implementation of quality tools in small medium industry mirzan
TRANSCRIPT
IMPLEMENTATION OF QUALITY TOOLS IN SMALL MEDIUM INDUSTRY
MIRZAN AIDIF BIN MOHD SHAKHIR
A report in partial fulfillment of the requirements for the award of the degree of
Bachelor of Mechanical Engineering
Faculty of Mechanical Engineering
Universiti Malaysia Pahang
NOVEMBER 2008
ii
SUPERVISOR DECLARATION
“We hereby declare that we have read this thesis and in our opinion this thesis is
sufficient in terms of scope and quality for the award of the degree of Bachelor of
Mechanical Engineering”
Signature : ……………………………………..
Name of Supervisor : MR MOHD FADZIL ABDUL RAHIM
Position : ……………………………………..
Date : NOVEMBER 13th, 2008
Signature : ……………………………………..
Name of panel : ……………………………………..
Position : ……………………………………..
Date : ……………………………………..
iii
STUDENT DECLARATION
I hereby declare that this thesis entitled “Implementation of Quality Tools In Small
Medium Industry” is the result of my own research except as cited in the references.
The thesis has not been accepted for any degree and is not concurrently submitted in
candidature of any other degree.
Signature : ..........................................................
Name : MIRZAN AIDIF BIN MOHD SHAKHIR
ID Number : MA 05022
Date : NOVEMBER 13th, 2008
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ACKNOWLEDGEMENTS
First I would like to express my grateful to ALLAH S.W.T. as for the
blessing given that I can finish my project. In preparing this paper, I have engaged
with many people in helping me completing this project. First, I wish to express my
sincere appreciation to my main thesis supervisor Mr Mohd Fadzil Abdul Rahim, for
encouragement, guidance, advices and motivation. Without his continued support
and interest, this thesis would not have been the same as presented here. Last but not
least I acknowledge without endless love and relentless support from my family, I
would not have been here. Father, mother, sister and brothers, you all have given me
the inspirations and encouragement until these days. Thank you all.
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ABSTRACT
Quality tools are one of the methods used to control and improve productivity by
many ways such as reducing the repetitive mistake. Quality plays such an important
role in the manufacturing industry in order to raise the profit of the company and also
the company’s name. SMI has many problems in their company specifically in the
processing line. This is because they just focusing in producing the products and not
taking the lack occur in the processing very well. This study is about to apply the
quality tools in the processing line in order to identify where the highest waste is
occur at and to give suggestion for improvement at the major waste involves in the
processing line. The selected SMI is producing spice which is one of important
ingredients in Malaysian food. There are four stages for producing spice, weighing,
roasting, grinding and packaging. Due to the interview there are two causes
contribute to waste, which are roasting and grinding process. From the data taken and
the analysis done, it shows the highest waste occur in the grinding process which
cause by four factors, expose to the moving fan, spices stick at the grind blade,
rotating gear and tupperware without lid. This shows that quality tools managed to
find the highest waste occur in the processing line. The company can reduce the
waste by put on the lid on the table used for cooling the spice, service the grinding
blade once after running three time to avoid the wet spices will attract more spices to
stick together, build a compartment at the rotating gear as obstacle and put on the lid
on the tupperware to ensure the spice will not getting away from the tupperware.
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ABSTRAK
Perkakas kualiti merupakan salah satu kaedah digunakan untuk mengawal dan
menigkatkan produktiviti dengan banyak cara antaranya mengurangkan kesilapan
yang berulang. Kualiti memainkan peranan penting bagi syarikat pembuatan untuk
meningkatkan keuntungan dan menaikkan nama syarikat. SSK mempunyai banyak
masalah di dalam syarikat mereka terutamanya di bahagian pemprosessan. Ini adalah
kerana mereka hanya fokus dalam penghasilan produk dan tidak mengambil
kekurangan di bahagian pemprosessan dengan baik. Pengkajian ini adalah tentang
menggunakan perkakas kualiti di bahagian pemprosessan untuk mencari dimanakah
berlakunya pembaziran yang tertinggi dan untuk memberi cadangan bagi
meningkatkan kawasan pembaziran major yang terlibat. SSK yang terpilih
menghasilkan rempah yang mana merupakan salah satu ramuan yang penting dalam
masakan orang Malaysia. Ada empat perigkat bagi menghasilkan rempah, timbang
berat, panggang, mengisar dan mempaket. Berdasarkan temubual ada dua penyebab
yang menyumbangkan pembaziran, yang mana adalah panggang dan mengisar.
Daripada data yang diambil dan analisis yang dijalankan, ia menunjukkan
pembaziran yang tertinggi berlaku di proses mengisar yang mana disebabkan oleh
empat faktor, terdedah kepada kipas yang bergerak, rempah melekat pada mata
pengisar, gear yang berpusing dan bekas tanpa penutup. Ini menunjukkan perkakas
kualiti berjaya mencari pembaziran tertinggi yang berlaku di bahagian pemprosessan.
Syarikat tersebut boleh mengurangkan pembaziran dengan meletakkan penutup pada
meja yang digunakan untuk menyejukkan rempah, servis mata pengisar sekali
selepas menggunakan tiga kali untuk mengelakkan rempah yang lembab menarik
lebih banyak rempah yang melekat, membina pengkotak pada gear yang bergerak
sebagai penghalang dan meletakkan penutup pada bekas bagi mengelakkan rempah
terkeluar.
