Track: Quality

Abstract

In this paper, the process of implementation of statistical process control is being described with respect to the production line at the plant. In this way, main purpose of implementing the statistical process control is to analyze that how much performance of a process is contributing to maintaining the required level of quality. Control charts in the statistical control process are significant tools for analyzing the variability of product quality characteristics. Therefore, the charts are helpful for the management to determine that at which level the process needs to be changed. In addition to this, the control charts also help the management to estimate the process capability for the purpose of achieving the desired level of quality. For the purpose of analyzing the importance of using the statistical process control, a healthy water factory was selected. This factory has the processes of producing the healthy water in small size bottles. The main problem for which the SPC was used in the factory was that the quality characteristics in the plant were increased significantly and resulted in the low process capabilities hence leading to the low productivity at the plant. In this way, the work objectives were to decrease the variability in the quality characteristics of the production process and improve the quality characteristics at the points of control. In this respect, the three points of control have been selected for making the experiments. These three points includes the feed water in wells, the permeate water produced after the chemical treatment and the final water product after the filling operations. For this purpose, two significant quality characteristics were set as the purpose of making experiments. These quality characteristics were named as total dissolved solids and power of hydrogen. During the experiment, the one sample was taken as the point of control at the first points of control. For this, X and moving range charts (I-MR charts) have been established and revised and three samples was taken at the final product point of control. For this, X bar and R charts have been established and revised during the whole process. The Minitab software has been used for making the experiment. In addition to this, the process capabilities have been used and established at the low level of values such as Cp and Cpk. During the process, the factory workers have been questioned for the different circumstances. As a result, the corrective actions suggested by the staffs have been incorporated in the experimentation. Thus, new control charts were developed when the corrective actions were incorporated. Later on, new practices indices and values were incorporated and improvements were noted during the whole process. thus, the effectiveness of the statistical process control system and the feasibility could be concluded as the result of experiments.