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STATISTICAL QUALITY CONTROL OF PREMIER SOAP IN
SOAP MANUFACTURING INDUSTRY
(A CASE STUDY OF PZ CUSSION PLC ABA ABIA STATE)
TABLE OF CONTENT
Title page
Approval page
Dedication
Acknowledgement
Abstract
Table of content
Chapter one
1.0 Introduction
1.1.1 Specification, production and inspection
1.2 Brief history of Pz cusson plc
1.3 Background of the study
1.3.1 Statistical quality control
1.3.2 Importance of statistical quality control
1.4 Control chart
1.4.1 Purpose of control chart
1.4.2 Types of control chart
1.5 Statement of the problem
1.6 Objective of the study
1.7 Statement of hypothesis
1.8 Scope of the study
1.9 Limitation of study
1.10 Definition of terms
CHAPTER TWO
2.0 Literature review
CHAPTER THREE
3.0 Research methodology
3.1 Source of data collection
3.2 Technique of data Analysis
3.2.1 Statistical quality control technique
3.2.1 Control chart for Attributes
3.3 Factors influencing the choice of Acceptance sampling at
Pz cusson Nigeria Plc.
3.4 Analysis of variance (ANOVA)
CHAPTER FOUR
4.0 Data presentation and analysis
4.1 Introduction
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4.2 Data presentation
4.3 Data Analysis
4.4 Computation of P-Chart on the defective on the colour of
premier soap.
4.5 Test of hypothesis for difference in the means on the
weight of premier soap produced by Pz cusson plc Aba.
CHAPTER FIVE
5.0 Summary, Conclusion recommendation
5.1 Summary
5.2 Conclusion
5.3 Recommendation
References
Appendix
CHAPTER ONE
1.0 INTRODUCTION
The reputation attached to an organization for the quality of
its product is accepted as a key to its success and the future of
its employees. To prepare in today’s economic climate, any
organization and its suppliers must be dedicated to neverending and more efficient ways to obtain products
that consistently meet customer’s
or services
needs.
Prior to the 1900s, U.S industry was largely characterized by
small shops making relatively
simple product, such as candles
or furnitures. In these small shops the individual workers was
generally a craftsman who was completely responsible for the
quality of the work. The worker could get the quality through
the personal selection of the materials, skillful manufacturing,
and selected fitting and adjustment.
In the early 1900s factories sprang up, where people with
limited training were formed into large assembly lines, products
became much complex, the individual workers no longer had
complete
control over the quality of the product. A semi-
professional staff, usually the inspection department, became
responsible for the quality of the product.
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1.0.1 SPECIFICATION, PRODUCTION AND INSPECTION
Before production starts, a decision is necessary as to
what is to be made. Next, comes the actual manufacturing of
the product. Finally it must be determined whether the product
manufactured is what was intended. It is conferment to think
of all matters related to quality of manufactured in terms of
those three functions: specification production and inspection.
Statistical quality control should be reviewed as a list of
tools, which may influence decision co-operation among those
responsible for these three different function or decision at a
higher level than one of them. For this reason, the techniques
should
be
understood
at
a
management
level
that
encompasses all the three function. No production process is
good enough to produce all items of production exactly alike,
some variability is unavoidable.
The amount of this basic variability of the process is so
great that, it is impossible to make all the product fall within
the specific limits.
When control chart shows that this is true, and when the
specification cannot be changed, the alternative are either to
make a fundamental change in the production process that will
reduce its basic variability or to the fact that it will always be
necessary to sort the good product from the bad ones.
The quality responsibility was usually fulfillment by a
100% inspection of all the important characteristics. If there
were any discrepancies noted, these problems were handled by
the manufacturing department supervisor.
In essence, quality was attained by “inspecting the quality
into the product”.
During the 1920s, Dr. Walter A Shewart of the Bell
telephone laboratories, developed the concept of statistical
quality control. He introduced the concept of controlling” the
quality of a product as it was being manufactured, rather than
inspecting
the
quality
into
the
product
after
it
was
manufactured.
1.2 BRIEF HISTORY OF PZ CUSSON PLC
George Paterson and Goerge Zochorius set up a trading
post in Sierra Lone in 1897. in 1899 Paterson Zochonis (Pz)
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opened a Brach office in Nigeria. They acquired their first soap
factory in Nigeria in 1948.
In 1969, a manufacturing base was established in Ghana.
Paterson and Zochonis entered the detergent and refrigerator
markets simultaneously in Nigeria in the year 1973, Pz
acquired cusson Group ltd, Pz started up soap manufacturing in
Melbournic, Austrialia in 1976 Minerua S.A, a leading great
edible oils and fats manufacturer was acquired in 1977.
Consequently, Pz production purchased its first soap
factory in Kenya in 1983. Production started at this pethum
Thani site in Thailand in 1986. in 1988, Pz cusson Indonesia
was established, 1993, Pz brought the state-owned pollens
Wrodaw in Poland, followed in 1995 by Pollena Uroda.
In 2002, Paterson Zochoris was changed to Pz cusson Plc.
Pz cusson entered into a joint venture with Galnbia plc to
supply evaporate milk and milk powder in Nigeria in 2003. In
2004, they acquired the Charles Worthinton haircare business.
Today,
they
deal
not
only
on
soap
but
also
on
Pharmaceuticals and confectories as well as treazers etc with
its head office at No 45/47 Town planning way Illupeju
industrial Estate Lagos.
1.3 BACKGROUND OF THE STUDY
Statistical quality control is generally described as the
control of product quality
by statistical methods. Various
techniques developed by mathematical
statisticians
for the
analysis of data may be used in control of product quality. This
research work addresses the statistical quality control of soap
manufacturing “premier soap” in Pz cusson ltd. However, it
detailed the statistical techniques, application of control chart
and analysis of variance.
