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Transcript of TQM - L Rossi [EDocFind.com]
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Total Quality ManagementTotal Quality Management
and Quality Assuranceand Quality Assuranceinin
Salt Production and ProcessingSalt Production and Processing
Presentation byPresentation by
Lorenzo LocatelliLorenzo Locatelli--RossiRossi
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DEFENTION OF QUALITYDEFENTION OF QUALITY
ASSURANCEASSURANCE QA is a wideQA is a wide--ranging concept which coversranging concept which covers
all matters which individually or collectivelyall matters which individually or collectivelyinfluence the quality of a product.influence the quality of a product.
It applies to equipment, product design,It applies to equipment, product design,supplies and logistics, management andsupplies and logistics, management andhuman resources development.human resources development.
All elements designed to ensure thatAll elements designed to ensure thatproducts are of the quality required for theirproducts are of the quality required for theirintended use.intended use.
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TOTAL QUALITY MANAGMENTTOTAL QUALITY MANAGMENT
TQM is a management strategy to embedTQM is a management strategy to embed
awareness of quality in all organizationalawareness of quality in all organizational
processes (quality thinking).processes (quality thinking). QA through statistical methods is a keyQA through statistical methods is a key
component.component.
Overall quality management influencesOverall quality management influencescompany profitability.company profitability.
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PROFITABLE BUSINESSPROFITABLE BUSINESS
No business can succeed if the product hasNo business can succeed if the product has
no quality and guaranteed consistency.no quality and guaranteed consistency.
Consistent quality guarantee is closely linkedConsistent quality guarantee is closely linkedto affordability.to affordability.
No one can afford inconsistent, bad qualityNo one can afford inconsistent, bad quality
and no guarantee.It is too expensive!and no guarantee.It is too expensive!
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W. Edwards Deming (1900W. Edwards Deming (1900--1993)1993)
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STANDARDSSTANDARDS
In order to have quality we need StandardsIn order to have quality we need Standards
Standards areStandards are::
An accepted or approved example of somethingAn accepted or approved example of somethingagainst which others are judged or measured.against which others are judged or measured.
GuidelineGuideline
Point of ReferencePoint of Reference
Ensures Consistency in the ProductEnsures Consistency in the Product
Guarantee of QualityGuarantee of Quality
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TQMTQM-- AREAS OF INTERESTAREAS OF INTEREST
11-- Prime RequirementsPrime Requirements
22-- Processing TechnologyProcessing Technology
33-- Production: TQM and QAProduction: TQM and QA
66-- Packing Iodized SaltPacking Iodized Salt
77-- Warehousing and DispatchingWarehousing and Dispatching
88-- Marketing and The ConsumerMarketing and The Consumer
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11-- PRIME REQUIRMENTSPRIME REQUIRMENTS
1a1a-- PeoplePeople
1b1b-- FactoryFactory
1c1c-- TechnologyTechnology1d1d-- Salt (Raw Material)Salt (Raw Material)
1e1e-- IodateIodate
1f1f-- Spare PartsSpare Parts1g1g-- Packing MaterialPacking Material
1h1h-- Auxiliary SuppliesAuxiliary Supplies
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1a1a-- PEOPLEPEOPLE
Every person:Every person:
Is an important investmentIs an important investment
Must know why their job is importantMust know why their job is important
Knowledgeable about the and productKnowledgeable about the and product
Given an opportunity to suggest ideasGiven an opportunity to suggest ideas
Ownership of his/her place of workOwnership of his/her place of work
Importance of participationImportance of participation
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1b1b-- FACTORYFACTORY
Designed to be practical and economicalDesigned to be practical and economical
Must be people friendlyMust be people friendly
Allocate clearly defined spacesAllocate clearly defined spaces
Proper place for resting/eating and lockersProper place for resting/eating and lockers
First Aid kit and person trainedFirst Aid kit and person trained
Emergency and fire pointsEmergency and fire points
Kept clean all places at all timesKept clean all places at all times
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1c1c-- TECHNOLOGYTECHNOLOGY
Appropriate TechnologyAppropriate Technology
Vacuum processVacuum process
Washing/Refining processWashing/Refining process
Rock Crushing processRock Crushing process
ReRe--Packing processPacking process
11-- Investment CostsInvestment Costs
22-- Running CostsRunning Costs33-- Maintenance CostsMaintenance Costs
FinalProduct CostsFinalProduct Costs
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TechnologycontinueTechnologycontinue
Each process has a different:Each process has a different:
11-- Investment CostsInvestment Costs
22-- Running CostsRunning Costs
33-- Maintenance CostsMaintenance Costs
These costs influence theThese costs influence the
FinalProduct CostsFinalProduct Costs
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SALT 1dSALT 1d--
The salt must:The salt must:
Meet the StandardsMeet the Standards
Stored in an appropriate placeStored in an appropriate place
All the above factors have a cost implication.All the above factors have a cost implication.
