A study on ISO
9001 Quality Management System Certifications – Reasons behind the failure of
ISO certified Organizations
Durai Anand Kumar and V. Balakrishnan
Anna university of
Technology, Coimbatore, Tamil Nadu, India
*Corresponding Author E-mail: - hai_durai@yahoo.com
BSTRACT:
The purpose of this study is to highlight
the basic facts about the ISO certification and why considerable proportion of
organizations fail even after getting certified to International system
standards such as ISO 9001 Quality Management System (QMS)
This study investigated the practical
problems faced by the certified organizations represented by a sample group of 100 contractors from the UAE (40 Mechanical Contractors, 30 Electrical
Contractors and 30 Civil contractors and a stratified random sample of 40
organizations with 1-50 staff,40 organizations with 51-100 staff and 20
organizations with more than 100 staff) and classified them through 25
variables, evaluated the effectiveness
of the organizations and highlighted the major areas of system gaps.
This study has revealed that there were
certain system gaps in majority of the ISO 9001 QMS Certified organizations.
The gaps were classified into 4 basic categories such as a) Leadership related
issues b) Strategy related issues c) Quality system related issues and d)
Social responsibility related issues. Out of the ten constructs tested
hypothetically, nine constructs revealed a significant relationship impacting
the overall system performance. Out of these 9 significant elements, only 5
have been specified in ISO 9001 Standard explicitly. With these gaps,
compliance to the minimum requirements of ISO 9001 QMS is a challenge and such
organizations need a solution to rectify these gaps and achieve business
excellence.
This study can be used as a basis to verify
the effectiveness of management system in any organization and also to identify
the barriers which hinder the business
benefits. This study remains a basis for further research to develop and
customize a model for organizations to achieve business excellence.
KEYWORDS:
International
Organization for Standardization (ISO) is the world’s largest non-profit
organization to develop and publish international management system standards
on various subjects such as ISO 9001:2008 (Requirements for a QMS), ISO
14001:2004 (Requirements for an Environment Management System), Food safety
standard ISO 22000:2005, Information Security Management Standard (ISO
27001:2005), etc. ISO is having a
network of more than 160 member countries all over the world. The national
standards institutions of countries represent their country for governing the
accreditation framework.
Representatives
from all these countries work as a team to generate the concept, draft it,
brainstorm and finalize it as an international standard. Theses
standards are generically defined to suit any organization in the world
regardless of their size, scope and location.
It
is optional for the organizations to select the individual standards for
implementation as well as certification by third party competent organizations
called typically as “Certification Bodies”. Since the early 2001, bigger corporates started demanding the ISO certification for
their suppliers, with a view to unify the systems of multiple suppliers. This
demand, in one way added attraction to ISO standards, but on the other hand,
caused these standards turn more theoretical and commercial, thus turning the
credibility of certification a question mark.
As
depicted in Figure 1, the number of organizations certified to ISO management
system standards all over the world is hiking absolutely and it has crossed a
million organizations by 2009. But the striking fact admitted by the interested
parties is that in a considerable proportion of the organizations, ISO System
certification is used as a marketing tool to participate in tender and beyond
this level no value addition by these certifications to the business.
As
the certification bodies also have to be more and more competitive, a
considerable portion of such organizations are not aware of the real benefits
of implementing systems are achieved fully or not.
After
the main certification assessment for ISO, organizations are supposed to be
visited periodically say at least once every year, but many of such assessments
bring out the system performance is shocking and even for attaining a level of
“minimum compliance” is a big deal for those so called “Certified”
organizations.
Colin
Carnall (2007) defined an excellent or high
performing company shall demonstrate the
concern for future, human resource development, quality, excellence, reward
system and have focus on customers and all stakeholders.
Any
ISO 9001certified organization is supposed to have an effective Quality System
and achieve maximum customer satisfaction, profit, employee motivation,
improvements and minimum rejections, reworks, customer complaints and problems.
