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International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 132
Critical success factors of Total Quality Management implementation in
Indian Iron and Steel Industries (IISI)
K Shiva Shankar Reddy1, Haldhar Ram Chandrakar2
1 Scholar Final year M.Tech (Industrial Engg & Management) CSIT Durg.
2 Associate Professor Department of Mechanical Engg CSIT Durg, Chhattisgarh, India.
--------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - Over the past few decades, many organizations
have implemented Total Quality Management (TQM) to
create a culture of continuous quality improvement and
improve business performance. Various QMS implemented
in organizations are ISO 9000, Total Quality Management
(TQM), Aerospace Standards (AS) and many others. These
standards cover aspects such as management leadership,
process management, teamwork, quality improvement, and
relationships with suppliers and customers. It is expected
that the implementation of TQM will ultimately improve the
overall performance of the business.
The main objective of my project is to investigate and
evaluate Total Quality Management (TQM) practices in steel
production and also to determine their impact on their
performance. In this regard, a TQM implementation
questionnaire on business performance factors is prepared
and a survey study is to be conducted with quality
management and engineering professionals to collect their
opinions on QMS implementation. A sample questionnaire is
distributed to experts, managers and supervisors of various
firms to study and cover the overall impact of QMS
implementation on various business performance factors.
Key Words: Quality Control (QI), Quality Control (QC),
Quality Assurance (QA)Total Quality Management (TQM),
Critical Success Factors (CSF), Indian Iron & Steel
Industries (IISI).
1. Introduction:
Organizations that adopt a quality management strategy
focus on achieving and maintaining high quality outputs
using management practices as inputs and quality
performance as outputs. Pioneers in TQM, such as Deming,
Juran, Crossby, and Feigenbaum, emphasized the
importance of quality philosophy as an essential
competitive weapon for organizational transformation.
Researchers define quality management (QM) as a set of
guiding principles and management style adopted by
managers in organizations to improve organizational
competitiveness and performance. A study by many
researchers identifies relationships between QM practices
and examines the effects of these practices on
performance, but finds inconsistencies and conflicting
results among researchers. These findings suggest that
there is a positive relationship between QM or TQM
practices and firm performance and among other
variables such as product quality, product and process
performance, perceived quality, quality drivers, reduced
costs, more satisfied customers, and improved financial
performance. In general, a large body of literature
emphasizes the positive impact of QM practices on
performance, but others have not found a relationship
between QM practices—TQM—and performance.
Therefore, quality management (QM) plays an important
role in the productivity and performance of an
organization. Quality practices seem to be important for
the continued survival of Indian organizations. Today,
despite this debate, TQM is widely accepted and is the
most important research topic in both academic and
professional settings. However, there is a lack of
agreement on the research and some results contradict
the theories of quality management.
With increasing throat cut competition and the age of
globalization, the concept of supply chain quality
management is at the forefront of industry today. It
requires coordination with suppliers and customers,
rather than treating them as opponents, so that the flow of
materials from the supplier to the end customer is
smoother. It includes optimization of various concepts
such as reducing product delivery times, supporting just-
in-time concepts, improving product quality, etc. To be
successful in their business, organizations need to control
not only costs but also quality in the supply chain.
Successful supply chain management largely depends on
how quality is managed throughout the system. So it is not
false to say that quality management is essential for
success in today's competitive world. Different types of
quality need to be managed both inside and outside of the
supply chain system. This includes information quality,
product quality, service quality, etc. This has resulted to
the successful implementation of quality management
systems in different organizations around the world. The
implementation of QMS is used in organizations as one of
the most effective tools for managing and improving
quality and thus increasing the company's
competitiveness. Organizations implement various quality
management systems, the most well-known are the
standards given by the International Organization for
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 133
Standardization (ISO) and Total Quality Management
(TQM) tools. Other quality management systems
implemented are AS standards typically implemented in
the aerospace industry, TS standards implemented
specially in the automotive industry and so on. The basis
for organizations is that they want to improve business
performance as a result of the implementation of quality
management systems through the improvement of one or
more intermediate factors such as information quality,
operational performance, service quality, etc. This work
examines the impact of the implementation of quality
management systems on business performance through
the improvement of various intermediate products.
1.1 Research Objectives
Plenty of organizations have already implemented a QMS
as a rate controlling and expediting measure for change.
QMS practices are expected to improve organizations
performance by improving information quality,
operational performance and quality of services, products
etc. Many researchers have identified a strong relationship
between various TQM practices and investigated their
tangible and intangible effects on quality performance,
financial and market performance through various
models. In fact, most studies have identified a relationship
between different quality management constructs and the
impact of each on performance measures. There is a lack
of research in the literature on the overall effect of QMS on
business performance through the improvement of other
factors and the examination of the overall effect of QMS
implementation on various performance factors. Based on
the analysis of past research, the aim of the project is to
study the impact of TQM implementation in the steel
sector.
My objective is to explore the relationship between
Quality Management Practices (QMP) and Organizational
Performance (OP) in the manufacturing sector by
developing a conceptual framework and recognizing the
importance of QMP Critical Success Factors (CSFs) to
organizational performance, and to develop a quality
management practice measurement tool for Indian
manufacturing and service organization. To achieve this
goal, a well-developed set of items to measure the QMP
constructs had to be developed. The development of a
valid tool for quality management practices that can be
used in multiple countries and multiple organizations will
be useful for practical and academic perspectives. In
addition, the literature review promises to reveal a lack of
research regarding some critical factors of QM practices.
Therefore, current research proposes a holistic framework
for QM practices based on a comprehensive overview of
the factors that contribute to the success of QM practices.
2.0 Literature Review
Snezana Topalovic, 2014:- Implementation of total quality
management to improve production performance and
increase customer satisfaction levels. In the banking
sector, the following four TQM variables, i.e. top
management commitment, courtesy, responsibility,
tangible values, have an impact on customer satisfaction
and business improvement.
Bell & Omachonu, 2011: – A framework of quality
management practices, recognized by organizations and
governments worldwide and subsequently becoming the
de facto standard for management systems.
Buttewort–Henemann: Total quality can be achieved by
managing business processes that ensure total customer
satisfaction at all levels.
Terziovski & Power, 2007, Arumugam et al., 2008, Suet al.,
2008: However, many studies reveal that effective ISO
implementation can benefit organizations through
improved efficiency, management controls and
productivity, leading to increased performance.
