Download Cost of Quality Consulting Best Practices

ality is the best business plan," John Lasseter, a pioneer of 3D animation and former chief creative officer at Pixar and Walt Disney Animation Studios, once quipped. For organizations navigating the complexities of today's rapidly changing business landscape, Lasseter's words hold significant truth.

Quality vs. Cost: The Misconception

Many organizations see quality assurance and the associated costs as a necessary evil—a drain on resources that could be better spent elsewhere. However, this perspective could not be further from reality. The Cost of Quality (CoQ) is not about the price of creating a quality product or service; it is about the cost incurred due to not creating a quality product or service. This includes rework, waste, and even loss of customers due to a product not meeting their expectations.

The Four Categories of Quality Costs

The American Society for Quality (ASQ), a leading authority on quality, divides the CoQ into four categories that executives must understand and control to maintain profitability. These include:

• Prevention costs: These are costs associated with preventing defects before they happen by building a quality product from the start. This includes design review, supplier evaluation, preventive maintenance, and training.
• Appraisal costs: Costs associated with evaluating and inspecting the products or services to ensure they meet the desired quality. This could involve testing, quality audits, and inspection equipment.
• Internal failure costs: These costs arise when a product fails to meet quality standards while it's still within the organization. Consider costs related to rework, scrap, downtime, or even product redesign in extreme cases.
• External failure costs: These are costs incurred when a product fails once it is in the hands of the customer. This includes warranty claims, returns, lost sales, and even reputational damage due to negative reviews.

Strategic Management and CoQ

Leaders at Fortune 500 companies and beyond should recognize the financial impact of CoQ. A study from Strategic Planning and Operational Excellence indicated that quality-related costs can be as high as 20-30% of revenue for many organizations. By understanding, measuring, and reducing CoQ, businesses can unlock hidden profits and gain a competitive advantage.

Strategic Management of quality begins with "Leadership Commitment." As a C-level executive, it falls on you to set the tone for quality within your organization. This includes promoting a culture of quality, allocating resources for prevention costs, and integrating quality objectives into your strategic planning process.

Investment in Quality: The Compounding Effect

Investing in quality can provide a compounding effect. While prevention and appraisal costs may be upfront and tangible, the costs of not investing—namely internal and external failure costs—are often more significant and damaging. They can incur legal liabilities, damage brand reputation, and erode customer loyalty—costs that are much harder to quantify and remedy.

Lean Management and CoQ

Lean Management principles can also play a critical role in reducing CoQ. By focusing on creating value for the customer and eliminating waste, Lean Management contributes to improved quality. Techniques such as Value Stream Mapping help to identify and eliminate non-value adding processes, thus reducing the potential for defects and lowering overall quality cost.

Operational Excellence and CoQ

Operational Excellence—another key strategy that directly impacts CoQ—strives to balance cost reduction with increased productivity. Tools such as 5S, Six Sigma, and Total Quality Management (TQM) can allow organizations to reduce waste, decrease defects, and optimize processes, thereby reducing the CoQ and contributing to higher profits.

Remember, as Peter Drucker correctly observed, "Quality in a product or service is not what the supplier puts in. It is what the customer gets out and is willing to pay for." As a C-level executive, strategically managing the Cost of Quality should be a priority in your organization. Not just because of the financial implications, but because of the lasting impact it can have on customer satisfaction and brand reputation.