As the ground reality was questioning this theory, this study was initiated to
evaluate how effective were the ISO certified organizations
II
– Keywords:
·
ISO
·
ISO 9001
·
Quality
·
QMS
·
Certification
III Abbreviation and Expansion:
·
ISO – International Organization for standardization
·
QMS – Quality Management System
IV Review of Literature:
ISO
has published more than 18000 standards, but for this study, ISO 9001 Quality Management System has been
focused for its requirements.ISO 9001 Standard has the latest revision by 2008.
This has 8 clauses of requirements , as below:-
Clause
1 – Scope
Clause
2 – Normative References
Clause
3 – Terms and Definitions
Clause
4 – Quality Management System Requirements
Clause
5 - Management Responsibility
Clause
6- Resource Management
Clause
7 – Product Realization
Clause
8 – Measurement, Analysis and Improvement
Clauses
1 to 3 are for information only. From clause 4 to 8 are for the organizations
to comply with, especially the clause 4 being an umbrella clause, includes the
requirements in a macro level. All these clauses 4 to 8 have detailed the
requirements through multiple sub clauses. If any of such clause requirements
not applicable (from the clause 7) shall be addressed in the exclusion section
of the quality manual with suitable justification.
The
ISO 9001 QMS architecture has been composed of 8 basic principles, as detailed
below in Table 1:-
|
1 |
Customer
focused organization |
Organizations
depend on their customers and therefore should understand current and future
customer needs, should meet customer requirements and strive to exceed
customer expectations |
|
2 |
Leadership |
Leaders
establish unity of purpose and direction. They should create and maintain the
internal environment in which people can become fully involved in achieving
the organization's objectives |
|
3 |
Involvement
of people |
People
at all levels are the essence of an organization and their full involvement
enables their abilities to be used for the organization's benefit. |
|
4 |
Process
approach |
A
desired result is achieved more efficiently when activities and related
resources are managed as a process. |
|
5 |
System
approach to management |
Identifying,
understanding and managing a system of interrelated processes as a system
contributes to the organization’s effectiveness and efficiency in achieving
its objectives. |
|
6 |
Continual
improvement |
Continual
improvement of the organization's overall performance should be a permanent
objective of the organization. |
|
7 |
Factual
approach to decision making |
Effective
decisions are based on the analysis of data and information. |
|
8 |
Mutually
beneficial supplier relationships |
An
organization and its suppliers are interdependent and a mutually beneficial
relationship enhances the ability of both to create value. |
Mohamed
Zairi(2005) defines the Quality management systems
review panel of senior managers, led by the Quality Director, meets regularly
to review achievements in terms of business excellence.
V
Materials and Methods:-
A
survey was organized with a target group of 100 contractors from UAE as
responders. This included Mechanical , Electrical and Civil Contractors.
The
survey was organized through a formal gathering of key staff from these
contracting organizations. The important areas were discussed and their
responses were reckoned to arrive at the survey.
Data
Analysis:
1. Customer Satisfaction:
56% of organizations stated that they maintain the same level of customer
satisfaction before and after ISO Certification. 24% organizations were
positive to improve their customer satisfaction, as a result of implementing
ISO 9001 System. 20% of organizations did not agree on any such improvement.
2. Continual Improvements: 28% of respondents had a formal account of the
continual improvements after ISO certification. 44% respondents felt
improvements, but they were not sure whether it was because of ISO QMS and also
they did not have any quantified figures behind such improvements.
28%
organizations denied of any continual improvements after ISO certification.
3. Brand Image and Ease of Marketing: 60%
of respondents were positive to agree that their brand image and ease of
marketing were improved after getting certified to ISO 9001. Respondents with
no change in this brand image and marketing before and after certification was
40%
4. Internal Audits:
32% of respondents revealed that their internal audit process was adding value
to their business, 8% of respondents had been neutral whereas 60% organizations
denied to agree on any value addition by internal audits.
5. Linking ISO with Business Strategy:
48% of respondents gave a shocking reply that the ISO model in their
organization had no interface to Strategy and vice versa. 32% of respondents
stayed neutral by accepting there was a strategy but unaware of how it was
linked to systems. 20% respondents felt positively that their strategy and
systems were linked well each other.
6. Documentation Issues:
52% of responded organization felt that the documents volume increased after
ISO certification, 36% felt the same volume of documentation before and after
certification where as 12% organizations were happy to streamline and reduce
the paperwork after ISO certification.