Magd, 2008: Quality has been identified as one of the
competitive strategies for improving business
performance in the global market. In order to increase
efficiency, continuous improvement and performance of
firms, many firms adopt quality management practices as
a quality management tool.
Massoud M. Arshida & Syed Omar Agil: - Critical success
factors for TQM in the Libyan Iron and Steel Company are
continuous improvement, top management commitment,
education and training, supplier quality management,
employee empowerment, recognition and rewards, and
customer focus.
3.0 Methodolgy
3.1 DATA COLLECTION
3.1.1 PRIMARY DATA
Primarily the data is collected from some previous articles,
websites and some other theoretical books which are
related to my Total Quality Management project.
3.1.2 SECONDARY DATA
In secondary data, as shown in the research flow diagram,
two qualitative and quantitative approaches to collect data
for research purposes. Two methods, questionnaire
survey and semi-structured interviews are used to collect
the data. The main intention of the questionnaire was to
recognize the critical success factors of TQM
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 134
implementation in iron and steel industry in India. For
better understand the implementation of TQM in iron and
steel industry in India interview method is mainly used.
Interviews with quality managers in steel industries were
used for topics and problems that emerged from the
findings of the questionnaires.
3.2 SEMI-STRUCTURED INTERVIEW
In semi stuctured interview, total of 140 copies of the
questionnaire were distributed to the target quality
managers who are working in Indian Iron and Steel
Industries. In questionnaire Five-point Likert scales with
the options of Strongly disagree, disagree, neutral, agree
and strongly disagree were used. Ollis et al. (2003)
reported that this scale gives respondents more comfort in
choosing widely. The questionnaire contains 27
statements to identify critical success factors of TQM
implementation.
The questionnaire was validated by distributing it to
academics in India who specialize in TQM and quality
management. They provide feedback on the content of the
questionnaire; their comments were taken into account; a
change was made and the document was revalidated.
Around 140 questionnaires sent to the target people, out
of which a total of 130 have completed questionnaires and
revert. The collected data were analyzed using Likert scale
mean and standard deviation. Consultation with quality
managers were used to elevate a clear understanding of
the issues that resulted from the questionnaire and to
obtain additional information on TQM implementation.
Figure: Research flow chart
QUESTIONNARIE DESIGN
RESULT & DISCUTIONS
DATA COLLECTION
DATA ANANLYSIS
SEMI STRUCTURED INTERVIEW
Andhra Pradesh, Karnataka,
West Bengal, Chhattisgarh,
Jharkhand, Maharashtra
Odisha & Gujarat
1. DESCRIPTIVE ANANLYSIS.
2. MEAN & STANDARD DEVIATION
3. T-TEST
CONCLUSION
LITERATURE REVIEW
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 135
3.3 DATA ANALYSIS
3.3.1 Classification of respondents (demographic
analysis)
Figure : Classification of respondents as per education
qualifications.
Figure: Classification of respondents as per designation
Figure : Classification of respondents as per experience.
The data, which were collected through a questionnaire
design and a semi-structured interview, were analyzed
using a five-point Likert scale method. In this method, five-
point Likert scales (strongly disagree, disagree, neutral,
agree and strongly disagree) were used in the TQM
questionnaire. The questionnaire contains 27 statements
to judge the critical success factors for TQM
implementation.
A Likert scale is a type of rating scale which is used to
measure attitudes or opinions of the people under review.
Using this scale, respondents are asked to rate thinhgs on
their level of agreement and knowledge.
A type of psychometric response scale in which
respondents specify their level of agreement with a
statement, usually on five points: (1) Strongly disagree;
(2) I do not agree; (3) neither consent nor dissent; (4) I
agree; (5) Full consent.
A Likert scale consists of a series of five Likert-type
statements representing similar questions related to a
critical success factor of TQM and combined into a single
composite score/variable. Likert scale data can be
analyzed as interval data, i.e. the mean is the best measure
of central tendency. use means and standard deviations to
describe scale.
[CATEGO
RY NAME]
[PERCEN
TAGE]
[CATEGO
RY NAME]
[PERCEN
TAGE]
[CATEGO
RY NAME]
[PERCEN
TAGE]
[CATEGO
RY NAME]
[PERCEN
TAGE]
[CATEGO
RY NAME]
[PERCEN
TAGE]
AVP
5%
Sr.
Manager
8%
Manager
28%
Dy.
Manager
20%
Asst.
Manager
16%
Jr.
Manager
4%
Sr. Engg.
15%
Asst.
Engg.
4%
CLASSIFICATION OF RESPONDENTS AS
PER DESIGNATION
Below 5
Years
0%
5 to 10
Years
39%
11 to 15
Years
32%
16 to 20
Years
21%
Above 20
Years
8%
CLASSIFICATION OF RESPONDENTS
AS PER EXPERIENCE
[CATEGORY
NAME]
[PERCEN
TAGE]
CLASSIFICATION OF RESPONDENTS AS
PER EDUCATION QUALIFICATIONS
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 136
3.3.2 Descriptive analysis
Five-points Likert scale method MEAN & STANDARD
DEVIATION with T-TEST calculations with one example:
Opinion on statement Rating
Agreed Managers
in No.
A. Strongly Disagree 1 27
B. Disagree 2 43
C. Neutral 3 14
D. Agree 4 15
E. Strongly Agree 5 31
Total 130
Critical
Success Factor
MEAN MEAN 2 SD T-TEST
Continuous
improvement.
4.31 19.2 3.86
0.64
2.85 10.45 2.76
4.42 20.33 3.99
Top
management
commitment
2.19 6.18 2.00
0.32
3.67 14.79 3.34
2.49 7.18 2.17
3.4 13.2 3.13
3.91 17.42 3.68
2.62 8.88 2.50
3.2 11.8 2.93
3.84 15.21 3.37
3.63 14 3.22
Education and
training
3.91 15.68 3.43
0.71
2.26 6.75 2.12
2.37 7.03 2.16
Employee
Empowerment
2.30 7.27 2.23
0.63
2.85 10.31 2.73
2.48 7.90 2.33
Supplier Quality
management
2.22 6.95 2.17
0.82
3.92 17.05 3.62
2.48 7.88 2.32
Recognition &
Reward
2.58 8.11 2.35
0.79
3.98 17.13 3.63
Customer focus
3.35 12.38 3.01
0.27
4.09 17.91 3.72
4.13 17.41 3.64
4.48 21.28 4.1
Mean = ((27*1) +(43*2) +(14*3) +(15*4)
+(31*5))/130
= 2.85
Mean-2 = ((27*12) +(43*22) +(14*32) +(15*42)
+(31*52))/130
= 10.31
Standard deviation (SD)
= √(Mean2- mean)
= √(10.31-2.85)
= 2.73
T-TEST:
T-test is conducted by using excel in the following way:
All Mean values of individual critical success factor are
selected for array-1
All Standard deviation of individual critical success factor
values are selected for array-2
Two tail distribution and
Two sample equal variance (homoscedastic)
4.0 RESULT & DISCUSSION
Critical Success Factors (CSF)
The weightage of each TQM factor was evaluated by using
a set of questions and a five-point Likert scale. Quality
managers were asked to rate their response from 1 to 5
whether they agreed or disagreed with the given
statements. Using five-point Likert scale, the mean is
measured as 3 ((1+2+3+4+5)/5), therefore the mean is
greater than 3, indicate that the statement is agreed. The
above table shows the mean of each factor examined in the
current study. Critical success factors are continuous
improvement, top management commitment, education
and training, supplier quality management, employee
empowerment, recognition and rewards, and customer
focus.