Premier as the soap implies is soap which some notable
people cannot do without. On the usage of soaps in Nigeria
today, competition is very high.
1.3.1 STATISTICAL QUALITY CONTROL
This
is
the
application
of
statistical
techniques
or
procedures to industrial operations. It involves the technique of
sampling at every stage of production and statistical inference
about the variability of the product quality.
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IMPORTANCE OF STATISTICAL QUALITY CONTROL
Some major economic of the statistical quality control includes
the following.
i.
It
protects
producers
from
having
their
products
rejected when such products contain a relatively low
number of defective i.e when such products conforms in
quality and uniformity to specification.
ii.
It
protect
consumers
from
accepting
a
product
containing high number of defective.
iii.
It provides full information about the quality of the
goods being produced the implication of which guides
the producer into knowing when to adjust the system.
iv.
It encourages the producer to keep the process in
control.
v.
It protects the producer from imputing batch raw
materials into process. Testing the raw material to
know if they conform to specification before using them
for production.
1.3.2 CONTROL CHART
Walter
A.S
of
Bell
telephone
laboratories
in
a
memorandum dated May 16, 1924 introduced the concept of
the techniques is chronicled in a number of articles by Shewart
and his 1931 Candmark book, economic control quality of
manufacturing process.
The control chart usually consist of three horizontal lines.
The top line represented the upper control limit, the bottom
line which is the lower control limit, the center line, an
acceptable average for the process based on specification or
historical data.
The control chart is constructed in such a way that can
plot the results of processing the quality of a manufactured
product through periodic monitoring the manufactured process.
Each line the process is monitored and at a point placed in the
control chart. As long as the point’s falls within the two control
limits, we do not question the quality of the product. But when
a plotted points falls outside the control limit, this alert the
production manager to possibility that the quality of the
product is unacceptable.
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PURPOSE OF CONTROL CHART
1. Control charts identify hen assignable cause of variation
or changes have entered the process.
2. It is also a graphical display of the actual measurement of
a chart showing limit, which reflect the capability of the
particular quality characteristics.
3. These charts indicate to workers, group leaders, quality
control
engineers,
production
supervisor
and
management whether the production of the part or
service is “in control” or out of control”.
TYPES OF CONTROL CHART
Control chart for variables, control chart for attribute and
control for the number of defect per unit.
Control chart for variables includes the Average control
chart ( -chart) Range control chart (R) and δ chart (standard
deviation).
Control chart for attributes: observations are recorded as
either defective, or non-defective, and statistic of interest are
the proportion defective in a sample of size n example P-chart.
1.4 STATEMENT OF THE PROBLEM
According to Osuala, (1987) the statement of a research
problem services to elaborate upon the information in the title
of the study.
Below are the important problems questions for this study:
1.
Does
the
product
(-premier
soap)
conform
to
specification?
2.
Does the color of the conform the targeted standard?
3.
Is there any significant difference between the mean
weights of soap?
1.5 OBJECTIVE OF THE STUDY
The objectives of this research work are:
1. To find out whether the production process is in statistical
quality control.
2. To know if the color of soap is out of control.
3. To find out if there is any significant difference in the
mean weight of premier soap manufactured by Pz cusson
plc or not.
1.6 STATEMENT OF HYPOTHESIS
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Based on the problem above, the following
Hypothesis is deducted for the study:
1.
Ho: The product does not conform to specification
H1: The product conform to specification
2.
Ho: The color of soap does not conform to standard
H1: The colour of soap conforms to standard.
3.
Ho: There is no significant different between the mean
weight
H1: There is significant different between the mean
weight
1.7 SCOPE OF THE STUDY
This research work covers the quality control process,
problems and solution to the manufacturing industries, such as
in the production of “premier soap in Pz cusson industry Plc
Aba” on the quality control measure.
1.8 LIMITATION OF THE STUDY
This study was limited to the following factors:
i.
Time factor
ii.
For business confidentially, information on the various
quantities of some components or raw materials were
regarded as part of the organizations private affair.
Example: quality of palm oil, distilled water etc.
1.9 DEFINITION OF TERMS
The following definitions are used within the context of
this research work.
a. Quality of a product is a measure of the product ability to
meet the expectations of the customer.
b. Statistical quality control: Is a technique or procedure of
sampling at every stage of production and statistical
inference about the variability of the product quality.
c. Control chart: is a graphical display of the actual
measurement of quality characteristics on a chart showing
limit which reflect the process capability on the particular
quality characteristics.
d. Control limit: These are limit showing the maximum range
of
variation
characteristics.
permissible
in
the
measured
quality
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e. Process control: this is the act of observing the functions
of each of the factors leading to the production of any
goods on a continuous basis to ensure that the process or
means of production is kept in control.
f. Product control: this is the act of observing different
attributes of quality specification of a product with the aim
of ensuring that the product conforms to specification.
This is done by taken a sample from a batch of inspection
lot with the aim of accepting or rejecting.
g. Specification: Is a set standard to which a process is to
conform to.
h. Standard: An average or normal required quality, quality,
level, grade etc
i. Chance cause of variation: These are the inherent and
uncontrollable variation malfunctioning associated with
any process or experiment.
j. Assignable cause of variation: They are variation resulting
from operational malfunctioning
k. Inspection by Attributes: A method of inspection where
either the unit of product is classified as “defective” or
“non defective”.
l. UCL: Upper control limit
m.LCL: Lower control limit
n. Tolerance limit: This provides a basis for acceptance or
rejection of a finished product.