TQM - L Rossi [EDocFind.com]

8/7/2019 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.

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