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India, along with China, is predicted to be the next economic
superpower in the coming decades.
A group of university students from India contacted the QFD
Institute some time ago. Their letter reflects a common concern among those
attempting to master QFD from literature and software alone: They
unwittingly become trapped in the outdated canned approaches and
misconceptions about QFD, because there is no one to point them otherwise.
When they try to transplant their misinterpretation into action, they
encounter implementation bottlenecks, incomprehensive data analysis,
deployment missteps, and other problems, any one of which could lead
to a failed project or invalid research results.
We are sharing a part of the correspondence because it has several
important points that others too may find useful, besides giving a
glimpse of the state of QFD education in other part of the world.
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Questions about House
of Quality |
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[Students] We are a group of university students in India
doing a research implementation of a modified form of Total QFD
along with our professors. We have found QFD to be a complicated
process . It also does not incorporate the opinions and
preferences of all levels of employees in a company.
[QFD Institute] Yes,
QFD is a powerful
method that aims to assure
customer satisfaction through the efficient delivery of value
throughout the development process of a product and process as
well as throughout the organization toward that effort; it is a
method that can be applied to a simple apparatus to business
process re-engineering to a very large, highly complex system such
as an aerospace project. You would expect some complexity form a
such powerful method, wouldn't you?
The aim of QFD is to satisfy customers, not
employees. The input to QFD comes from customers, not employees.
Perhaps you are confusing Quality Function Deployment with Policy
Deployment (Hoshin Kanri) or TQM (Total Quality Management)?
Policy Deployment uses the same tool set as QFD and does
incorporate input from all areas in an organization in order to
plan the accomplishment of the organizational strategy. Even then,
and also in TQM, the essential part of strategy or improvement is
often to satisfy those customers whom the organization exists to
serve (thus the role for QFD in TQM).
[Students] Decomposing house of quality to separate tables
is problematic...
[QFDI] We do not understand what problem you are referring
to. "House of Quality" matrix is simply one of many matrices used
in QFD. When the use of this matrix is appropriate, it can be
easily assembled from several components, as we show how to in our
two-day QFD Green Belt® Course.
[Students] Interpretation of the symbols used in QFD is
difficult for those who are not familiar with QFD.
[QFDI] The current recommended international symbol set for
QFD is the International symbol set from meteorology for cloud
cover. This is very intuitive, and internationally accepted. But
any use of symbols should be explained with an accompanying
legend.
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Understand the "chain
of customers" to understand why QFD is good for you |
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[Students] We think QFD is biased towards design
improvement. Therefore when QFD is applied in TQM environment,
only the quality improvement in product design is prone to
improve.
[QFDI] What "improves" when you do QFD is what your
tailored QFD process aims to improve.
There are many companies that use QFD to improve product design,
while many that use it to improve technology, process, usability,
interoperability, software, service, etc. And currently in North
America, the dominant approach for organizational improvement is
not TQM (as was the case in the 1980's) but Six Sigma. QFD is a
key part of Design for Six Sigma (DFSS).
[Students] Other functions, namely production process,
procurement, R & D, service, marketing and so on, may not get the
benefit of applying QFD in the company...
[QFDI] QFD aims to benefit customers directly, not
employees. We apply QFD in order to benefit the customer, and to
do so better than any competitor. Thus we assure the jobs of
everyone in our organization. That is the ultimate benefit to
employees, isn't it?
QFD puts customers on the top priority. Why? Because the customer
is the only one who puts money in the "chain of systems".
Everyone else (employees, sales, marketers, distributors,
retailers, suppliers, vendors, etc.) is simply passing the token
up and down in the chain. If the customer stops putting money in
the chain (stops purchasing your product or service), nothing
matters because pretty soon there will be no money and no reason for
the company to keep those functions (employees) on the payroll.
By the way, if employee satisfaction is the goal of your project,
there is a published case study titled
"QFD for Quality of
Work Life" by a Canadian company called TELUS, in
the
1995 volume of the Symposium Proceedings.
In this study, QFD was applied to improve employees' job
satisfaction and quality of work life so that the company could
continue attracting and retaining high quality employees who were
needed for the increasingly competitive telecom market following
the government deregulation.
[Students] We feel that the personnel associated with those
functions tend to lose interest on QFD implementation and thereby
the efforts to achieve continuous quality improvement will be
affected.
[QFDI] We have to point out two issues:
1. Whether people "lose interest" or
not
is a result of the "implementation," not the method.
Implementation of QFD should be carefully planned, and a
tailored approach should be implemented.
2.
QFD has deployments (subsystems) for any issue that
is important to customers such as
schedule, cost, delivery,
reliability, etc., for example. So it is possible for every
function to participate in a QFD project -- if what those
functions do is important to customers.