7. Cultural and Behavioral Issues: 52%
of organizations revealed it was very difficult to maintain the System culture
and team relationships when the data and information need to be shared within
the organization and people need to work as a team. 16% felt a refined culture
and behavior in the organization since ISO certification. 32% remained neutral
and did not comment anything.
8. Management Commitment:
32% of the respondents revealed a positive commitment from their top
management, 52% did not agree on the adequate commitment by top management. 16%
of organizations did not have any comments.
9. Motivation and Recognition:
Even though most organizations had a HR mechanism for promotions, increments,
etc 64% organizations felt the staff role in ISO system and achievements were
not the basis for recognition, but the
sales and operational performance only. 24% respondents were happy to get
motivated and recognized for their contribution related to Quality
improvements. 12% of respondents were neutral.
10. Bureaucracy in Systems:
56% of respondents feel the necessity to re-engineer their end to end processes
and eliminate non-value adding processes. 24% respondents had no bureaucracy
issues. 20% of them had no comments.
11. Customization:
52% of organizations responded as their system, policies and objectives were
not tailored to suit their business and seemed so generic.
44%
organizations claimed to have a well customized system. 4% of respondents were
not aware on the level of customization.
12. Internal Communication:
68% of organizations were happy with a well established internal network of
communication through Telephones, E-mails, Newsletters, meetings, seminars
including the state of art technologies like GPRS. 20% felt a boring formal way
of communication primarily by letters. 12% stayed neutral.
13. ISO Awareness:
64% of respondents felt that their staff were aware of their system, its policy
and the objectives related to them. 20% of respondents were facing a challenge
in promoting the system awareness and 16% stayed neutral.
14. Organizational Learning:
56% of organizations responded of no common mechanism to benchmark or learn the
best practices within various departments of the organizations or outside the
organization. 32% of the respondents replied that their organization encourages
knowledge sharing and 12% did not have any relevant idea.
15. Customer Complaints:
36% of respondents claimed to reduce the customer complaints after
certification. 24% of respondents did not accept to reduce customer complaints
since certification. 40% of respondents were neutral that there is no change in
the number of complaints before and after certification.
16. Customer
feedback: 28% of the respondents agreed with an
effective feedback system being available at their company. 52% did not agree
that they have any effective means to measure the customer feedback. 20% stayed
neutral
17.Job responsibility, Authority and
Accountability: 36% of organizations were not aware of their
job roles and the accountability behind it. 28% responded to know their roles
well. 36% of respondents stayed neutral.
18.In-process Quality and Efficiency: 32%
of the respondents stated a clear improvement in the in-process quality and
efficiency since getting certified. 20% stayed with no comments whereas 48% did
not agree with in-process quality and efficiency improvements since
certification.
19. Sub-Contractor Development: 56%
of organizations did not agree that the subcontractor’s development initiatives
were increased since certification. 28% agreed to have improved initiatives on
the same since certification. 16% stayed neutral with no comments.
20. Key Performance reporting system: 12%
respondents stayed neutral, 32% of the
respondents
had a balanced score card system and 56% of the respondents did not have any
such reporting system.
21. Staff Capabilities: 16%
organizations agreed that they had professional methods to plan and develop
staff capabilities. 24% organizations had no idea on the subject.
60%
organizations denied that they had any such system.
22. Stakeholder Perception: 56%
organizations had no formal measure to understand and fulfil
stakeholders perception, but customers. 12% stayed with no comments and 32%
respondents had a mechanism to obtain the perception of their stakeholders.
23. Management Review: 24%
of the respondents agreed that the management review in their company conducted
professional reviews beyond the minimum
requirements of ISO. 56% did not agree that they have any effective review
mechanism, but a typical document. 20% stayed neutral.
24. Corporate Social Responsibility: 36%
of organizations were not aware of their corporate social initiatives. 28%
responded to demonstrate social responsibility. 36% of respondents stayed
neutral.
25. Overall System effectiveness:
44% of respondents had opinion that their organization has effective quality
systems after certification, 56% respondents felt that their system was not
effective even after certification .
Hypothesis Testing:-
Primary
data collected were analyzed for the internal relationship between variables.
