IMPLEMENTATION OF TQM PILLARS IN A MANUFACTURING FACTORY: AN EMPIRICAL CASE STUDY

The process of detection and elimination of errors on a continuous basis from any system is known as TQM. This helps in improvement of productivity, efficiency, cost reduction by improving the methods and minimizing waste materials. This study aims at identifying the basis pillars in RMG industry through application of TQM principles. RMG is the highest productive industrial sector in Bangladesh economy and improvement in the product quality will have direct effect on the economic stability. Tools such as flow charts, Pareto charts, Check sheets, Cause & Effect diagrams, Histograms and scatter diagrams are utilized from variety of industries in Bangladesh to analyze the data collected. The outcome shows that the process has helped in elimination and reduction in waste scrap materials. This has also help reducing the costs and enable the organization to enhance the utilization of available resources without further investment.


INTRODUCTION
Total Quality Management (TQM) is a holistic approach to the management of the entire organization. The process focuses on improving the quality of the products of a company, including goods and services, by continuously enhancing internal practices.
The standards set in the TQM approach that represent internal priorities as well as any industry standards currently in place. TQM is considered a customer-focused process that aims to improve business operations continuously. It seeks to ensure all associated employees work toward the common goals of enhancing product or service quality, as well as strengthening the procedures that are in place for production. William Deming's work had a major impact on Japanese manufacturing, developed TQM (Miller & William Johnson. 1996). U.S. Naval Air Systems created the term TQM which stands for "Total Quality Management." A company uses TQM as a long-term strategy for achieving customer satisfaction. Total Quality Management requires all staff of the organization to improve the products, processes, and services. All staff of the organization for improving the processes, products, and services. All staffs, no matter what role, are responsible for the quality and quality assurance. The entire business culture is TQM when done correctly (Hake &, Chris, ed. 1991). TQM views a company as a collection of processes. It maintains that organizations must seek to continuously improve these processes by incorporating the knowledge and experiences of workers.
The simple goal of TQM is, "Do the right things, right the first time, every time." TQM is infinitely adaptable and variable.
The application of TQM has carried over to all aspects of the organizational workings and is identified as a general management tool now (Hashmi & Khurram, 2007). Manu companies have adopted TQM principles in their operations on the basis that it is the most appropriate strategy to increase productivity and gain a competitive advantage.
But still companies are finding it hard to upkeep with the standards TQM principles since the advantages obtained exclusively from application of TQM have not been examined in isolation in organizational and management research (Powell, T.C. 1995).
The practice of TQM principles require changes to all three levels of the organizational operations that include technology, people and structure.

SIGNIFICANCE OF THE STUDY
This exploration result will contribute essentially to advance and encourage TQM adjustment in the RMG division of Bangladesh. The administration offered by RMG organizations in Bangladesh is agreeable to the clients. Be that as it may, as far as expanding rivalry and the presentation of new guidelines and guidelines, this investigation is noteworthy for Bangladesh instant pieces of clothing organizations in the worldwide business setting. The need of this investigation can be defended. One, to guarantee quality execution, each association needs to build up a quality domain.
Two, the primary reason for the association is for the most part to variegate the serious market and furthermore help up the fare and benefit through expanding quality execution. Three, Organizations need to include their every representative just as their promise to adapt up to guaranteeing quality execution and changing economic situations. Four, for business achievement and supportability, guaranteeing consumer loyalty is the precondition. Five, it was unequivocally suggested the significance of gathering work and interdisciplinary research. In addition, governments and different associations will likewise profit by the discoveries of this examination that are right now actualizing TQM approaches, just as those trying to set up TQM rehearses inside their frameworks to accomplish supportable upper hands and to improve their presentation for their organizations.
The fundamental target of our investigation is: 1. To discover fundamental columns which are required for actualizing TQM in Garments businesses 2. To improve efficiency and item quality.
3. To improve the nature of the piece of clothing industry of Bangladesh by executing a TQM approach.

METHODOLOGY
Quality is a complex terminology. Quality is the price consumers willing to pay for a product. The examination of a product to improve the quality goals of a product is done. The most popular quality analysis is TQM tools (Oxford Talking Dictionary, 1998, Total Quality, 1992.
The research methodology consists of three important steps: 1. From the previous literature conducting, we identified the pillars to implement TQM in practice in our selected RMG industry.
2. Analyzing the present situation of product quality. (Define the Defects Name, Data Collection of Frequency of defects, analysis with TQM tools). Data has been collected from the selected RMG industry.
3. Finally, by implementing the Total Quality Management Approach (TQM Approach), we analyze the Improvement of product quality and productivity.

TQM COMPONENTS AND FACTORS
TQM include various factors other than the most commonly used ones like techniques and tools in quality improvement. The literature has identified two streams in which these aspects can be categorized. One is the management systems that involve planning, leadership and human resource (Evans, James R., & William M. Lindsay, 1999) and the other is the technical systems that is made up of technical tools (diagrams and charts etc). these are also categorized as soft and hard aspects (Gomes, I., et al. 1999).
The hard aspects includes the production activity and control techniques for all the work processes that result in proper functioning of the system under the just in time philosophy along with ISO 9000 principles and other TQM tools. The whole TQM hierarchy consists of critical factors that are collection of practices, techniques and tools and methods for the implementation of these techniques and tools (Gomes, I., et al. 1999 1996, Grandzol, John R., & Mark Gershon. 1998) and also (Quazi, Hesan A., et al. 1998, Chowdhury, Mesbahuddin, Himangshu Paul, & Anupam Das. 2007) who also stated valid and reliable instruments of quality management measurement in industrial as well as service firms.

