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Total Quality ManagementTotal Quality Management

and Quality Assuranceand Quality Assuranceinin

Salt Production and ProcessingSalt Production and Processing

Presentation byPresentation by

Lorenzo Locatelli-RossiLorenzo Locatelli-Rossi

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INTERNAL AND EXTERNAL QAINTERNAL AND EXTERNAL QA

Internal QC-Internal QC- are the procedures used by theare the procedures used by the

producer/processor to ensure that theirproducer/processor to ensure that their

productproduct consistentlyconsistentl

y meet internalmeet internal

requirements and government and industryrequirements and government and industry

standardsstandards..

External QC-External QC-periodicperiodic inspection byinspection by

government regulatory body that confirm thatgovernment regulatory body that confirm thatproducts andproducts and procedures meets standards

procedures meets standards

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DEFENTION OF QUALITYDEFENTION OF QUALITY

ASSURANCEASSURANCE

QA is a wide-ranging concept which coversQA is a wide-ranging concept which coversall matters which individually or collectivelyall matters which individually or collectivelyinfluence 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 andsupplies and logistics, management andhuman resources development.human resources development.

All elements designed to ensure thatAll elements designed to ensure thatproducts are of the quality required for theirproducts are of the quality required for theirintended use.intended use.

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TOTAL QUALITY MANAGMENTTOTAL QUALITY MANAGMENT

TQM is a management strategy to embedTQM is a management strategy to embed

awareness of quality in all organizationalawareness of quality in all organizational

processes (quality thinking).processes (quality thinking).

QA through statistical methods is a keyQA through statistical methods is a key

component.component.

Overall quality management influencesOverall quality management influences

company profitability.company profitability.

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PROFITABLE BUSINESSPROFITABLE BUSINESS

No business can succeed if the product hasNo business can succeed if the product has

no quality and guaranteed consistency.no quality and guaranteed consistency.

Consistent quality guarantee is closely linkedConsistent quality guarantee is closely linked

to affordability.to affordability.

No one can afford inconsistent, bad qualityNo one can afford inconsistent, bad quality

and no guarantee. It is too expensive!and no guarantee. It is too expensive!

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

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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 somethingAn 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

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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 QA6- Packing Iodized Salt6- Packing Iodized Salt

7- Warehousing and Dispatching7- Warehousing and Dispatching

8- Marketing and The Consumer8- Marketing and The Consumer

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1- PRIME REQUIRMENTS1- PRIME REQUIRMENTS

1a- People1a- People

1b- Factory1b- Factory

1c- Technology1c- Technology

1d- Salt (Raw Material)1d- Salt (Raw Material)

1e- Iodate1e- Iodate

1f- Spare Parts1f- Spare Parts

1g- Packing Material1g- Packing Material

1h- Auxiliary Supplies1h- Auxiliary Supplies

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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

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

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1c- TECHNOLOGY1c- TECHNOLOGY

Appropriate TechnologyAppropriate Technology

Vacuum processVacuum process

Washing/Refining processWashing/Refining process

Rock Crushing processRock Crushing process

Re-Packing processRe-Packing process

1- Investment Costs1- Investment Costs

2- Running Costs2- Running Costs

3- Maintenance Costs3- Maintenance Costs

Final Product CostsFinal Product Costs

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TechnologycontinueTechnologycontinue

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

1- Investment Costs1- Investment Costs

2- Running Costs2- Running Costs3- Maintenance Costs3- Maintenance Costs

These costs influence theThese costs influence the

Final Product CostsFinal Product Costs

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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.

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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)

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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 inSpares cost money; as a part and as inproductionproduction

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1g- PACKING MATERIAL1g- PACKING MATERIAL

Supplied with bag/packs as per orderSupplied with bag/packs as per order

QuantityQuantity

Printing QualityPrinting Quality

Quality 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?

