Philip Crosby Crosby is known for the concepts of
“Quality is Free” and “Zero Defects”, and his quality improvement
process is based on his four absolutes of quality: Four Absolutes
1. Quality is conformance to requirements, and not for goodness. 2.
The system of achieving quality is prevention and not
appraisal.
Key theories
Quality, Crosby emphasised, is neither intangible nor
immeasurable. It is a strategic imperative that can be quantified
and put back to work to improve the bottom line. Acceptable quality
or defect levels and traditional quality control measures represent
evidence of failure rather than assurance of success. The emphasis,
for Crosby, is on prevention, not inspection and cure. The goal is
to meet requirements on time, first time and every time. He
believes that the prime responsibility for poor quality lies with
management, and that management sets the tone for the quality
initiative from the top.
Crosby's approach to quality is unambiguous. In his
view, good, bad, high and low quality are meaningless concepts, and
the meaning of quality is conformance to requirements.
Non-conforming products are ones that management has failed to
specify or control. The cost of non-conformance equals the cost of
not doing it right first time, and not rooting out any defects in
processes.
Zero defects does not mean that people never make
mistakes, but that companies should not begin with allowances or
sub-standard targets with mistakes as an in-built expectation.
Instead, work should be seen as a series of activities or
processes, defined by clear requirements, carried out to produce
identified outcomes.
Systems that allow things to go wrong - so that those
things have to be done again - can cost organisations between 20%
and 35% of their revenues, in Crosby's estimation.
His seminal approach to quality was laid out in Quality
is free and is often summarised as the 14 steps:
The 14 steps
- Management commitment: The need for quality improvement
must be recognised and adopted by management, with an emphasis on
the need for defect prevention. Quality improvement is equated with
profit improvement. A quality policy is needed which states that
'… each individual is expected to perform exactly like the
requirement or cause the requirement to be officially changed to
what we and the customer really need.'
- Quality improvement team: Representatives from each
department or function should be brought together to form a quality
improvement team. These should be people who have sufficient
authority to commit the area they represent to
action.
- Quality measurement: The status of quality should be
determined throughout the company. This means establishing quality
measures for each area of activity that are recorded to show where
improvement is possible, and where corrective action is necessary.
Crosby advocates delegation of this task to the people who actually
do the job, so setting the stage for defect prevention on the job,
where it really counts.
- Cost of quality evaluation: The cost of quality is not
an absolute performance measurement, but an indication of where the
action necessary to correct a defect will result in greater
profitability.
- Quality awareness: This involves, through training and
the provision of visible evidence of the concern for quality
improvement, making employees aware of the cost to the company of
defects. Crosby stresses that this sharing process is a - or even
the - key step in his view of quality.
- Corrective action: Discussion about problems will bring
solutions to light and also raise other elements for improvement.
People need to see that problems are being resolved on a regular
basis. Corrective action should then become a habit.
- Establish an ad-hoc committee for the Zero Defects
Programme: Zero Defects is not a motivation programme - its purpose
is to communicate and instil the notion that everyone should do
things right first time.
- Supervisor training: All managers should undergo formal
training on the 14 steps before they are implemented. A manager
should understand each of the 14 steps well enough to be able to
explain them to his or her people.
- Zero Defects Day: It is important that the commitment
to Zero Defects as the performance standard of the company makes an
impact, and that everyone gets the same message in the same way.
Zero Defects Day, when supervisors explain the programme to their
people, should make a lasting impression as a 'new attitude'
day.
- Goal setting: Each supervisor gets his or her people to
establish specific, measurable goals to strive for. Usually, these
comprise 30-, 60-, and 90-day goals.
- Error cause removal: Employees are asked to describe,
on a simple, one-page form, any problems that prevent them from
carrying out error-free work. Problems should be acknowledged
within twenty-four hours by the function or unit to which the
problem is addressed. This constitutes a key step in building up
trust, as people will begin to grow more confident that their
problems will be addressed and dealt with.
- Recognition: It is important to recognise those who
meet their goals or perform outstanding acts with a prize or award,
although this should not be in financial form. The act of
recognition is what is important.
- Quality Councils: The quality professionals and
team-leaders should meet regularly to discuss improvements and
upgrades to the quality programme.
- Do it over again: During the course of a typical
programme, lasting from 12 to18 months, turnover and change will
dissipate much of the educational process.It is important to set up
a new team of representatives and begin the programme over again,
starting with Zero Defects day. This 'starting over again' helps
quality to become ingrained in the organisation.
Putting quality to the test
Crosby often used stories to convey his message, and
audit techniques and questionnaires to clarify organisational and
individual understanding.
Below we reproduce a quick 'true or false' questionnaire
that features in Quality is free. (Answers are provided at the end
of this article.)
- Quality is a measure of goodness of the product that
can be defined as fair, good, excellent.
- The economics of quality require that management
establish acceptable quality levels as performance
standards.
- The cost of quality is the expense of doing things
wrong.
- Inspection and test should report to manufacturing so
manufacturing can have the proper tools to do the
job.
- Quality is the responsibility of the quality
department.
- Worker attitudes are the primary cause of
defects.
- I have trend charts that show me rejection level at
every key operation.
- I have a list of the ten biggest quality
problems.
- Zero defects is a worker motivation
programme.
- The biggest problem today is that customers don't
understand.
In The eternally successful organisation (1988), a
broader approach to improvements is reflected, and Crosby
identified five characteristics essential for an organisation to be
successful:
- People routinely do things right first
time.
- Change is anticipated and used to
advantage.
- Growth is consistent and profitable.
- New products and services appear when
needed.
- Everyone is happy to work there.
In perspective
Throughout his work, Crosby's thinking was consistently
characterised by four absolutes:
- The definition of quality is conformance to
requirements.
- The system of quality is prevention.
- The performance standard is zero defects.
- The measurement of quality is the price of
non-conformance.
The major contribution made by Crosby is indicated by
the fact that his phrases 'zero defects', 'getting it right
first time', and 'conformance to requirements' have
now entered not only the vocabulary of quality itself, but also the
general vocabulary of management.
When Crosby's name is not mentioned in the very same
sentence as the best-known quality thinker, Deming, then it would
certainly be mentioned in the next. Crosby's practical and
easy-to-read books on quality became - and remain - bibles to many,
demystifying some of the jargon formerly associated with quality.
His timing was perfect for the quality movement, and his writing
has marketed quality to a wide audience.
Crosby’s work on improving quality in organisations laid
the foundations for more recent quality tools, such as: six sigma,
lean processes and business excellence.