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TABLE OF CONTENTS
Page
TITLE PAGE i
SUPERVISOR DECLARATION ii
STUDENT DECLARATION iii
DEDICATION iv
ACKNOWLEGDEMENTS v
ABSTRACT vi
ABSTRAK vii
TABLE OF CONTENTS viii
LIST OF TABLES xi
LIST OF FIGURES xiii
CHAPTER 1 INTRODUCTION
1.1 Project background 1
1.2 Why SMI 2
1.3 Scope of Project 2
1.4 Problem Statement 3
1.5 Objective 3
CHAPTER 2 LITERATURE REVIEW
2.1 Definition of Quality 4
2.2. Seven Basic Quality Tools 5
2.2.1 Check sheet 5
2.2.2 Pareto chart 6
2.2.2.1 Weight Pareto chart 7
2.2.3 Cause and effect diagram 9
2.2.4Conclusion of Seven Basic Quality Tools 10
2.3 Implementation of Quality Tools in previous case 10
2.3.1 Seven Basic Quality Tools (Pareto chart) 10
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CHAPTER 3 METHODOLOGY
3.1 Introduction 12
3.2 Literature Review on the topic 12
3.3 Define the objective, scopes and problem statement 12
3.4 Find the small medium industry 13
3.5 Interview 13
3.5.1 Important finding from the interview 16
3.6 Find the major defects and start taking data 16
3.7 Analysis 19
3.8 Conclusion 19
3.9 Chapter summary 20
CHAPTER 4 RESULTS AND DISCUSSION
4.1 Introduction 21
4.2 Results 21
4.2.1 Results of 10 random spices 21
4.2.2 Results of 3 Kurma spice 25
4.2.2.1 Data 1 25
4.2.2.2 Data 2 26
4.2.2.3 Data 3 28
4.3 Important finding from 3 data taken 29
4.4 Discussion 30
4.4.1 Expose to wind (fan) 30
4.4.2 Spices stick at the grinding blade 31
4.4.3 Tupperware without lid 33
4.4.4 Rotating gear 34
4.5 Suggestion for improvement 35
4.5.1 Case 1; Expose to wind (fan) 35
4.5.2 Case2; Spices stick at the grinding blade 37
4.5.3 Case 3; Tupperware without the lid 37
4.5.4 Case 4; Rotating gear 38
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CHAPTER 5 CONCLUSION AND RECOMMENDATIONS
5.1 Conclusion 41
5.2 Recommendation 41
REFERENCES 42
APPENDICES
Appendix A Interview 43
Appendix B Check sheet of 10 random spices and Kurma spice 44-46
Appendix C Data of 10 random spices and Kurma spice 47-50
Appendix D Gantt chart of PSM 1 and PSM 2 51-53
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LIST OF TABLES
Table No. Title Page
3.1 Check Sheet for taking of 10 random spices 17
3.2 Check sheet for taking 3 data of the selected spice 17
4.1 Data for Beriani spice, Kari Daging, Opor spice, 22
Kurma spice and Nasi Dagang
4.2 Data for Satay spice, Soto spice, Gulai Kawah, Kari Ikan 22
and Rendang
4.3 Data of waste during the process in kilogram (kg) for 22
Beriani spice, Kari Daging, Opor spice, Kurma spice
and Nasi Dagang
4.4 Data of waste during the process in kilogram (kg) for 23
Satay spice, Soto spice, Gulai Kawah, Kari Ikan
and Rendang
4.5 Data of waste during the process in percentage (%) for 23
Beriani spice, Kari Daging, Opor spice, Kurma spice
and Nasi Dagang.
4.6 Data of waste during the process in percentage (%) for 23
Satay spice, Soto spice, Gulai Kawah, Kari Ikan
and Rendang
4.7 Data 1 for Kurma spice 25
4.8 Waste during the process (data 1) 25
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4.9 Data 2 for Kurma spice 26
4.10 Waste during the process (data 2) 27
4.11 Data 3 for Kurma spice 28
4.12 Waste during the process (data 3) 28
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LIST OF FIGURES
Figure No. Title Page
2.1 Because it clearly organize data, check sheet is 6
the easiest way to track information
2.2 Typically the left y-axis is frequency of occurrence, 7
and the right y-axis is the cumulative percentage of the
total number of occurrence.
2.3 The most frequently occurring defects are wrinkles 8
and stains. Based just on this information, it can decide
to develop and improvement project and around reducing
wrinkles and strains.
on weld hardness
2.4 The most costly defects are scratches and dirt specs. Based 8
on this more informative data, it can decide that it is better
to develop an improvement project to reduce scratches and
dirt specs.
2.5 Fish bone diagrams display the various possible causes of 9
the final effect. Further analysis can prioritize them.
2.6 Pareto chart of grinding operations problems. 11
3.1 PJ FOOD Industries 13
3.2 Flowchart of processing spices 14
3.3 Weighing process 14
3.4 Roasting process 15
3.5 Grinding process 15
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3.6 Packaging process 16
3.7 Flowchart of methodology 20
4.1 Graph shows the waste value in roasting and grinding 24
process
4.2 Pareto Chart of Defects (Data 1) 26
4.3 Pareto Chart of Defects (Data 2) 27
4.4 Pareto Chart of Defects (Data 3) 29
4.5 Fish bone diagram of causes waste in grinding process 30
4.6 Spices expose to the moving fan 30
4.7 Spices stick at the grinding blade (front view) 31
4.8 Spices stick at the grinding blade (top view) 31
4.9 Spices stick at the grinding compartment 32
4.10 Spices stick at the grinding machine 33
4.11 The spices move out from the tupperware 33
4.12 The rotating gear 34
4.13 Spices stick at the grinding machine 35
4.14 Top view of the table 36