Implementation of Statistical Process Control SPC at Al-Safa Dairy Plant

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Malak Tamam
Zeina Abdelhaq
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Today in global and local competitive market, food companies are working hard to improve Quality of their products. Statistical quality control was used to maximize effectiveness of production quality. Statistical process in quality control, statistical process control ensures that the final product meets the pre-determined guidelines for safety, functionality and overall customer expectations. When this same process is applied during operations, not only are quality guidelines maintained, but waste of both materials and time can also be reduced. The important aspects that should be covered in the project, achieve the highest levels of quality for food products. To become the plant is a leader in the field of manufacturing milk and its derivatives, and the production of quality products and free of preservatives to match other products. There by achieving a good level of earnings to support needy families through the Commission for Zakat and Zakat Fund Palestinian projects. The factory shall seek to work on the development of products through research and development department in order to reach a high standard and commensurate with the needs of future export. This project aims to improve and implement an advanced quality system in SAFA-Dairy plant. Thus, increase customer satisfaction and decrease the percentage of out of control and variance also to achieve continuous improvement for the process. Then, measure the progress of the process and measure the process capabilities which are measurable property of the process to the specifications. Subsequently, implement the possible quality tools (Pareto chart, cause and effect diagram, control charts, histogram, check sheets, scatter diagram, process flow diagram). Finally, monitoring and optimizing quality of products since out of control situation allowing implementation of corrective actions and prevention of failure before an out of control  state become an out of specification. The methodology consists of all steps that should be carried throughout the project. First of all, the problem statement will be well defined to clarify the purpose of our work then control charts and models will be made according to the data from the factory (25 samples) on Minitab to check out control points and eliminate them during the process, after that we will use the new input data (new 25 samples) to establish new control charts and diagrams. Furthermore, if the observed variability of the attributes of a process is within the range of variability from natural causes, the process is said to be under statistical control.  The practitioner of SPC tracks the variability of the process to be controlled. When that variability exceeds the range to be expected from natural causes, one then identifies and corrects assignable causes. And so the quality of products will be increased and so increase customer satisfaction and this might help the company to increase its level of reputation.   Main results are clarified to show that some major issues the company thinks it doesnt have that effect on their products such as the effect of frozen water in refrigerators of row milk during the logistics process that came out of more than three out of control points, also After making the process capability for the Freezing Point (FP), there were some points under the LSL, this means that the percentage of FP is under the accepted range (0) and so the freezing point of the row milk is largely affected by the percentage of the water. In addition of the main effect of the type of food and seeds of cows (resource of row milk) on the percentage of fat in milk, more water would decrease of the amount of solids. Furthermore it was discovered that the Lactose isnt affected by any of the other gradients of milk except water and so it can keep its percentage almost constant. About process capability of solids, half of the samples were down of LSL. This is because the decline in the nutritional value of the sample and the low proportion of solids that are non- fat from the minimum approved a 8.20 .This is linked to the conditions of dairy cattle farms in terms of the type of food, the size of milk per cow, and the disparity between the two semesters summer and winter. These factors affect the ratio of the constituent materials for milk ups and downs. In our project, we considered the SPC method as a continuous improvement tool used to improve the quality of Al-Safa factory systems by using its tools to check and detect out of control points, and we tried to make correction actions to solve the problems in the whole system. Moreover quality plans were used to summarize the data and frequencies of each test used to know how to and when to make inspections.