Tqm - L Rossi

Total Quality Management and Quality Assurance in Salt Production and Processing Presentation by Lorenzo Locatelli-Rossi

INTERNAL AND EXTERNAL QA  Internal QC- are the procedures used by the producer/processor to ensure that their product consistently meet internal requirements and government and industry standards.  External QC- periodic inspection by government regulatory body that confirm that products and procedures meets standards

DEFENTION OF QUALITY ASSURANCE  QA is a wide-ranging concept which covers all matters which individually or collectively influence the quality of a product.  It applies to equipment, product design, supplies and logistics, management and human resources development.  All elements designed to ensure that products are of the quality required for their intended use.

TOTAL QUALITY MANAGMENT  TQM is a management strategy to “”embed awareness” of quality in all organizational processes (quality thinking).  QA through “statistical methods” is a key component.  Overall quality management influences company profitability.

PROFITABLE BUSINESS  No business can succeed if the product has no quality and guaranteed consistency.  Consistent quality guarantee is closely linked to affordability.  No one can afford inconsistent, bad quality and no guarantee. It is too expensive!

W. Edwards Deming (1900-1993)

STANDARDS  In order to have quality we need Standards Standards are:  An accepted or approved example of something against which others are judged or measured.  Guideline  Point of Reference  Ensures Consistency in the Product  Guarantee of Quality

TQM- AREAS OF INTEREST 1- Prime Requirements 2- Processing Technology 3- Production: TQM and QA 6- Packing Iodized Salt 7- Warehousing and Dispatching 8- Marketing and The Consumer

1- PRIME REQUIRMENTS 1a- People 1b- Factory 1c- Technology 1d- Salt (Raw Material) 1e- Iodate 1f- Spare Parts 1g- Packing Material 1h- Auxiliary Supplies

1a- PEOPLE Every person:  Is an important investment  Must know why their job is important  Knowledgeable about the and product  Given an opportunity to suggest ideas  Ownership of his/her place of work  Importance of participation

1b- FACTORY       

Designed to be practical and economical Must be people friendly Allocate clearly defined spaces Proper place for resting/eating and lockers First Aid kit and person trained Emergency and fire points Kept clean all places at all times

1c- TECHNOLOGY Appropriate Technology  Vacuum process  Washing/Refining process  Rock Crushing process  Re-Packing process 1- Investment Costs 2- Running Costs 3- Maintenance Costs Final Product Costs

Technology………continue Each process has a different: 1- Investment Costs 2- Running Costs 3- Maintenance Costs These costs influence the Final Product Costs

SALT 1dThe salt must:  Meet the Standards  Stored in an appropriate place All the above factors have a cost implication.

1e- IODATE     

Meets standards Stored in appropriate place Control of issuance of the product Always in stock sufficient quantities Avoid over supply (frozen capital)

1f- SPARE PARTS Properly Stored Catalogued Control over issuance Know your supplier Replace immediately Spares cost money; as a part and as in production     

1g- PACKING MATERIAL  Supplied with bag/packs as per order Quantity Printing Quality Quality plastic/carton Proper size  Tapes and glues  Proper issuance procedure  Hold appropriate quantity in stock  Supplier keeps stock?

1h- AUXILIRY SUPPLY  Proper maintenance of all electrical equipment and cables  Caution against danger  Proper electrical links  Stand-by generator (if appropriate)  Appropriate stock of extra fuel  Water Leakages

What about the Prime Materials  They all carry an investment cost  Some are short term other long term investments  They are all equally important and any “additional” cost must be avoided.

How to Control costs/quality TQM applies principles of controlling the quality of machine-based factories operations to controlling the quality of people-based management operations

2- PROCESSING TECHNOLOGY  What ever the process, daily production data must be recorded. Data must include: - Time of start/stop and eventual breakdowns - Specific reason/s for breakdowns and solutions adopted. - Maintenance daily report list of areas requiring work.

Processing Technology…………  Plan for weekly, monthly and yearly maintenance program.  TQM aims to do things right the first time rather than need to fix problems after they emerge and cause more problems.  A bad or non existent maintenance plan is a costly business. There is no savings!

Processing Technology…………  Tally daily production with number of packs/bags issued.  Tally the end of the month consumption of iodate and iodized salt production.  Calculate plant capacity efficiency by comparing hours over tons of iodized salt

PRODUCTION: TQM and QA We focus on Iodized Salt: 1- The processing equipment:  Tanks, pipes, pumps and nozzle or dozers; daily check-up to ensure that are they clean and in good working order.  Monitor even during production.  If dry mix or a solution; is the mix well prepared? 2- Iodization:  At the start, titration must be done continuously until standard has been achieved.  After which, minimum once every hour.

PRODUCTION: TQM & QA ………….      

Keep an hourly record every day Base your findings on titration not on the rapid test kit Chart the results Share the Results Make a monthly report Follow-up on issues that have been raised

Charting Daily Iodizing Progress

Packing Iodized Salt  Guaranteed production of iodized salt needs to be packed and sealed in order to retain its guaranteed quality.  Ensure that seams and seals can withhold transport/handling.  Maybe a small pin-prick hole avoids problems  Bag the packed salt in an orderly fashion

WAREHOUSING AND DISPATCHING  Goods to be protected from water, dust and other pollutants.  Goods to be placed off the floor (on pallets) and away from the wall.  Practice the First In Last Out (FILO).  Ensure that trucks carrying the product have clean trailers and goods are covered

MARKETING AND THE CONSUMER  Iodized Salt pack/bag must have full details of the production company.  It must indicate a “Customer Care” contact incase of product dissatisfaction.  Prepare a “complaints handling procedure”.  Product must state type and quantity of iodine.  Interact with wholesaler/retailers if and when possible  The customer is always right!  Customer confidence builds business

SUMMARY OF TQM / QA PRINCIPLES       

Set quality standards Monitor and record plant efficiency Plan for good maintenance program Involve/interact with workforce Measure iodization output against standards Define corrective action for non-compliance Focus on quality - TQM

INCREASING AVAILABILITY OF IODIZED SALT  Consumer education / awareness  Prohibit the production, import and sale of non-iodized salt.  Production facilities should interact with MoH  Zero rated import duties on iodate  Some form of tax rebate for producers as iodized salt is of national importance.