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Extracting high-quality
data from low-quality inputs |
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[Students] The literatures on QFD are not clear over the
method of receiving and gathering customers' reactions. Those
reactions generally assume two forms, namely "complaints" and
"vague remarks"... There is no provision in QFD to extract these
two forms, which may originate from both internal and external
customers through various communication channels.
[QFDI] As QFD has been dealing with vague inputs for 40
years, a variety of methods have been developed to extract
high-quality customer needs from such low-quality inputs.
One of such methods, for example, is Voice of Customer Analysis.
There exists extensive literature on Voice of Customer analysis,
especially in the
QFD Symposium Transactions.
This entire field grew out of initial work in QFD in North America
in the mid-1980s. In this area you will find a rich and
comprehensive set of techniques for dealing with stated, unstated,
and implied customer needs, and how to translate such needs from
verbatim and observations.
We don't know what literatures you are relying on, but it is quite
possible that they are outdated. Many English-language books on
QFD that we see in the market appear to teach old schools of QFD.
They are based on the truncated, oversimplified versions of QFD
which were taught in some countries and industries over 20-30
years ago. You can tell when you see these terms such as "4-phase
model" and "Hows and Whats" for the House of Quality. They also
give you an impression that a House of Quality matrix is all you
need to know to do a QFD.
QFD has gone through numerous advancements since its inception in
1960s and it continues to advance, merging with new concepts and
sharpening tools. The state-of-art QFD today is called
Modern QFD.
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Expand your QFD knowledge
to expand your vision |
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[Students] QFD is predominantly used for evolving the new
product...
[QFDI] In North America, most QFD use is for product
development. In Japan, QFD is most often used for process
improvement. QFD does both. (Thus, Comprehensive QFD).
Each organization has its unique goals, so you must tailor QFD to
your needs. You cannot refer to 'QFD' as if it were some
monolithic method or a canned approach. QFD can be referred only
as implemented by a specific organization or project.
Come to our annual Symposium, and you will find out each
implementation uses different parts of QFD in different ways, and
why. None follows the same deployment sequence, tools, or
the number of matrices; many do not use the House of Quality
matrix; some use no matrix at all.
Once you develop sufficient understanding of the methodology, you
will understand why one QFD implementation that fits a project may
not be a right QFD for another at all. The Symposium is an
excellent place to see this in action.
[Students] There are many contradiction and doubts
regarding the totality of QFD.
[QFDI] Are these contradictions inherent in the method, or
are they a characteristic of how the method was explained to you?
When you encounter similar contradictions in physics, for example,
do you question the entire field of physics or your understanding
of it because of the way it was taught to you?
Of all quality systems including TQM, TQC, DFSS, Taguchi, etc.,
we know QFD is the only comprehensive quality system that can
address both quality product design and the organizational
process for delivering it. In academic terms, the former is
referred as Broadly Defined QFD, the latter as Narrowly Defined
QFD. Comprehensive QFD is a model that encompasses both.
Comprehensive QFD does so by identifying both spoken and
unspoken customer needs from the voice of customer analysis,
translating them into engineering and business requirements, and
aligning the organizational resources and activities to delivering
the target customer value.
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Suggestions for studying
QFD |
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[Students] We look forward from you with better
suggestions.
[QFDI] May we suggest:
1. Attend a future Symposium on QFD. The QFD Institute's
annual
Symposium on QFD is the oldest continuing conference
dedicated to QFD applications and state-of-art QFD training.
It started as a forum for people to exchange ideas and learn about
QFD, better way to design and do business, and relevant quality
and design methodologies. It continues to provide a supportive
environment for industry professionals and academics alike to
present and learn from each other. Much advancement made in recent years was born from this
conference. The forum engages audience and speakers in
candid questions & answers in a supportive environment, whether
you are new to QFD or experienced. The QFD Institute's
Symposium usually offers a
Student
Special and all Symposium attendees receive a complimentary
QFD Student Pack.
There is also an International QFD Symposium, which hosting
rotates among member nations. Please visit the
International
Council for QFD for the latest schedule.
Both conferences welcome attendees from all over the world.
2. Study some of the
Symposium
Proceedings. So that
you can see what the current best practice in QFD actually is. There are abundant literature and case
studies published since 1989. These papers tell you not only actual implementations but also
what challenges companies faced and how they were resolved, what
to do and what not to do, how the organization changed because of
the QFD implementation, what was learned, how organizational
functions can communicate better, etc. For example, at the 2003
International Symposium in Mexico, it was reported that companies
like Toshiba has hundreds of QFD projects that are ongoing.
3. Attend the introductory
QFD Green Belt®
Certificate Course. If you can, attending this course is
the most efficient way to learn the state-of-art QFD methods and
best practices. Dr. Akao, founder of QFD, personally recommended
this course at the 12th International Symposium on QFD.
It has workshop components, so you can bring a part of your
project and have hands-on practice in the class. For upcoming
dates and locations, please see
Calendar.
This course can be also scheduled as an in-house training.
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