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Quality Improvement

"Breakthrough improvement" is one component of the Juran Trilogy. It refers to the meticulous uncovering and diagnosing of the root causes of chronic and costly problems within existing products or processes. It devises remedial changes that remove or manage the causes, and implements controls to prevent the problems from reoccurring.

Breakthrough improvement seeks to create unprecedented beneficial change by improving upon the current organizational standards. Once managers recognize the extent of the Cost of Poor Quality (COPQ), usually through a COPQ study, their dissatisfaction with the results compels them to make a conscious, deliberate decision to build lasting improvements. Juran can accomplish this by setting in motion breakthrough improvement.

Breakthrough improvement is carried out by adhering to a universal sequence of events:

1

Identify a business problem-something wrong with a product, service, or process that impacts the performance of the business

2

Establish a project

3

Measure and Analyze the current process to establish precise knowledge of baseline performance

4

Generate and test theories as to the causes of the poor performance

5

Prove root causes of the poor performance

6

Develop remedial improvements-changes to the process that remove or manage the causes of poor performance

7

Establish new controls to prevent recurrence and to sustain the new standards

8

Deal with resistance to change

9

Replicate the result and start a new project

Practitioners of Six Sigma will recognize this as a fundamental way of expressing the Define-Measure-Analyze-Improve-Control sequence followed in Six Sigma D.M.A.I.C. Improvement. Note that in following this sequence, much attention is paid to thoroughly understanding how the current bad process actually performs. Then, and only then, is an attempt made to understand what causes the process to produce the defects which are under investigation. Only when evidence has been accumulated to prove what the root causes are, can remedial changes be designed. No remedies or improvements are even discussed, much less designed and implemented, until the root cause(s) of the problem are scientifically established beyond a doubt.

The sequence goes further to assure that breakthroughs are sustained. New controls, particularly on the remedial changes made to the process being improved, are designed and implemented. Periodic audits are performed to ascertain that the controls are indeed being applied successfully.

Historically, a breakthrough meant that we achieved a 10% improvement in the performance of a process as evidenced by the accepted quality levels (AQLs) of the 1970s. In today's competitive society, a breakthrough may mean a 10 fold improvement or an improvement to 6 sigma or 3.4 ppm defective.

Juran can help your organization with quality improvement by diagnosing, and subsequently remedying, the root causes of chronic and costly problems.