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1e1e-- IODATEIODATE
Meets standardsMeets standards
Stored in appropriate placeStored in appropriate place
Control of issuance of the productControl of issuance of the product
Always in stock sufficient quantitiesAlways in stock sufficient quantities
Avoid over supply (frozen capital)Avoid over supply (frozen capital)
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1f1f-- SPARE PARTSSPARE PARTS
Properly StoredProperly Stored
CataloguedCatalogued
Control over issuanceControl over issuance
Know your supplierKnow your supplier
Replace immediatelyReplace immediately
Spares cost money; as a part and as inSpares cost money; as a part and as inproductionproduction
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1g1g-- PACKING MATERIALPACKING MATERIAL
Supplied with bag/packs as per orderSupplied with bag/packs as per order
QuantityQuantity
Printing QualityPrinting Quality
Quality plastic/cartonQuality plastic/carton
Proper sizeProper size
Tapes and gluesTapes and glues
Proper issuance procedureProper issuance procedure Hold appropriate quantity in stockHold appropriate quantity in stock
Supplier keeps stock?Supplier keeps stock?
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1h1h-- AUXILIRY SUPPLYAUXILIRY SUPPLY
Proper maintenance of all electricalProper maintenance of all electrical
equipment and cablesequipment and cables
Caution against dangerCaution against danger Proper electrical linksProper electrical links
StandStand--by generator (if appropriate)by generator (if appropriate)
Appropriate stock of extra fuelAppropriate stock of extra fuel Water LeakagesWater Leakages
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Whataboutthe Prime MaterialsWhataboutthe Prime Materials
They all carry an investment costThey all carry an investment cost
Some are short term other long termSome are short term other long terminvestmentsinvestments
They are all equally important and anyThey are all equally important and anyadditional cost must be avoided.additional cost must be avoided.
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Howto Controlcosts/qualityHowto Controlcosts/quality
TQM applies principles of controlling the qualityTQM applies principles of controlling the quality
of machineof machine--based factories operations tobased factories operations to
controlling the quality of peoplecontrolling the quality of people--basedbased
management operationsmanagement operations
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22-- PROCESSING TECHNOLOGYPROCESSING TECHNOLOGY
What ever the process, daily production dataWhat ever the process, daily production data
must be recorded. Data must include:must be recorded. Data must include:
-- Time of start/stop and eventual breakdownsTime of start/stop and eventual breakdowns-- Specific reason/s for breakdowns andSpecific reason/s for breakdowns and
solutions adopted.solutions adopted.
-- Maintenance daily report list of areasMaintenance daily report list of areasrequiring work.requiring work.
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Processing TechnologyProcessing Technology
Plan for weekly, monthly and yearlyPlan for weekly, monthly and yearly
maintenance program.maintenance program.
TQM aims to do things right the first timeTQM aims to do things right the first timerather than need to fix problems after theyrather than need to fix problems after they
emerge and cause more problems.emerge and cause more problems.
A bad or non existent maintenance plan is aA bad or non existent maintenance plan is acostly business. There is no savings!costly business. There is no savings!
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Processing TechnologyProcessing Technology
Tally daily production with number ofTally daily production with number of
packs/bags issued.packs/bags issued.
Tally the end of the month consumption ofTally the end of the month consumption ofiodate and iodized salt production.iodate and iodized salt production.