Most of the TQM managers were agreed that these factors
play a significant role in achieving effective TQM
implementation in an organization. This result is
supported by parallel reaserch done in the same area. Top
management commitment plays a significant role in
promoting TQM implementation in steel sector. As far as
Steel sector is concerned,top management commitment
and customer focus play a significant role in the successful
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 137
implementation of TQM. For the win-win condition of TQM
implementation, customer focus is a key element in
addressing and resolving customer problems and
complaints in companies that apply the TQM philosophy.
The development of a quality policy must reflect the goal
of the organization which includes corporate values,
expectations and focus.
From the questionnaire survey, the following statements
are identified as critical success factors for TQM
implementation.
1. In your organization, TQM is implemented in all
departments.
In the survey, in steel industries TQM is implemented in all
departments. This statement is strongly disagreed by 32%,
disagree by 41% only 11% & 6% quality managers are
agreed & strongly agreed as shown in above chart.
2. Your organization is having competent TQM leaders.
The above chart shows that, the steel industries are
doesn’t having adequate TQM leaders. Up-to 41% of
quality managers are strongly agreed and up-to 22% are
agreed and 6% & 14% are agreed & strongly agreed
respectively. It is shows that in steel industry there is no
sufficient TQM leaders to implement TQM successfully.
3. Sufficient TQM leaders are there in your blast furnace
department.
In blast furnace department, TQM leaders are less in
number 21% strongly agreed and 33% are agreed. As
shown in above figure, more than 50% TQM leaders are
saying that blast furnace department doesn’t having
sufficient TQM leaders to implement TQM successfully
specially in small scale steel industries.
Due to insufficient of number of TQM leaders, the
interaction level between TQM leader and the top
management or the shop floor workmen is also not that
much of efficient. It effects on contentious process
improvement.
4. Excellent interaction between TQM leaders and shop
floor workmen.
32%
41%
11% 11%
6%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
A.
Strongly
Disagree
B.
Disagree
C.
Neutral
D. Agree E.
Strongly
Agree
Accepted
quality
managers
(%)
41%
22%
17%
6%
14%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
A.
Strongly
Disagree
B.
Disagree
C.
Neutral
D. Agree E.
Strongly
Agree
Accepted
quality
managers
(%)
21%
33%
11% 12%
24%
0%
5%
10%
15%
20%
25%
30%
35%
A.
Strongly
Disagree
B.
Disagree
C.
Neutral
D. Agree E.
Strongly
Agree
Accepted
quality
managers
(%)
32%
19%
25%
14%
9%
0%
5%
10%
15%
20%
25%
30%
35%
A.
Strongly
Disagree
B.
Disagree
C.
Neutral
D. Agree E.
Strongly
Agree
Accepted
quality
managers
(%)
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 138
In survey, found that more than 50% of quality managers
said that there is no good interaction between TQM
leaders and shop floor workmen.
Interaction from shop floor workmen is most important to
communicate the message or instructions top
management to the shop floor workmen. And also finding
the problems faced by the workmen, ideas collection from
shop floor workmen to solve problems.
Interaction from top management is also most important
to modify the process to solve the problems and
continuous improvement in process technology.
TQM leaders are having direct contact with top
management and shop floor workmen. If the TQM leaders
are not sufficient then the interaction from shop floor
workmen will decreases as shown in the blow. The
communication gap will create between top management
and shop floor workmen it is most important for
continuous improvement in process.
5. Short time breakdowns will deteriorate the product
quality.
Short time breakdowns are deteriorating the quality of
individual department product. It is strongly agreed by
43% and agreed up-to 34% of quality managers in the
survey.
6. During short time breakdown time there will be a
quick communication between internal customer and
internal supplier.
During short time breakdown periods there will be a quick
communication this statement is disagreed by TQM quality
managers up-to 65% (strongly disagree 46% & disagreed
19%). Shor time breakdowns will deteriorate the quality
of product but the communication gap between internal
customer and internal supplier shown in above figure.
If there is a quick communication, then internal customer
will take the necessary measures/actions to maintain
same quality and avoid the problems. Poor quality of raw
material, which are supplied by the internal supplier will
reduce productivity and increase the cost of production.
In blast furnace process the raw material quality is most
important (physical properties and chemical properties).
The process is carried out by assuming the quality of raw
material is good and constant. If any changes in raw
material quality, rite action at rite time is most impotent to
maintain product quality because whatever the actions are
taken the reaction will start (minimum time to start
reactions inside the furnace) after 2-3 hours. After starting
reaction, result on quality will occur after 3-4 hours
minimum sometimes 2-3 days (if rite action at rite time
not taken).
7. In short time breakdown periods, internal supplier is
storing the product (sinter/pellet/coke) separately till
getting quality analysis report.
During short time breakdowns,
a. The quality of internal supplier product
(sinter/pellet/coke) will be deteriorated by short
time breakdowns and
b. Internal supplier will not be informing quickly to
the internal customer.
8%
11%
4%
34%
43%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
A.
Strongly
Disagree
B.
Disagree
C.
Neutral
D. Agree E.
Strongly
Agree
Accepted
quality
managers
(%)
46%
19%
12% 11% 12%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
A.
Strongly
Disagree
B.
Disagree
C.
Neutral
D. Agree E.
Strongly
Agree
Accepted
quality
managers
(%)
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 139
Even though “internal supplier is storing the product
(sinter/pellet/coke) separately till getting quality analysis
report” this statement is disagreed by 77% (strongly
disagreed by 16% & disagreed by 61%) of quality
managers as per my survey.
