Application of Statistical Process Control in a Production Process

Maruf Ariyo Raheem

doi:10.11648/j.sjams.20160401.11

Abstract

This study evaluates the process of production of Champion Breweries Plc., located at Aka Offot, Uyo, Akwa Ibom State Nigeria. The information on the following measurable characteristics used during production were obtained; Brilliance (Haze), pH, Original Gravity (O.G) and Alcohol Percentage. Information on the number of defective crates recorded for the period of fifteen (15) days on Amstel Malta were also obtained from the bottling section. Mean (X ̅) and Range (R) control charts for variable were adopted to ascertain if the process with respect to each quality characteristics is statistically in control. The result shows that, the out-of-control points for BRILLANCE (B) were four (4) and one (1) out of twenty (20) for the mean and range charts respectively. For pH: two (2) and one (1) out of control for mean and range charts respectively. For Original Gravity (O.G): five and zero were out of control for mean and range charts respectively. For Alcohol Percentage (A): twelve and zero were out-of-control for mean and range charts respectively. Since the out-of-control points for Alcohol have exceeded the average of all points, the entire process is disregarded, and hence the process has to be overhauled. Using the P-chart to examine the defects in the finished produce daily for 15 days; it was found that 11 points were out of control, also the need for overhaul of the entire production line. Given the overall findings it could be deduced that the process was largely out-of-control, hence the need for total overhaul and the revised control schemes as appropriate. Thus, revised control schemes were formulated for the different quality characteristics for the process to be in control and the following control schemes were proposed for the future upper and lower specifications: B (X ̅: 0.6563, 0.2738; R: 0.4940, 0.00), pH (X ̅: 3.9786, 3.7916; R; 0.2871, 0.00).

Highlights

Quality control being one of the prominent tools employed to ensure a certain level of quality in a product or service, has emerged as a prime tool and an important factor required by any successful industry operating in today’s highly competitive business environment to incorporate in order to ensure quality of standard
To achieve the set target, the following objectives shall be adopted: To develop variable control charts for the measurable quality characteristics used during production
In this research four measurable quality characteristics used as raw-materials by a brewing company located in Uyo, in the production of their major products such as beer and Amstel Malta Brilliance (Haze), pH, Original Gravity (O.G) and Alcohol Percentage were obtained

Summary

Introduction

Quality control being one of the prominent tools employed to ensure a certain level of quality in a product or service, has emerged as a prime tool and an important factor required by any successful industry operating in today’s highly competitive business environment to incorporate in order to ensure quality of standard. Quality control is defined as the use of techniques and activities towards achieving, sustaining and improving the quality of products or services. It may be defined as all the features and characteristics of the product or service that contributes to the satisfaction of customer’s needs; (price, safety, availability, reliability and usability, etc.). According to Alford and Beatty (1951), quality control is an industrial management technique by means of which products of uniform and acceptable quality are manufactured or rendered. It answers the question of ‘What to produce?’ What is required (or expected)?

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Methods

Conclusion