Calculate plant capacity efficiency byCalculate plant capacity efficiency by
comparing hours over tons of iodized saltcomparing hours over tons of iodized salt
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PRODUCTION: TQM and QAPRODUCTION: TQM and QA
We focusonWe focuson Iodized SaltIodized Salt::
11-- The processing equipment:The processing equipment:
Tanks, pipes, pumps and nozzle or dozers; daily checkTanks, pipes, pumps and nozzle or dozers; daily check--up toup toensure that are they clean and in good working order.ensure that are they clean and in good working order.
Monitor even during production.Monitor even during production.
If dry mix or a solution; is the mix well prepared?If dry mix or a solution; is the mix well prepared?
22-- Iodization:Iodization:
At the start, titration must be done continuously until standardAt the start, titration must be done continuously until standardhas been achieved.has been achieved.
After which, minimum once every hour.After which, minimum once every hour.
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PRODUCTION: TQM & QA .PRODUCTION: TQM & QA .
Keep an hourly record every dayKeep an hourly record every day
Base your findings on titration not on theBase your findings on titration not on the
rapid test kitrapid test kit Chart the resultsChart the results
Share the ResultsShare the Results
Make a monthly reportMake a monthly report
FollowFollow--up on issues that have been raisedup on issues that have been raised
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Charting Daily IodizingProgressCharting Daily IodizingProgress
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Packing Iodized SaltPacking Iodized Salt
Guaranteed production of iodized salt needsGuaranteed production of iodized salt needs
to be packed and sealed in order to retain itsto be packed and sealed in order to retain its
guaranteed quality.guaranteed quality. Ensure that seams and seals can withholdEnsure that seams and seals can withhold
transport/handling.transport/handling.
Maybe a small pinMaybe a small pin--prick hole avoids problemsprick hole avoids problems Bag the packed salt in an orderly fashionBag the packed salt in an orderly fashion
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WAREHOUSING ANDWAREHOUSING AND
DISPATCHINGDISPATCHING Goods to be protected from water, dust andGoods to be protected from water, dust and
other pollutants.other pollutants.
Goods to be placed off the floor (on pallets)Goods to be placed off the floor (on pallets)and away from the wall.and away from the wall.
Practice the First In Last Out (FILO).Practice the First In Last Out (FILO).
Ensure that trucks carrying the product haveEnsure that trucks carrying the product haveclean trailers and goods are coveredclean trailers and goods are covered
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MARKETING AND THE CONSUMERMARKETING AND THE CONSUMER
Iodized Salt pack/bag must have full details of the productionIodized Salt pack/bag must have full details of the productioncompany.company.
It must indicate a Customer Care contact incase of productIt must indicate a Customer Care contact incase of productdissatisfaction.dissatisfaction.
Prepare a complaints handling procedure.Prepare a complaints handling procedure.
Product must state type and quantity of iodine.Product must state type and quantity of iodine.
Interact with wholesaler/retailers if and when possibleInteract with wholesaler/retailers if and when possible
The customer is always right!The customer is always right! Customer confidence builds businessCustomer confidence builds business
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SUMMARY OF TQM / QASUMMARY OF TQM / QA
PRINCIPLESPRINCIPLES Set quality standardsSet quality standards
Monitor and record plant efficiencyMonitor and record plant efficiency
Plan for good maintenance programPlan for good maintenance program Involve/interact with workforceInvolve/interact with workforce
Measure iodization output against standardsMeasure iodization output against standards
Define corrective action for nonDefine corrective action for non--compliancecompliance Focus on qualityFocus on quality -- TQMTQM
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INCREASING AVAILABILITY OFINCREASING AVAILABILITY OF
IODIZED SALTIODIZED SALT Consumer education / awarenessConsumer education / awareness
Prohibit the production, import and sale ofProhibit the production, import and sale of
nonnon--iodized salt.iodized salt. Production facilities should interact with MoHProduction facilities should interact with MoH
Zero rated import duties on iodateZero rated import duties on iodate
Some form of tax rebate for producers asSome form of tax rebate for producers asiodized salt is of national importance.iodized salt is of national importance.