If poor-quality material is mixed with good quality this
will create a problem in blast furnace. Most of the
industries are stored separately till getting quality analysis
when already internal customer i.e., Blast furnace is facing
problems.
In some steel industries, every time during short time
breakdown periods the poor-quality material is stored
separately. After getting quality analysis it will supply to
the internal customer by communicating with each other.
The internal customer small amount of the poor-quality
material is blended with large amount of good quality
material by storing poor quality material separately in
storage bins at stock house.
8. Well support of top management in investing capital
for new technology.
Top management is well supported to invest capital for
new technology implement this is disagreed quality
managers by 72% & strongly disagreed by 4%. Only 21%
are agreed & 4% are strongly agreed by quality managers.
Present market competition is mere so to give strong
competition in the market for long term need to
implement new technology is more important. It will give
result that good control in quality, reducing production
cost per unit is also reduce and increasing productivity.
5.0 Conclusion & Future Scope Of Work
5.1.1 CONCLUSION
All the 7 parameters listed in the table above were
identified by the quality managers who were interviewed
as critical factors in the Indian iron and steel industry.
These factors are continuous improvement, top
management commitment, education and training,
supplier quality management, employee empowerment,
recognition and rewards, and customer focus.
Critical Success
Factor
MEAN MEAN2 SD T-TEST
Continuous
development.
3.86 16.66 3.53 0.17
Top management
commitment
3.22 12.07 2.93 0.22
Education and
training
2.85 9.82 2.57 0.37
Employee
Empowerment
2.54 8.49 2.43 0.39
Supplier Quality
management
2.87 10.62 2.71 0.37
Recognition &
Reward
3.28 12.62 2.99 0.29
Customer focus 4.01 17.24 3.62 0.51
Table: TQM critical success factor’s average vales.
16%
61%
0%
5%
18%
0%
10%
20%
30%
40%
50%
60%
70%
A.
Strongly
Disagree
B.
Disagree
C.
Neutral
D. Agree E.
Strongly
Agree
Accepted
quality
managers
(%)
4%
72%
0%
21%
4%
0%
10%
20%
30%
40%
50%
60%
70%
80%
A.
Strongly
Disagree
B.
Disagree
C.
Neutral
D. Agree E.
Strongly
Agree
Accepted
quality
managers
(%)
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 140
Through this research, I found that in the steel industry,
each department should have at least 2-3 numbers. Head
of TQM except HOD (Head of Department). TQM managers
focus primarily on quality by finding the cause of poor
quality, get feedback directly from the shop floor worker
from time to time, and focus on continuous process
improvement through the quality cycle, i.e. PDCA.
If the quality managers in each department are sufficient,
in case of any problems (short-term failure or raw
material change) in any department (sinter/pellet/coke
oven), they immediately informed the TQM manager of the
direct internal customer (blast furnace). Then this TQM
leader (blast furnace) calculates the following
Answer: To what extent the physical and chemical
properties of the raw material ie agglomerate/pellet/coke
will change and how it will behave inside the furnace is
calculated before affecting the final quality of the hot
metal.
B. To what extent it will affect the quality of the blast
furnace product ie hot metal and near SMS.
C. A constant quality of hot metal is maintained by
i. Change of input raw material according to
availability.
ii. Change in load ratio (Sinter: Ore: Pellet)
iii. Changing process parameters.
D. Sometimes TQM leaders in blast furnaces cannot
control the quality, and if they refuse, they immediately
report to TQM leaders in the superior department (SMS),
then they go to PCM.
5.1.2 FUTURE SCOPE OF WORK
Education and training level in an organization
and their instant feedback is improved by
a. Motivating the worker who developing new plans to
do work with friendly or who develops new process
plans.
b. Improvement in quality of daily routine work is
enhanced through developing plans.
Employee Empowerment found to be improved
by involving TQM managers in their departments by
taking the following responsibilities in a lead role.
a. Daily meetings with top management and HOD
regarding how to achieve target production with
quality by available raw material and their quality.
b. Daily meetings with all other department TQM
leaders regarding breakdowns (what is the problem?
Why occurred? Finding solutions doesn’t repeat the
same thing etc.) and what extent internal supplier
quality is influenced on internal customer quality and
finally external customer quality with respect to
production cost.
Supplier Quality management has been
enhanced by the organization by means of
a. Fastest communication between departments
(internal customer and internal supplier) regarding
quality, to take rite action at rite time.
b. Conducting institutional and on field trainings
timely to all.
6.0 REFERENCES
1. Critical success factors of Total Quality Management
implementation with in the Libyan Iron and Steel
Company; Massoud M. Arshida & Syed Omar Agil,
September 24-26,2013.
2. Implementation of total Quality Management in
order to improve production performance and
enhancing the level of customer satisfaction (Snezana
Topalovic, 2014).
3. Oakland S. Total Quality Management – The route to
improving performance. Second Edition Oxford:
Buttewort - Henemann; 1993.
4. Stevenson J. Production / Operations Management.
Fourth Edition. Boston: Irwin. Homewood; 1993.
5. Zairi M. The TQM lagasy- Guru’s contributions and
theoretical impact. The TQM Journal, 2013.
6. Fotopoulos CV, Psomas EL. The structural
relationship between total quality management
factors and organizational performance. The TQM
Journal, 2010.
7. Implementation of Total Quality Management in
order to improve production performance and
enhancing the level of customer satisfaction. Snezana
Topalovic Octomber-9, 2014.
8. Implementation of self-assessment evaluation for
Total Quality Management: a case study of wholesale
sectors; 2012.
9. The present status of quality and manufacturing
management techniques and philosophies within the
Libyan Iron and Steel industry; Rajab Abdullah
Hokoma, Mohammad Kurshid Khan, Khalid Hussain,
August-2009.
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 141
10. Total Quality Management in industrialized building
system: Implementation and benefits in construction
projects; Awag Mohsen Alawag, Wesam Salam
Alaloul, M.S. Liew, Muhammad Ali Musarat, Abdullah
O. Baarimah, Syed Saad, Syed Ammad- June-15,2022.
11. Relationship between Total Quality Management and
Organizational performance: Empirical evidence
from selected airlines in Nigeria aviation industry;
April-2020.
