Total Quality Management Total Quality Management and Quality Assurance and Quality Assurance

in in Salt Production and Processing Salt Production and Processing

Presentation by Presentation by

Lorenzo Locatelli-RossiLorenzo Locatelli-Rossi

INTERNAL AND EXTERNAL QAINTERNAL AND EXTERNAL QA

Internal QC-Internal QC- are the procedures used by the are the procedures used by the producer/processor to ensure that their producer/processor to ensure that their product product consistentlyconsistently meet internal meet internal requirements and government and industry requirements and government and industry standardsstandards..

External QC-External QC- periodicperiodic inspection by inspection by government regulatory body that confirm that government regulatory body that confirm that products and products and procedures meets standardsprocedures meets standards

DEFENTION OF QUALITY DEFENTION OF QUALITY ASSURANCEASSURANCE

QA is a wide-ranging concept which covers QA is a wide-ranging concept which covers all matters which individually or collectively all matters which individually or collectively influence 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 and supplies and logistics, management and human resources development.human resources development.

All elements designed to ensure that All elements designed to ensure that products are of the quality required for their products are of the quality required for their intended use.intended use.

TOTAL QUALITY MANAGMENTTOTAL QUALITY MANAGMENT

TQM is a management strategy to “”embed TQM is a management strategy to “”embed awareness” of quality in all organizational awareness” of quality in all organizational processes (quality thinking).processes (quality thinking).

QA through “statistical methods” is a key QA through “statistical methods” is a key component.component.

Overall quality management influences Overall quality management influences company profitability.company profitability.

PROFITABLE BUSINESSPROFITABLE BUSINESS

No business can succeed if the product has No business can succeed if the product has no quality and guaranteed consistency.no quality and guaranteed consistency.

Consistent quality guarantee is closely linked Consistent quality guarantee is closely linked to affordability.to affordability.

No one can afford inconsistent, bad quality No one can afford inconsistent, bad quality and no guarantee. It is too expensive!and no guarantee. It is too expensive!

W. Edwards Deming (1900-1993)W. Edwards Deming (1900-1993)

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 something An accepted or approved example of something

against 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

TQM- AREAS OF INTERESTTQM- AREAS OF INTEREST

1- Prime Requirements1- Prime Requirements

2- Processing Technology2- Processing Technology

3- Production: TQM and QA3- Production: TQM and QA

6- Packing Iodized Salt6- Packing Iodized Salt

7- Warehousing and Dispatching7- Warehousing and Dispatching

8- Marketing and The Consumer8- Marketing and The Consumer

1- PRIME REQUIRMENTS1- PRIME REQUIRMENTS

1a- People1a- People1b- Factory1b- Factory1c- Technology 1c- Technology 1d- Salt (Raw Material)1d- Salt (Raw Material)1e- Iodate1e- Iodate1f- Spare Parts1f- Spare Parts1g- Packing Material1g- Packing Material1h- Auxiliary Supplies1h- Auxiliary Supplies

1a- PEOPLE1a- PEOPLE

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

1b- FACTORY1b- FACTORY

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 points Emergency and fire points Kept clean all places at all timesKept clean all places at all times

1c- TECHNOLOGY1c- TECHNOLOGY

Appropriate TechnologyAppropriate Technology Vacuum processVacuum process Washing/Refining processWashing/Refining process Rock Crushing processRock Crushing process Re-Packing processRe-Packing process1- Investment Costs1- Investment Costs2- Running Costs2- Running Costs3- Maintenance Costs3- Maintenance CostsFinal Product CostsFinal Product Costs

Technology………continueTechnology………continue

Each process has a different:Each process has a different:

1- Investment Costs1- Investment Costs

2- Running Costs2- Running Costs

3- Maintenance Costs3- Maintenance Costs

These costs influence theThese costs influence the

Final Product CostsFinal Product Costs

SALT 1d-SALT 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.

1e- IODATE1e- IODATE

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)

1f- SPARE PARTS1f- SPARE 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 in Spares cost money; as a part and as in production production

1g- PACKING MATERIAL1g- PACKING MATERIAL

Supplied with bag/packs as per orderSupplied with bag/packs as per orderQuantityQuantityPrinting QualityPrinting QualityQuality plastic/cartonQuality plastic/cartonProper 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?