BASIC PILLARS FOR TQM IMPLEMENTATION
From the past research study, we have accumulated information about the establishment of TQM. A portion of the audits proposed four columns, while others propose nine columns for a fruitful execution of TQM. Be that as it may, we have picked TQM execution, which are spoken to in Table-1. A concise depiction of every column is given a while later. That must note that the request for the columns set in the table doesn't speak to the general significance of the columns.

Use of quality control tools and techniques
To improve the quality first, the representative needs to distinguish the right quality issues they have to utilize suitable devices and methods. In such manner, SPC(Statistical Process Control) is the best specialized apparatus that assumes a noteworthy job. It incorporates seven essential apparatuses in particular Pareto graph, Process stream outline, Cause-and-impact outline, Check sheets, Histogram, Control graphs, and Scattered chart which will help to identify visually if their process is "in control" or "out of control" and when to take corrective action.

Front-line employee involvement in decision-making
Quality is the responsibility of everyone. It can be beneficial for industry and employees to involve and empower employees in decision-making, as quality employees are the backbone of a smoothly run organization. Asking them for their opinions can give different perspectives to make better decisions. It can be done in three ways suggestion box, leadership team, and employee survey.

Sharing information with everyone
Poor communication, vague instructions, and anticipations, poor attending skills, inaccurate data, lack of cooperation among team members of the various department can be very costly. This can lead the industry in making a decision which is based on a false assumption and unreliable data. So an Industry should be designed in a manner that obtaining reliable and fast feedback gets smooth.

Focus on customer satisfaction
The primary and basic goal of an organization is to appease the customer. So the customer should be the priority of any industry. Quality is not only defined by durability, packaging, timely delivery, reliability, and so on but also a customer's total experience with the organization. The industry needs to understand their target customer well. On the other hand, customer feedback should be monitored carefully.

Benchmarking
Benchmarking is a methodical, continuous technique by which an industry can compare its performance with another industry, which is considered to be standard.
Simply benchmarking is learning from others. Companies use benchmarking to analyze the performance and identifying the strengths and weaknesses of the company and what needs to make Improvement.
Continuous Improvement of the process and the goal TQM is a never-ending approach. It aims to ensure that all of the employees of the industry feel consistently empowered to improve efforts, results. Most writers favor a 'zero defect' and a 'do it right the first time' stance towards the quality system, which requires a zero-defect mindset of the workers. from the selected garments industry.  The data collected determines these lines and conclusions are drawn on the basis of variations in these lines as they represent predictable or unpredictable changes. Bar Chart: Presentation of categorical data with bars n rectangular shape whose length

ANALYSIS OF PRODUCT QUALITY
represents the values is known as a bar chart. Fig. 6 depicts that the total weekly irregularity of defect where scratch of sewing having the prominent 43.22% percent of weekly irregularity.  Introduction to total quality management And Training Employees The introduction of workers to the tools and techniques that are required to improve quality has been done. They are trained with seven total quality management tools and techniques. They understand the philosophy of Total quality management.

Development of teamwork and promote cooperation
We have eliminated the blaming each other and started teamwork. This means working for a solution when a problem arises. We have started a reward system. This will encourage the employees to work harder for Improvement.

Use of quality control tools and techniques
Employees are trained to use seven Statistical Process Control tools and techniques. Now they can use them to improve quality.

Involvement of frontline employees in decision making
We started taking ideas about different problems from frontline employees. It created a various perspective on a particular problem. As a result, we found various ways to solve a problem or improve quality.

Sharing information with everyone
We have started a team approach. Divided the employees into several groups in which each and everyone knows their roles. This will help them to solve a problem properly more accurately.

Focus on customer satisfaction
We trained the employees on how to take customer's feedback and make them realize how important customer satisfaction is. So now the main motto is to take customer's needs and meet them appropriately.

Benchmarking
We started Benchmarking so that we can compare our products and process versus industry leaders in this sector.

Continuous Improvement of the process and the goal
We set an improvement goal every two months for the persistent Improvement of processes and products. The base level percentile value improvement is shown in the above table (before TQM   implementation) CONCLUSION TQM is a way of running organizations that is a continuous process based on principles that are systematic in nature, it has a proven track record and cannot be ignored like a management fad. To survive an organization in today's competitive market, they need to give importance to continuous improvement in their product and quality and process regarding fulfilling customer satisfaction. In this paper, we tried to discuss several pillars of Total Quality Management and how an organization should implement TQM and how to improve quality by implementing it in the garments industry. Though it is not easy to implement TQM in an organization, it will take time and some extra effort from everyone. In our study, we found that the implementation of TQM is productive, and it improves quality. In light of today's circumstance, it is clear that every organization is trying to take a competitive advantage. So to be in the competition and to compete, there should be no compromise of quality, and there must be the continual improvement of product and processes.