of a failure to complete it correctly the first time
26
What are external failure costs?
These are a type of nonconformance cost of quality. They occur when a defect is not detected until after the product is already with the consumer and include: * Customer service costs for handling complaints and returns * Warranty fulfillment costs * Product recall and liability costs * Public relations costs * Sales returns and allowances * Lost contribution margin * Environmental costs - fines and unplanned cleanup costs due to failure to comply with environmental regulations
27
What are the opportunity costs of quality?
The opportunity costs of **poor** quality -- the benefits lost due to the production of defective products, such as lost sales, lost profits, and inefficient use of resources.
28
What are the two main types of costs associated with quality management?
* Conformance costs * Nonconformance costs ## Footnote Conformance costs include prevention and appraisal costs, while nonconformance costs include internal and external failure costs.
29
What does a **Cost of Quality** (COQ) report show?
It shows the financial impact of implementing processes for prevention and appraisal and for responding to internal and external failures.
30
How does activity-based costing (ABC) simplify the preparation of a COQ report?
ABC identifies costs with activities, making it easier to identify costs of activities required to prevent or respond to poor quality.
31
What is **Total Quality Management**? | (TQM)
A management approach committed to customer satisfaction and continuous improvement of products or services. ## Footnote The basic premise of TQM is that quality improvement is a way of increasing revenues and decreasing costs.
32
What are the core principles, or critical factors, common to all TQM systems?
* They have support and active involvement of top management * They have clear and measurable objectives * Timely recognition of quality achievements * Continuous training in TQM * Continuous improvement (kaizen) * They focus on satisfying customer expectations and requirements * Involvement of all employees
33
What is the role of **quality circles** in TQM?
They are small groups of employees who work together and meet regularly to discuss and resolve work-related problems and monitor solutions.
34
What is **Statistical Quality Control**? | (SQC)
A method of determining whether a process is in control or out of control using statistical techniques.
35
What is a histogram used for in quality management?
It is a bar graph used in quality management to represent the frequency of events in a set of data, helping to pinpoint problem areas.
36
What is a **Pareto diagram** and what is it used for in quality management?
A specific type of histogram that shows the frequency of causes for quality problems and orders them from most to least frequent.
37
What is a **cause-and-effect** (Ishikawa) diagram?
A visual tool that organizes causes and effects to sort out root causes and identify relationships between causes and their effects. ## Footnote It is also called a fishbone diagram.
38
What are the "**Four M**'s" in manufacturing that often cause quality problems?
* Machines * Materials * Methods * Manpower
39
How does Total Quality Management (TQM) relate to Activity-Based Management (ABM)?
TQM is compatible with ABM as it uses activity-based costing data to trace costs to products or customers, enhancing process performance and reducing costs. ## Footnote A company with a good ABC system needs only to modify the system to identify costs and activities relating to costs of quality.
40
What are non-value-adding activities?
Activities that do not add value to the product or service and should be reduced or eliminated. ## Footnote Unnecessary and inefficient activities are non-value-adding activities, and the cost drivers of those activities need to be reduced or eliminated.
41
What is the purpose of **ISO 9000 standards**?
To assure **consistent quality** throughout a company's production process.
42
# True or False: ISO 9000 standards assure the quality of individual products.
False ## Footnote The ISO 9000 standards are not established to assure the quality of an individual product but rather to assure that the quality is consistent throughout the company’s production of that type of product.
43
How does a commitment to quality affect productivity?
It usually increases productivity by reducing defective units, improving efficiency, and fostering a "do it right the first time" culture.
44
What is **customer-response time**?
The length of time between receipt of an order from a customer and the receipt of the product by the customer.
45
What are the components of customer-response time?
* Order receipt time * Manufacturing cycle time * Order delivery time