Hypothesis testing was carried out for 9 constructs as below:-
As
an example, the first one is illustrated below in the tables 2 and 3:-
HO : Null hypothesis:
There is no relationship between internal audit
and customer complaint
HA :
Alternative hypothesis: There is a significant relationship between
internal audit and reduction of customer
complaint
Table 2 :
hypothesis testing
|
|
YES |
NO |
NEUTRAL |
TOTAL |
|
YES |
32 |
- |
- |
32 |
|
NO |
02 |
22 |
36 |
60 |
|
NEUTRAL |
02 |
02 |
04 |
08 |
|
TOTAL |
36 |
24 |
40 |
100 |
Table 3 : Hypothesis testing
|
Observed |
Expected |
(O — E)2/ E |
|
32 |
11.52 |
36.4 |
|
2 |
21.6 |
17.42 |
|
22 |
14.4 |
4 |
|
36 |
24 |
6 |
|
2 |
2.88 |
0.26 |
|
2 |
1.92 |
0.003 |
|
4 |
3.2 |
0.2 |
|
Calculated value total = |
64.28 |
|
where
is the observed frequency for bin i and is the
expected frequency for bin i. The expected
frequency is calculated by
Calculated
Chi Square = 64.28Degrees of Freedom = (c - 1)(r - 1) = 2(2) = 4
Table
Chi Square value is 9.488 (for 95% significance level)
Reject
Ho because 64.28 is greater than 9.488
(for 95% significance level).
Thus,
we would reject the null hypothesis and accept the alternative hypothesis that
there is a significant relationship between internal audit and reduction of
customer complaint.
Similar
to the test indicated above, other tests were conducted and the result is as
below:-
There
is a significant relationship hypothetically proven between:
a) Effectiveness of Internal Audit and reduction of
Customer Complaints
b)
Effectiveness of internal audits and overall System effectiveness
c) Top Management’s commitment and overall system
effectiveness
d) Specifically tailored system and overall system
effectiveness
e) Stakeholder perception monitoring and customer
satisfaction
f) Key performance indicators and overall system
effectiveness
g) Organization Culture and Corporate Social
Responsibility
h) Staff knowledge and learning and the overall
system effectiveness
i) Top Management commitment and Internal Audit.
No
significant relationship between
j) No. of years of organization’s existence in the
market and top management commitment.
VI – CONCLUSION:
Even
though more than a million organizations have been certified to ISO QMS 9001
standard till date, there are certain common problems faced by majority of
these certified organizations, which influences their business performance.
These
problems are broadly classified into three categories as
·
Leadership related issues
(Inadequate Commitment by Top Management, Lack of Motivation, Recognition,
Organizational learning , Strategic Planning and long term focus)
·
Strategy Related Issues
(Mission, Vision, Values, Strategic Planning, Strategy Mapping, Cascading down
the line, KPIs and Initiatives)
·
Quality System related issues
(Weak PDCA cycle, generic system,
internal audit not in depth, non value adding meetings/trainings and excessive
paperwork)
·
Society oriented gaps (Corporate
Social Responsibility, Environmental Management andSustainability)
When
an organization carefully eliminates these above mentioned gaps, it can be sure
of the whole business model to be effective with value added processes,
methods, systems and efficient resources contributing for continual
improvements and towards business excellence.
VII.
Scope for further Research:
The
study was used to evaluate the level of effectiveness of QMS 9001 systems and
classify the broad categories of gaps.
As
a matter of logic, when the organizations struggle to demonstrate a minimum
compliance to QMS, it may not be possible for these organizations to reach the business excellence, unless a
customized model bridges between the
minimum compliance to business excellence through a strategic framework,
tailored specifically to suit the organization in terms of scope, scale and
core competencies.
It
is felt that beyond this study, there is a scope for developing a strategic
framework to reach business excellence through developing a strategic
management system.
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“ISO 9000:2005 Quality Management Systems – Fundamentals and Vocabulary”, Third
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4. ISO,
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Received on 27.06.2011 Accepted on 07.08.2011
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Asian J. Management 2(4): Oct.-Dec., 2011 page
191-196