1h- AUXILIRY SUPPLY1h- AUXILIRY SUPPLY

Proper maintenance of all electrical Proper maintenance of all electrical equipment and cablesequipment and cables

Caution against dangerCaution against danger Proper electrical linksProper electrical links Stand-by generator (if appropriate)Stand-by generator (if appropriate) Appropriate stock of extra fuelAppropriate stock of extra fuel Water LeakagesWater Leakages

What about the Prime MaterialsWhat about the Prime Materials

They all carry an investment costThey all carry an investment cost

Some are short term other long term Some are short term other long term investmentsinvestments

They are all equally important and any They are all equally important and any “additional” cost must be avoided.“additional” cost must be avoided.

How to Control costs/qualityHow to Control costs/quality

TQM applies principles of controlling the quality TQM applies principles of controlling the quality

of machine-based factories operations to of machine-based factories operations to

controlling the quality of people-based controlling the quality of people-based

management operationsmanagement operations

2- PROCESSING TECHNOLOGY2- PROCESSING TECHNOLOGY

What ever the process, daily production data What 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 and Specific reason/s for breakdowns and solutions adopted.solutions adopted.

- Maintenance daily report list of areas Maintenance daily report list of areas requiring work.requiring work.

Processing Technology…………Processing Technology…………

Plan for weekly, monthly and yearly Plan for weekly, monthly and yearly maintenance program.maintenance program.

TQM aims to do things right the first time TQM aims to do things right the first time rather than need to fix problems after they rather 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 a A bad or non existent maintenance plan is a costly business. There is no savings!costly business. There is no savings!

Processing Technology…………Processing Technology…………

Tally daily production with number of Tally daily production with number of packs/bags issued.packs/bags issued.

Tally the end of the month consumption of Tally the end of the month consumption of iodate and iodized salt production.iodate and iodized salt production.

Calculate plant capacity efficiency by Calculate plant capacity efficiency by comparing hours over tons of iodized saltcomparing hours over tons of iodized salt

PRODUCTION: TQM and QAPRODUCTION: TQM and QA

We focus on We focus on Iodized SaltIodized Salt::

1- The processing equipment:1- The processing equipment: Tanks, pipes, pumps and nozzle or dozers; daily check-up to Tanks, pipes, pumps and nozzle or dozers; daily check-up to

ensure 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?2- Iodization:2- Iodization: At the start, titration must be done continuously until standard At the start, titration must be done continuously until standard

has been achieved.has been achieved. After which, minimum once every hour.After which, minimum once every hour.

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

Keep an hourly record every dayKeep an hourly record every day Base your findings on titration not on the Base your findings on titration not on the

rapid test kitrapid test kit Chart the resultsChart the results Share the Results Share the Results Make a monthly reportMake a monthly report Follow-up on issues that have been raisedFollow-up on issues that have been raised

Charting Daily Iodizing ProgressCharting Daily Iodizing Progress

Packing Iodized SaltPacking Iodized Salt

Guaranteed production of iodized salt needs Guaranteed production of iodized salt needs to be packed and sealed in order to retain its to be packed and sealed in order to retain its guaranteed quality.guaranteed quality.

Ensure that seams and seals can withhold Ensure that seams and seals can withhold transport/handling.transport/handling.

Maybe a small pin-prick hole avoids Maybe a small pin-prick hole avoids problemsproblems

Bag the packed salt in an orderly fashionBag the packed salt in an orderly fashion

WAREHOUSING AND WAREHOUSING AND DISPATCHINGDISPATCHING

Goods to be protected from water, dust and Goods 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 have Ensure that trucks carrying the product have

clean trailers and goods are coveredclean trailers and goods are covered

MARKETING AND THE CONSUMERMARKETING AND THE CONSUMER

Iodized Salt pack/bag must have full details of the production Iodized Salt pack/bag must have full details of the production company.company.

It must indicate a “Customer Care” contact incase of product It must indicate a “Customer Care” contact incase of product dissatisfaction.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

SUMMARY OF TQM / QA SUMMARY OF TQM / QA PRINCIPLESPRINCIPLES

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

INCREASING AVAILABILITY OF INCREASING AVAILABILITY OF IODIZED SALTIODIZED SALT

Consumer education / awareness Consumer education / awareness Prohibit the production, import and sale of Prohibit the production, import and sale of

non-iodized salt.non-iodized salt. Production facilities should interact with MoH Production facilities should interact with MoH Zero rated import duties on iodateZero rated import duties on iodate Some form of tax rebate for producers as Some form of tax rebate for producers as

iodized salt is of national importance.iodized salt is of national importance.