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1h- AUXILIRY SUPPLY1h- AUXILIRY SUPPLY

Proper maintenance of all electricalProper 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

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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 termSome are short term other long terminvestmentsinvestments

They are all equally important and anyThey are all equally important and anyadditional cost must be avoided.additional cost must be avoided.

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How to Control costs/qualityHow to Control costs/quality

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

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

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

management operationsmanagement operations

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2- PROCESSING TECHNOLOGY2- PROCESSING TECHNOLOGY

What ever the process, daily production dataWhat 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 andSpecific reason/s for breakdowns and

solutions adopted.solutions adopted.

- Maintenance daily report list of areasMaintenance daily report list of areas

requiring work.requiring work.

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Processing TechnologyProcessing Technology

Plan for weekly, monthly and yearlyPlan for weekly, monthly and yearly

maintenance program.maintenance program.

TQM aims to do things right the first timeTQM aims to do things right the first time

rather than need to fix problems after theyrather 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 aA bad or non existent maintenance plan is a

costly business. There is no savings!costly business. There is no savings!

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Processing TechnologyProcessing Technology

Tally daily production with number ofTally daily production with number of

packs/bags issued.packs/bags issued.

Tally the end of the month consumption ofTally the end of the month consumption of

iodate and iodized salt production.iodate and iodized salt production.

Calculate plant capacity efficiency byCalculate plant capacity efficiency by

comparing hours over tons of iodized saltcomparing hours over tons of iodized salt

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PRODUCTION: TQM and QAPRODUCTION: TQM and QA

We focus onWe focus on Iodized SaltIodized Salt::

1- The processing equipment:1- The processing equipment:

Tanks, pipes, pumps and nozzle or dozers; daily check-up toTanks, 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 standardAt the start, titration must be done continuously until standardhas been achieved.has been achieved.

After which, minimum once every hour.After which, minimum once every hour.

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

Keep an hourly record every dayKeep an hourly record every day

Base your findings on titration not on theBase your findings on titration not on therapid test kitrapid test kit

Chart the resultsChart the results Share the ResultsShare the Results

Make a monthly reportMake a monthly report

Follow-up on issues that have been raisedFollow-up on issues that have been raised

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Charting Daily Iodizing ProgressCharting Daily Iodizing Progress

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Packing Iodized SaltPacking Iodized Salt

Guaranteed production of iodized salt needsGuaranteed production of iodized salt needs

to be packed and sealed in order to retain itsto be packed and sealed in order to retain its

guaranteed quality.guaranteed quality.

Ensure that seams and seals can withholdEnsure that seams and seals can withhold

transport/handling.transport/handling.

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

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

WAREHOUSING ANDWAREHOUSING AND

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WAREHOUSING ANDWAREHOUSING AND

DISPATCHINGDISPATCHING

Goods to be protected from water, dust andGoods 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 haveEnsure that trucks carrying the product have

clean trailers and goods are coveredclean trailers and goods are covered

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MARKETING AND THE CONSUMERMARKETING AND THE CONSUMER

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

It must indicate a Customer Care contact incase of productIt must indicate a Customer Care contact incase of productdissatisfaction.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 / QASUMMARY OF TQM / QA

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SUMMARY OF TQM / QASUMMARY OF TQM / QA

PRINCIPLESPRINCIPLES

Set quality standardsSet quality standards

Monitor and record plant efficiencyMonitor and record plant efficiency

Plan for good maintenance programPlan for good maintenance program

Involve/interact with workforceInvolve/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 OFINCREASING AVAILABILITY OF

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INCREASING AVAILABILITY OFINCREASING AVAILABILITY OF

IODIZED SALTIODIZED SALT Consumer education / awarenessConsumer education / awareness

Prohibit the production, import and sale ofProhibit the production, import and sale of

non-iodized salt.non-iodized salt.

Production facilities should interact with MoHProduction facilities should interact with MoH

Zero rated import duties on iodateZero rated import duties on iodate

Some form of tax rebate for producers asSome form of tax rebate for producers as

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