12. Case studies on the implementation of TQM in the UK
automotive SMEs (Sha'ri Mohd. Yusof Universiti
Teknologi Malaysia, Johor Bahru, Malaysia, and
Elaine Aspinwall University of Birmingham,
Birmingham, UK, August 2000-February 2001)
13. Implementation of TQM: A Case Study in an Auto
Company (N. Venkateshwarlu, Ashish Agarwal and
Manoj Kulshreshtha, April - June 2011).
14. A Case Study of Total Quality Management in a
Manufacturing and Construction Firm (Ammar Al-
Saket, January 2003).
15. TQM implementation issues SME review and case
study (Sha'ri M. Yusof and Elaine Aspinwall,
University of Birmingham, UK, 27 May 2014).

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Critical success factors of Total Quality Management implementation in Indian Iron and Steel Industries (IISI)

  • 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 132 Critical success factors of Total Quality Management implementation in Indian Iron and Steel Industries (IISI) K Shiva Shankar Reddy1, Haldhar Ram Chandrakar2 1 Scholar Final year M.Tech (Industrial Engg & Management) CSIT Durg. 2 Associate Professor Department of Mechanical Engg CSIT Durg, Chhattisgarh, India. --------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - Over the past few decades, many organizations have implemented Total Quality Management (TQM) to create a culture of continuous quality improvement and improve business performance. Various QMS implemented in organizations are ISO 9000, Total Quality Management (TQM), Aerospace Standards (AS) and many others. These standards cover aspects such as management leadership, process management, teamwork, quality improvement, and relationships with suppliers and customers. It is expected that the implementation of TQM will ultimately improve the overall performance of the business. The main objective of my project is to investigate and evaluate Total Quality Management (TQM) practices in steel production and also to determine their impact on their performance. In this regard, a TQM implementation questionnaire on business performance factors is prepared and a survey study is to be conducted with quality management and engineering professionals to collect their opinions on QMS implementation. A sample questionnaire is distributed to experts, managers and supervisors of various firms to study and cover the overall impact of QMS implementation on various business performance factors. Key Words: Quality Control (QI), Quality Control (QC), Quality Assurance (QA)Total Quality Management (TQM), Critical Success Factors (CSF), Indian Iron & Steel Industries (IISI). 1. Introduction: Organizations that adopt a quality management strategy focus on achieving and maintaining high quality outputs using management practices as inputs and quality performance as outputs. Pioneers in TQM, such as Deming, Juran, Crossby, and Feigenbaum, emphasized the importance of quality philosophy as an essential competitive weapon for organizational transformation. Researchers define quality management (QM) as a set of guiding principles and management style adopted by managers in organizations to improve organizational competitiveness and performance. A study by many researchers identifies relationships between QM practices and examines the effects of these practices on performance, but finds inconsistencies and conflicting results among researchers. These findings suggest that there is a positive relationship between QM or TQM practices and firm performance and among other variables such as product quality, product and process performance, perceived quality, quality drivers, reduced costs, more satisfied customers, and improved financial performance. In general, a large body of literature emphasizes the positive impact of QM practices on performance, but others have not found a relationship between QM practices—TQM—and performance. Therefore, quality management (QM) plays an important role in the productivity and performance of an organization. Quality practices seem to be important for the continued survival of Indian organizations. Today, despite this debate, TQM is widely accepted and is the most important research topic in both academic and professional settings. However, there is a lack of agreement on the research and some results contradict the theories of quality management. With increasing throat cut competition and the age of globalization, the concept of supply chain quality management is at the forefront of industry today. It requires coordination with suppliers and customers, rather than treating them as opponents, so that the flow of materials from the supplier to the end customer is smoother. It includes optimization of various concepts such as reducing product delivery times, supporting just- in-time concepts, improving product quality, etc. To be successful in their business, organizations need to control not only costs but also quality in the supply chain. Successful supply chain management largely depends on how quality is managed throughout the system. So it is not false to say that quality management is essential for success in today's competitive world. Different types of quality need to be managed both inside and outside of the supply chain system. This includes information quality, product quality, service quality, etc. This has resulted to the successful implementation of quality management systems in different organizations around the world. The implementation of QMS is used in organizations as one of the most effective tools for managing and improving quality and thus increasing the company's competitiveness. Organizations implement various quality management systems, the most well-known are the standards given by the International Organization for
  • 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 133 Standardization (ISO) and Total Quality Management (TQM) tools. Other quality management systems implemented are AS standards typically implemented in the aerospace industry, TS standards implemented specially in the automotive industry and so on. The basis for organizations is that they want to improve business performance as a result of the implementation of quality management systems through the improvement of one or more intermediate factors such as information quality, operational performance, service quality, etc. This work examines the impact of the implementation of quality management systems on business performance through the improvement of various intermediate products. 1.1 Research Objectives Plenty of organizations have already implemented a QMS as a rate controlling and expediting measure for change. QMS practices are expected to improve organizations performance by improving information quality, operational performance and quality of services, products etc. Many researchers have identified a strong relationship between various TQM practices and investigated their tangible and intangible effects on quality performance, financial and market performance through various models. In fact, most studies have identified a relationship between different quality management constructs and the impact of each on performance measures. There is a lack of research in the literature on the overall effect of QMS on business performance through the improvement of other factors and the examination of the overall effect of QMS implementation on various performance factors. Based on the analysis of past research, the aim of the project is to study the impact of TQM implementation in the steel sector. My objective is to explore the relationship between Quality Management Practices (QMP) and Organizational Performance (OP) in the manufacturing sector by developing a conceptual framework and recognizing the importance of QMP Critical Success Factors (CSFs) to organizational performance, and to develop a quality management practice measurement tool for Indian manufacturing and service organization. To achieve this goal, a well-developed set of items to measure the QMP constructs had to be developed. The development of a valid tool for quality management practices that can be used in multiple countries and multiple organizations will be useful for practical and academic perspectives. In addition, the literature review promises to reveal a lack of research regarding some critical factors of QM practices. Therefore, current research proposes a holistic framework for QM practices based on a comprehensive overview of the factors that contribute to the success of QM practices. 