Implementation of statistical process control SPC in AZIZA poultry slaughterhouse

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Date
2013
Authors
Odai Dweekat
Asmaa Nouri
Aseel Khateeb
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Abstract
According to the importance of meat industry in our life, this project deals with Palestine Poultry Company (AZIZA) that produces a health chicken product. This project will address the statistical process control (SPC) as a method of monitoring, controlling, and improving a process through statistical analysis with its seven tools to solve the problems that AZIZA suffered from such as not enough sufficient quality system and they have a lot of data that havent been analyzed. As a result, they dont have any indicators about their progress in production and the causes for non-conforming products. As a result of implementing SPC method , many objectives could be realized such as improve an advanced quality system, decrease the percentage of out of control, and  implement the seven quality tools (Pareto chart, cause and effect diagram, control charts, histogram, check sheets, scatter diagram, process flow diagram). The seven tools of SPC are very important to detect the problems and their causes, e.g. the process control charts are the main tool that use in all variables (measured) test by taking about 25 slaughters through 9 months, and attribute (done visually) tests in the company. Moreover, the control charts for microbiological tests to analyze the data over the time and detection of the out of control points. Another tool used to define the causes and the effect of the out of control points is fish bone diagram. By the analysis of the control charts tool, the dynamic model was designed to determine the savings of implementing SPC, by eliminating or omitting unimportant, time consuming frequency of the tests. Another benefit of implementing SPC method is to develop a quality plan which represents the most important topic, which is adjust the frequency of the inspections taken at every turn.         Statistical process control (SPC) is a method of monitoring, controlling, and improving a process through statistical analysis. An important SPC tool is the control chart, which can be used to detect changes in production processes (Reneau, 2011). The main seven tools for SPC are Pareto Diagram, Cause and Effect Diagram, Check Sheets, Process Flow Diagram, Scatter Diagram, Histogram and Control Charts. Meat processing as discussed in this text includes all processes utilized in altering fresh meat except for simple grinding, cutting, and mixing. In the broadest sense, this includes curing, smoking, canning, cooking, freezing, dehydration, production of intermediate-moisture products, and the use of certain additives such as chemicals and enzymes. This definition excludes cutting, grinding, and packaging of fresh meat in retail stores and in homes. In this way the definition differentiates between first those processes that enter into the preservation and manufacture of meat products, and second those that alter the form of fresh meat in preparation for consumption. The original basis for meat processing was preservation by inhibiting or deterring microbial decomposition. Early meat-processing developments were based on this concept. In addition to preventing spoilage, preservation also resulted in flavorful and nutritious products. (A.M. Pearson, 1985). The two most important quality attributes for poultry meat are appearance and texture. Appearance is critical for both the consumers initial selection of the product as well as for final product satisfaction. Texture is the single most important sensory property affecting final quality assessment. Appearance quality attributes include skin color, meat color, cooked meat pinkness, and appearance defects such as bruises and hemorrhages. Since appearance is so critical for consumer selection, poultry producers go to great lengths to produce products with the appropriate color for a particular market and to avoid appearance defects which will negatively affect product selection or price. Historically, meat tenderness was primarily associated with live bird quality factors such as breed, sex, or age. However, modern production practices produce highly uniform young birds in which the major problems associated with meat texture are the result of processing errors or early deboning. Although other quality issues such as juiciness and flavor are important, they are more a function of product preparation and infrequent, but acute, production or processing errors which are usually easily corrected or avoided. An understanding of the major issues contributing to poultry color and meat tenderness is critical to producing uniform quality products.(Fletcher, 2002). From the data that the company has, the analysis done in MINITAB program to give the real situations and to detect the out of control manners.  This program gives the X-bar R, X-bar S, and other control charts. In statistical quality control, the X Bar-R chart is a type of control chart used to monitor a variable's data when samples are collected at regular intervals from a business or process. More over the X Bar-S Chart is a double chart that plots the average of values for each period on the top chart (X Bar Chart) and the standard deviation of the values for the period on the bottom chart (S Chart). The Process Capability is a measurable property of a process to the specification, expressed as a process capability index (e.g., Cpk or Cpm) or as a process performance index (e.g., Ppk or Ppm). The output of this measurement is usually illustrated by a histogram and calculations that predict how many parts will be produced out of specification (OOS). The Run chart (often known as line graphs outside the quality management field) display process performance over time. Upward and downward trends, cycles, and large aberrations may be spotted and investigated further. Histogram is a graphical representation showing a visual impression of the distribution of data. It is an estimate of the probability distribution of a continuous variable and was first. A histogram consists of tabular frequencies, shown as adjacent rectangles, erected over discrete intervals (bins), with an area equal to the frequency of the observations in the interval.       To obtain the benefits of the statistical process control tools, the company should take into consideration the following steps: 1.       The company must use the seven tools to increase their awareness about the problems, try to solve any problem that may happen in the future, detect the main sources of variability, and measure the progress of the process. 2.      The analysis shows that the implementation of SPC method will benefit the company in making savings in money and time consumptions. 3.      The advanced quality plan must be implemented for new frequency of tests to make the savings. 4.      Increase the number of samples taken for the microbiological tests, because the cost to test another sample is almost ignore. This project consider the SPC method as a continuous improvement tool used to improve the quality of systems by using its seven tools to check and detect out of control points , and try to make correction actions to solve the problems  in the system . Moreover quality plan that summarizes the data and frequencies of each test used to know how to and when to make inspections. After making the advanced quality plan, cost reduction model is the output to determine the savings for the company with respect to time, money reduction.   
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