adoption of total quality management CONCEPTS IN SUDANESE TEXTILE MILLS

Abstract

The research focuses in the process of adopting Total Quality Management principles in Sudanese Textile industries and adapting textile mills operations according to these principles looking for continuous quality improvement and customer satisfaction. Manufacturing (the process of transferring raw material into product that helps human being to live in a better way) is considered as a basic and effective element for the construction of todays economic that its nature has become known as knowledge based economic. Day by day more production (Production is the process of creation of goods and service at feasible cost) (1) can be produced. Competition rises between manufacturers and the old saying of “production is the cry of the day” has changed to be “quality is the cry of the day”. But to achieve this quality a new philosophy (Total Quality Management) that represent a new way of doing things, has to be adopted. Searching for the best way to improve product's quality (Quality as the adopted definition by the American Society for Quality Control "The totality of features and characteristics of product or service that bear on its ability to satisfy stated or implied needs") (1) and achieve customer satisfaction lead all organizations to develop some quality improving system (Inspection, Quality control, Quality Assurance System, Total Quality Management and Business Excellence). The study explains and demonstrates the way how Total Quality Management (TQM) principles can be implemented in industrial textiles in Sudan (with reference to El-Huda Textile Company Limited as a case study) to improve product quality against international aggressive competition by the formulation of the Quality Manual according to the ISO 9001-2000 Quality Management System. A frame system is required for the process of the implementation for TQM principles, this system can be ISO 9000 Quality Management System that has been adopted by over 90 countries (Europe, Asia and America) as an effective tool for TQM adoption process that can provide organizations performance improving, the ISO 9000 certification process is a passport for passing product to the European Community and this international acceptance let this Quality Management System to be considered as a corner stone for TQM implementation and further more to Business Excellence Award. ISO 9001-2000 Quality Management System implementation requires formulation of a Quality Manual with reference to specific clauses such as quality management system, management responsibility, resource management, product realization and measurement, analysis and continuous improvement. The supplier organization has to demonstrate its capacity and ability to supply high quality products that can gain customer satisfaction. The Quality Manual formulation process starts by stating and deploying the company quality policy among all company employees. Then establish the leading council from all company departments' mangers. This council is headed by the researcher and then the documentation team is constructed from all key functional department heads and supervisors and to those who plan, do, check and act for any part of the product. The Quality Manual for El-Huda Textile Company Limited (case study) is divided into twelve documented process procedure covering all company operations. Every documented process procedure include a number of items (scope, range, definitions responsibility, process, quality records and attachments) that describes the way how any process is completed and records maintaining which provide evidence that the product has been inspected and/or tested to satisfy stated or implied needs. These records have to show clearly whether the product has passed or failed, the inspections and / or tests according to defined acceptance criteria. Every document is considered as a means of communication between staff and employees and they have to know that "who will do what then; how, where and when" and then arranging training program for the process of Quality Manual formulation and its implementation. TQM is a philosophy that seeking to gain customer satisfaction through effective participation of all organization employees to lead and organize quality process and reduces defects to the minimum. TQM requires the balancing of five systems (Technology – Process – Structure – Task – People) The main target for TQM implementation is quality improvements, cost reduction and customer satisfaction and to increase company competition in local, regional and international markets. Any how TQM can represents the management leading style to create and organize processes, a philosophy that aids to achieve high quality levels for the produced products (targets should be realistic and achievable). TQM principles are tools, training and techniques. Tools indicate the statistical methods used to evaluate product's producing tolerance limits, training include all that can improve human performances to handle a job, techniques show the way for improving products and services delivered by the organization. TQM philosophy requires employees' participation and empowerments. As suggested by the researcher El-Huda Textile Company Limited management has committed itself to adopt the principles of Total Quality Management. So, the Quality Council stated a performance measure to measure and evaluate company performance and the statistical analysis of the collected data will help and provide a good planning for solving all existing quality problem and, to achieve required targets. A training program is designed for any functional group to improve employee working performance and the company overall performance can be assessed by using Sheikh Khalifa Excellence Award Really quality is a direct domain of the company culture and this culture is a result of values and ideas that are adopted by all company employees and expressed by manager's direction, orientation and behavior. The values push behaviors and behaviors direct quality The study has finalized that, planning, organizing, leading, controlling and staffing for the production operation is the only way for providing a quality product that can gain customer satisfaction and maintain survival for business growth. The researcher hopes that the adoption of Total Quality Management principles will provide a solution to the Sudanese Textile Mills critical problems, and offer a potential power for these Industrial Manufacturing Organizations to track its road map for survival against local and international market competition.