2.0 Literature Review Snezana Topalovic, 2014:- Implementation of total quality management to improve production performance and increase customer satisfaction levels. In the banking sector, the following four TQM variables, i.e. top management commitment, courtesy, responsibility, tangible values, have an impact on customer satisfaction and business improvement. Bell & Omachonu, 2011: – A framework of quality management practices, recognized by organizations and governments worldwide and subsequently becoming the de facto standard for management systems. Buttewort–Henemann: Total quality can be achieved by managing business processes that ensure total customer satisfaction at all levels. Terziovski & Power, 2007, Arumugam et al., 2008, Suet al., 2008: However, many studies reveal that effective ISO implementation can benefit organizations through improved efficiency, management controls and productivity, leading to increased performance. Magd, 2008: Quality has been identified as one of the competitive strategies for improving business performance in the global market. In order to increase efficiency, continuous improvement and performance of firms, many firms adopt quality management practices as a quality management tool. Massoud M. Arshida & Syed Omar Agil: - Critical success factors for TQM in the Libyan Iron and Steel Company are continuous improvement, top management commitment, education and training, supplier quality management, employee empowerment, recognition and rewards, and customer focus. 3.0 Methodolgy 3.1 DATA COLLECTION 3.1.1 PRIMARY DATA Primarily the data is collected from some previous articles, websites and some other theoretical books which are related to my Total Quality Management project. 3.1.2 SECONDARY DATA In secondary data, as shown in the research flow diagram, two qualitative and quantitative approaches to collect data for research purposes. Two methods, questionnaire survey and semi-structured interviews are used to collect the data. The main intention of the questionnaire was to recognize the critical success factors of TQM
  • 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 134 implementation in iron and steel industry in India. For better understand the implementation of TQM in iron and steel industry in India interview method is mainly used. Interviews with quality managers in steel industries were used for topics and problems that emerged from the findings of the questionnaires. 3.2 SEMI-STRUCTURED INTERVIEW In semi stuctured interview, total of 140 copies of the questionnaire were distributed to the target quality managers who are working in Indian Iron and Steel Industries. In questionnaire Five-point Likert scales with the options of Strongly disagree, disagree, neutral, agree and strongly disagree were used. Ollis et al. (2003) reported that this scale gives respondents more comfort in choosing widely. The questionnaire contains 27 statements to identify critical success factors of TQM implementation. The questionnaire was validated by distributing it to academics in India who specialize in TQM and quality management. They provide feedback on the content of the questionnaire; their comments were taken into account; a change was made and the document was revalidated. Around 140 questionnaires sent to the target people, out of which a total of 130 have completed questionnaires and revert. The collected data were analyzed using Likert scale mean and standard deviation. Consultation with quality managers were used to elevate a clear understanding of the issues that resulted from the questionnaire and to obtain additional information on TQM implementation. Figure: Research flow chart QUESTIONNARIE DESIGN RESULT & DISCUTIONS DATA COLLECTION DATA ANANLYSIS SEMI STRUCTURED INTERVIEW Andhra Pradesh, Karnataka, West Bengal, Chhattisgarh, Jharkhand, Maharashtra Odisha & Gujarat 1. DESCRIPTIVE ANANLYSIS. 2. MEAN & STANDARD DEVIATION 3. T-TEST CONCLUSION LITERATURE REVIEW
  • 4. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 135 3.3 DATA ANALYSIS 3.3.1 Classification of respondents (demographic analysis) Figure : Classification of respondents as per education qualifications. Figure: Classification of respondents as per designation Figure : Classification of respondents as per experience. The data, which were collected through a questionnaire design and a semi-structured interview, were analyzed using a five-point Likert scale method. In this method, five- point Likert scales (strongly disagree, disagree, neutral, agree and strongly disagree) were used in the TQM questionnaire. The questionnaire contains 27 statements to judge the critical success factors for TQM implementation. A Likert scale is a type of rating scale which is used to measure attitudes or opinions of the people under review. Using this scale, respondents are asked to rate thinhgs on their level of agreement and knowledge. A type of psychometric response scale in which respondents specify their level of agreement with a statement, usually on five points: (1) Strongly disagree; (2) I do not agree; (3) neither consent nor dissent; (4) I agree; (5) Full consent. A Likert scale consists of a series of five Likert-type statements representing similar questions related to a critical success factor of TQM and combined into a single composite score/variable. Likert scale data can be analyzed as interval data, i.e. the mean is the best measure of central tendency. use means and standard deviations to describe scale. [CATEGO RY NAME] [PERCEN TAGE] [CATEGO RY NAME] [PERCEN TAGE] [CATEGO RY NAME] [PERCEN TAGE] [CATEGO RY NAME] [PERCEN TAGE] [CATEGO RY NAME] [PERCEN TAGE] AVP 5% Sr. Manager 8% Manager 28% Dy. Manager 20% Asst. Manager 16% Jr. Manager 4% Sr. Engg. 15% Asst. Engg. 4% CLASSIFICATION OF RESPONDENTS AS PER DESIGNATION Below 5 Years 0% 5 to 10 Years 39% 11 to 15 Years 32% 16 to 20 Years 21% Above 20 Years 8% CLASSIFICATION OF RESPONDENTS AS PER EXPERIENCE [CATEGORY NAME] [PERCEN TAGE] CLASSIFICATION OF RESPONDENTS AS PER EDUCATION QUALIFICATIONS
