QUALITY IMPROVEMENT USING STATISTICAL PROCESS CONTROL TOOLS IN PROCESS CONTROL IN DAIRY INDUSTRY- THE CASE OF SEBETA AGRO INDUSTRY

Abstract

In order to gain a competitive advantage in a competitive market improving quality and productivity of product or process is needed for every business company. This study addresses the ideas of quality improvement using statistical process control tools in the process control in the production line of pasteurized milk. Statistical process control tools are significant to evaluate/monitor process variability, to detect changes in the production process and reduce milk quality defects by identifying the vital few defects that the trivial many causes and to give suggestion for quality improvement. In this study the approach used is direct observation, focus group discussion, bar chart, flow chart, control chart (X bar R chart and X bar S chart), Pareto and cause and effect diagram, have been applied to improve quality and productivity of products and reduction of quality problems and quality defects. There are various quality parameters in the process such as weight/volume, temperature, titrable acidity and milk fat which have influence on the quality of the final products of pasteurized milk. It has been found that Sebeta Agro Industry has many quality problems and quality defects in the process of pasteurized milk production line. The vital few problems in the process of pasteurized milk were increased temperature, underweight and overweight of pasteurized milk and defects were clotting/souring, return, breakage and damage. Specifically clotting/souring and returns were high in the process of pasteurized milk production line. The main aim of this study is to analyze the impacts of SPC tools on quality improvement and provide guidance how to use SPC tools in process control and problem analysis to improve quality and productivity performance. The major and root causes of pasteurized milk quality problems and defects were stated and possible remedy suggestions were proposed. Even though SAI has many limitations to apply all suggestions for quality improvement within short period of time, the company documented that suggestions will bring significant improvement for quality and productivity through time.