  • 5. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 136 3.3.2 Descriptive analysis Five-points Likert scale method MEAN & STANDARD DEVIATION with T-TEST calculations with one example: Opinion on statement Rating Agreed Managers in No. A. Strongly Disagree 1 27 B. Disagree 2 43 C. Neutral 3 14 D. Agree 4 15 E. Strongly Agree 5 31 Total 130 Critical Success Factor MEAN MEAN 2 SD T-TEST Continuous improvement. 4.31 19.2 3.86 0.64 2.85 10.45 2.76 4.42 20.33 3.99 Top management commitment 2.19 6.18 2.00 0.32 3.67 14.79 3.34 2.49 7.18 2.17 3.4 13.2 3.13 3.91 17.42 3.68 2.62 8.88 2.50 3.2 11.8 2.93 3.84 15.21 3.37 3.63 14 3.22 Education and training 3.91 15.68 3.43 0.71 2.26 6.75 2.12 2.37 7.03 2.16 Employee Empowerment 2.30 7.27 2.23 0.63 2.85 10.31 2.73 2.48 7.90 2.33 Supplier Quality management 2.22 6.95 2.17 0.82 3.92 17.05 3.62 2.48 7.88 2.32 Recognition & Reward 2.58 8.11 2.35 0.79 3.98 17.13 3.63 Customer focus 3.35 12.38 3.01 0.27 4.09 17.91 3.72 4.13 17.41 3.64 4.48 21.28 4.1 Mean = ((27*1) +(43*2) +(14*3) +(15*4) +(31*5))/130 = 2.85 Mean-2 = ((27*12) +(43*22) +(14*32) +(15*42) +(31*52))/130 = 10.31 Standard deviation (SD) = √(Mean2- mean) = √(10.31-2.85) = 2.73 T-TEST: T-test is conducted by using excel in the following way: All Mean values of individual critical success factor are selected for array-1 All Standard deviation of individual critical success factor values are selected for array-2 Two tail distribution and Two sample equal variance (homoscedastic) 4.0 RESULT & DISCUSSION Critical Success Factors (CSF) The weightage of each TQM factor was evaluated by using a set of questions and a five-point Likert scale. Quality managers were asked to rate their response from 1 to 5 whether they agreed or disagreed with the given statements. Using five-point Likert scale, the mean is measured as 3 ((1+2+3+4+5)/5), therefore the mean is greater than 3, indicate that the statement is agreed. The above table shows the mean of each factor examined in the current study. Critical success factors are continuous improvement, top management commitment, education and training, supplier quality management, employee empowerment, recognition and rewards, and customer focus. Most of the TQM managers were agreed that these factors play a significant role in achieving effective TQM implementation in an organization. This result is supported by parallel reaserch done in the same area. Top management commitment plays a significant role in promoting TQM implementation in steel sector. As far as Steel sector is concerned,top management commitment and customer focus play a significant role in the successful
  • 6. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 137 implementation of TQM. For the win-win condition of TQM implementation, customer focus is a key element in addressing and resolving customer problems and complaints in companies that apply the TQM philosophy. The development of a quality policy must reflect the goal of the organization which includes corporate values, expectations and focus. From the questionnaire survey, the following statements are identified as critical success factors for TQM implementation. 1. In your organization, TQM is implemented in all departments. In the survey, in steel industries TQM is implemented in all departments. This statement is strongly disagreed by 32%, disagree by 41% only 11% & 6% quality managers are agreed & strongly agreed as shown in above chart. 2. Your organization is having competent TQM leaders. The above chart shows that, the steel industries are doesn’t having adequate TQM leaders. Up-to 41% of quality managers are strongly agreed and up-to 22% are agreed and 6% & 14% are agreed & strongly agreed respectively. It is shows that in steel industry there is no sufficient TQM leaders to implement TQM successfully. 3. Sufficient TQM leaders are there in your blast furnace department. In blast furnace department, TQM leaders are less in number 21% strongly agreed and 33% are agreed. As shown in above figure, more than 50% TQM leaders are saying that blast furnace department doesn’t having sufficient TQM leaders to implement TQM successfully specially in small scale steel industries. Due to insufficient of number of TQM leaders, the interaction level between TQM leader and the top management or the shop floor workmen is also not that much of efficient. It effects on contentious process improvement. 4. Excellent interaction between TQM leaders and shop floor workmen. 32% 41% 11% 11% 6% 0% 5% 10% 15% 20% 25% 30% 35% 40% 45% A. Strongly Disagree B. Disagree C. Neutral D. Agree E. Strongly Agree Accepted quality managers (%) 41% 22% 17% 6% 14% 0% 5% 10% 15% 20% 25% 30% 35% 40% 45% A. Strongly Disagree B. Disagree C. Neutral D. Agree E. Strongly Agree Accepted quality managers (%) 21% 33% 11% 12% 24% 0% 5% 10% 15% 20% 25% 30% 35% A. Strongly Disagree B. Disagree C. Neutral D. Agree E. Strongly Agree Accepted quality managers (%) 32% 19% 25% 14% 9% 0% 5% 10% 15% 20% 25% 30% 35% A. Strongly Disagree B. Disagree C. Neutral D. Agree E. Strongly Agree Accepted quality managers (%)
  • 7. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 138 In survey, found that more than 50% of quality managers said that there is no good interaction between TQM leaders and shop floor workmen. Interaction from shop floor workmen is most important to communicate the message or instructions top management to the shop floor workmen. And also finding the problems faced by the workmen, ideas collection from shop floor workmen to solve problems. Interaction from top management is also most important to modify the process to solve the problems and continuous improvement in process technology. TQM leaders are having direct contact with top management and shop floor workmen. If the TQM leaders are not sufficient then the interaction from shop floor workmen will decreases as shown in the blow. The communication gap will create between top management and shop floor workmen it is most important for continuous improvement in process. 5. Short time breakdowns will deteriorate the product quality. Short time breakdowns are deteriorating the quality of individual department product. It is strongly agreed by 43% and agreed up-to 34% of quality managers in the survey. 6. During short time breakdown time there will be a quick communication between internal customer and internal supplier. During short time breakdown periods there will be a quick communication this statement is disagreed by TQM quality managers up-to 65% (strongly disagree 46% & disagreed 19%). Shor time breakdowns will deteriorate the quality of product but the communication gap between internal customer and internal supplier shown in above figure. If there is a quick communication, then internal customer will take the necessary measures/actions to maintain same quality and avoid the problems. Poor quality of raw material, which are supplied by the internal supplier will reduce productivity and increase the cost of production. In blast furnace process the raw material quality is most important (physical properties and chemical properties). The process is carried out by assuming the quality of raw material is good and constant. If any changes in raw material quality, rite action at rite time is most impotent to maintain product quality because whatever the actions are taken the reaction will start (minimum time to start reactions inside the furnace) after 2-3 hours. After starting reaction, result on quality will occur after 3-4 hours minimum sometimes 2-3 days (if rite action at rite time not taken). 7. In short time breakdown periods, internal supplier is storing the product (sinter/pellet/coke) separately till getting quality analysis report. During short time breakdowns, a. The quality of internal supplier product (sinter/pellet/coke) will be deteriorated by short time breakdowns and b. Internal supplier will not be informing quickly to the internal customer. 8% 11% 4% 34% 43% 0% 5% 10% 15% 20% 25% 30% 35% 40% 45% 50% A. Strongly Disagree B. Disagree C. Neutral D. Agree E. Strongly Agree Accepted quality managers (%) 46% 19% 12% 11% 12% 0% 5% 10% 15% 20% 25% 30% 35% 40% 45% 50% A. Strongly Disagree B. Disagree C. Neutral D. Agree E. Strongly Agree Accepted quality managers (%)
  • 8. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 139 Even though “internal supplier is storing the product (sinter/pellet/coke) separately till getting quality analysis report” this statement is disagreed by 77% (strongly disagreed by 16% & disagreed by 61%) of quality managers as per my survey. If poor-quality material is mixed with good quality this will create a problem in blast furnace. Most of the industries are stored separately till getting quality analysis when already internal customer i.e., Blast furnace is facing problems. In some steel industries, every time during short time breakdown periods the poor-quality material is stored separately. After getting quality analysis it will supply to the internal customer by communicating with each other. The internal customer small amount of the poor-quality material is blended with large amount of good quality material by storing poor quality material separately in storage bins at stock house. 8. Well support of top management in investing capital for new technology. Top management is well supported to invest capital for new technology implement this is disagreed quality managers by 72% & strongly disagreed by 4%. Only 21% are agreed & 4% are strongly agreed by quality managers. Present market competition is mere so to give strong competition in the market for long term need to implement new technology is more important. It will give result that good control in quality, reducing production cost per unit is also reduce and increasing productivity. 5.0 Conclusion & Future Scope Of Work 5.1.1 CONCLUSION All the 7 parameters listed in the table above were identified by the quality managers who were interviewed as critical factors in the Indian iron and steel industry. These factors are continuous improvement, top management commitment, education and training, supplier quality management, employee empowerment, recognition and rewards, and customer focus. Critical Success Factor MEAN MEAN2 SD T-TEST Continuous development. 3.86 16.66 3.53 0.17 Top management commitment 3.22 12.07 2.93 0.22 Education and training 2.85 9.82 2.57 0.37 Employee Empowerment 2.54 8.49 2.43 0.39 Supplier Quality management 2.87 10.62 2.71 0.37 Recognition & Reward 3.28 12.62 2.99 0.29 Customer focus 4.01 17.24 3.62 0.51 Table: TQM critical success factor’s average vales. 16% 61% 0% 5% 18% 0% 10% 20% 30% 40% 50% 60% 70% A. Strongly Disagree B. Disagree C. Neutral D. Agree E. Strongly Agree Accepted quality managers (%) 4% 72% 0% 21% 4% 0% 10% 20% 30% 40% 50% 60% 70% 80% A. Strongly Disagree B. Disagree C. Neutral D. Agree E. Strongly Agree Accepted quality managers (%)
  • 9. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 140 Through this research, I found that in the steel industry, each department should have at least 2-3 numbers. Head of TQM except HOD (Head of Department). TQM managers focus primarily on quality by finding the cause of poor quality, get feedback directly from the shop floor worker from time to time, and focus on continuous process improvement through the quality cycle, i.e. PDCA. If the quality managers in each department are sufficient, in case of any problems (short-term failure or raw material change) in any department (sinter/pellet/coke oven), they immediately informed the TQM manager of the direct internal customer (blast furnace). Then this TQM leader (blast furnace) calculates the following Answer: To what extent the physical and chemical properties of the raw material ie agglomerate/pellet/coke will change and how it will behave inside the furnace is calculated before affecting the final quality of the hot metal. B. To what extent it will affect the quality of the blast furnace product ie hot metal and near SMS. C. A constant quality of hot metal is maintained by i. Change of input raw material according to availability. ii. Change in load ratio (Sinter: Ore: Pellet) iii. Changing process parameters. D. Sometimes TQM leaders in blast furnaces cannot control the quality, and if they refuse, they immediately report to TQM leaders in the superior department (SMS), then they go to PCM. 5.1.2 FUTURE SCOPE OF WORK Education and training level in an organization and their instant feedback is improved by a. Motivating the worker who developing new plans to do work with friendly or who develops new process plans. b. Improvement in quality of daily routine work is enhanced through developing plans. Employee Empowerment found to be improved by involving TQM managers in their departments by taking the following responsibilities in a lead role. a. Daily meetings with top management and HOD regarding how to achieve target production with quality by available raw material and their quality. b. Daily meetings with all other department TQM leaders regarding breakdowns (what is the problem? Why occurred? Finding solutions doesn’t repeat the same thing etc.) and what extent internal supplier quality is influenced on internal customer quality and finally external customer quality with respect to production cost. Supplier Quality management has been enhanced by the organization by means of a. Fastest communication between departments (internal customer and internal supplier) regarding quality, to take rite action at rite time. b. Conducting institutional and on field trainings timely to all. 6.0 REFERENCES 1. Critical success factors of Total Quality Management implementation with in the Libyan Iron and Steel Company; Massoud M. Arshida & Syed Omar Agil, September 24-26,2013. 2. Implementation of total Quality Management in order to improve production performance and enhancing the level of customer satisfaction (Snezana Topalovic, 2014). 3. Oakland S. Total Quality Management – The route to improving performance. Second Edition Oxford: Buttewort - Henemann; 1993. 4. Stevenson J. Production / Operations Management. Fourth Edition. Boston: Irwin. Homewood; 1993. 5. Zairi M. The TQM lagasy- Guru’s contributions and theoretical impact. The TQM Journal, 2013. 6. Fotopoulos CV, Psomas EL. The structural relationship between total quality management factors and organizational performance. The TQM Journal, 2010. 7. Implementation of Total Quality Management in order to improve production performance and enhancing the level of customer satisfaction. Snezana Topalovic Octomber-9, 2014. 8. Implementation of self-assessment evaluation for Total Quality Management: a case study of wholesale sectors; 2012. 9. The present status of quality and manufacturing management techniques and philosophies within the Libyan Iron and Steel industry; Rajab Abdullah Hokoma, Mohammad Kurshid Khan, Khalid Hussain, August-2009.
  • 10. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 11 | Nov 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 141 10. Total Quality Management in industrialized building system: Implementation and benefits in construction projects; Awag Mohsen Alawag, Wesam Salam Alaloul, M.S. Liew, Muhammad Ali Musarat, Abdullah O. Baarimah, Syed Saad, Syed Ammad- June-15,2022. 11. Relationship between Total Quality Management and Organizational performance: Empirical evidence from selected airlines in Nigeria aviation industry; April-2020. 12. Case studies on the implementation of TQM in the UK automotive SMEs (Sha'ri Mohd. Yusof Universiti Teknologi Malaysia, Johor Bahru, Malaysia, and Elaine Aspinwall University of Birmingham, Birmingham, UK, August 2000-February 2001) 13. Implementation of TQM: A Case Study in an Auto Company (N. Venkateshwarlu, Ashish Agarwal and Manoj Kulshreshtha, April - June 2011). 14. A Case Study of Total Quality Management in a Manufacturing and Construction Firm (Ammar Al- Saket, January 2003). 15. TQM implementation issues SME review and case study (Sha'ri M. Yusof and Elaine Aspinwall, University of Birmingham, UK, 27 May 2014).