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ROLE OF
INSPECTION IN PRODUCT QUALITY MANAGEMENT DRIVE
CHAPTER ONE:
Introduction
1.1 Background of the Study
Doug
Wallace, a Materials Management subject expert with Life Cycle Engineering
[L.C.E] Consultancy Company Charleston, South Carolina; in a paper presentation
titled “Maintenance and Reliability Inventory Management” gave an apt and
practical illustration that underscores the need for inspection. He said, have
you heard of the guys that burned up a brand new piece of rotating equipment
because it was installed with no oil in it? That little oversight cost $80,000 for a replacement. When properly
lubricated, it would have cost less than $100”. Again, he said, “How about the
guys that cut a section out of their raw materials feeder line and then find
out the replacement piece was just a little bit too short to fit into the gap?
That little mistake cost thousands of dollars in unplanned repairs and
potentially hundreds of thousands in lost production”.
This brings
to mind the two renowned cases in Nigeria of Indomie Instant Noodles Poisoning
Crisis of 2004 and Pfizer Poisoning Crisis, Kano 1996. What these organizations
suffered in terms of cost, production revenue loss and image can only be
imagined.
Again,
operating in an unstable environment riffed with stiff competition; product
quality management has become in more ways than one the life-blood of the
organization. Be that as it may, and as strategic as product quality is to
success of the organization, it will be near impossible if not impossible to
achieve the goals of enhancing, maintain and sustaining product quality without
the eagle eye of inspection.
Inspection
itself is a word with many synonyms, so, whether a writer chooses the word
examination, observation, investigation or assessment, it will still be
inspection, and sometimes the word testing is adopted depending on what is
being inspected.
The general
idea and concept is to ascertain or determine quality or conformity of
materials, products and components to pre-set standards and specification.
So,
materials outsourced or insourced either as raw materials, components, spare
parts or MROs as well as the organizations output are subjected to thorough
examination to ensure that they conformed to specifications and standards
before they are certify for production or consumption.
This brings
to bear the subtle but distinct fact that inspection and quality are two
inseparable Siamese twin terms, where one can hardly be discussed without
alluding to the other. In fact, inspection is a tool often utilized by
organizations for the realization of product quality management objectives.
Thus, in other to understand the basis for inspection and its role in product
quality management drive of an organization, a concise but lucid perspective of
specification and standardization, the concept of quality management, quality
control and quality assurance will need to be understood as they are interwoven
and make it difficult to be discussed one without the other.
1.2 Statement of the Problem
The
effectiveness or ineffectiveness of the inspection exercise can mean the
successor failure of the organization. This is because the slightest oversight
of outsourced or and insourced materials and products from specification and
standards will often result to the production of defective output with multiple
and spiraling effects in multiple fronts with unimaginable consequences for
both the organization and consumers.
Consequently,
no where in the manufacturing industry are those consequences more truer, acute
and immediate as in the food and drugs industry.
The choice
of Northern Noodles Limited Kaduna, in an attempt to examine the role of
inspection in the quest for effective product quality management in the food
industry was prompted by a few negative indicators which combined to impair on
the quality of their products.
The issue
that arose for this study is asked, whose responsibility is it in the
organization to ascertain and certify the compliance of product inputs to
pre-determined standards and specifications? Again what measures are put in
place by the organization to ensure that defective materials not do enter the
production process? It is also asked, what measures are put in place to detect
defects even in the production process?
1.3 Objectives of the Study
It is a
truism that defective materials allowed to enter the production line can cause
the failure of the organization, as quality will be impinged upon eventually,
and this will be with great consequences to the organization and society at
large. It is therefore necessary that this must not be allowed to occur.
The
objective of this study is therefore built around the examination of the
quality management programs employed by the organization in its drive towards
ensuring quality of its outputs. The study in this light is therefore aimed at.
i) To determine the
responsibility for inspection in the organization.
ii) To determine the approach to
materials specification adopted by the organization.
iii) To determine the method of
inspection adopted by the organization.
iv) To determine the defect
preventive measures used by the organization.
v) To determine the control tools
used by the organization to ensure quality outputs.
1.4 Significance of the Study
The research
study is of immense importance in many facets. First, it is a requirement in
partial fulfillment for the award of Higher National Diploma (HND) in the
Department of Purchasing and Supply Management, Kaduna Polytechnic which the
researcher stands to receive, and without which he cannot graduate.
Again, as a
reservoir of knowledge, it will serve as a guide for further study to some
future researchers. Students will also benefit, because it will help expand and
expose them to the different perspectives on the subject matter. Further, and
importantly, it will be a tremendous benefits to the organization under
studied; as it will expose them to the dangers embedded in the laxity or
casualness given to the inspection exercise by the organization.
Finally, the
general public will also glean from its sublime significance, since everyone
buys in one way or another, and to property adopt the principles and approaches
of the inspection exercise in their personal acquisitions.
1.5 Scope of the Study
This
research work is focused on the role of inspection in product quality
management drive in Northern Noodles Limited, Kaduna, located along Kachia
road, Chikun Local Government Area, Kaduna. The research considered and covered
the period from 2011 and 2012. The searchlight was beamed on the Purchasing
Department, the Production Department, Quality Control and the Administrative
departments of the organization.
1.6 Research Questions
i) Who is responsible for
inspection in the organization?
ii) What is the approach to
materials specification in the organization?
iii) What method(s) of inspection does
the organization adopts?
iv) What preventive measures are put
in place by the organization to ensure that defective materials does not enter
the production line?
v) What control tools does the
organization used to ensure and sustain quality?
1.7 Definition of Terms
· Inspection: This describes
a process of careful examination of materials, services, component or a process
or work product to determine its conformity to set standards.
· Sourcing: This is a
purchasing procedure through which buyers seeks, survey and evaluate suppliers,
and determine policies relating to those who will most suitably meet the
requirement of the buying organization.
· Insourcing: This describes
the process by which an organization takes responsibility for providing
services and conducting its operations in-house or in other locations but by
its own staff.
· Outsourcing: This gives or
describes contracting out services and operations that are usually conducted
in-house to other firms that can do them better, cheaper and faster.
· Efficiency: This implies
the minimum used of resources to reach goals. That is, doing things right.
· Effectiveness: This means
pursuing and reaching the appropriate goals. In other words doing the right
thing.
· Specification: This is the
careful, detailed and distinct description of an item, or service to be
supplied in which the supplied item must conform to.
· Standardization: The
formulation and evaluation at national and at company levels, to define and
prescribe the specified quality and/or performance characteristics of a
material, product and/or operations and service.
· Standards: Are a model, or
general agreement of a rule established by the authority, consensus or
customers and used by various levels of interests.
· Quality: Quality is the
degree to which a set of inherent characteristics fulfill requirements.
· Material: Anything that can
be offered to the market for attention, acquisition, use or consumption for the
satisfaction of needs is referred to as material.
· Purchasing: This term in
this context denotes the act of a function in an organization that is
responsible for the procuring of materials into the organization.
· Supplier: This refers to an
organization or a person who supply or releases goods or service to a buying
organization.
· Defect: This is a situation
where a component, material, product or service does not meet its requirements
or specification and needs to be repaired or replaced or rejected.
· Productivity: This means
efficient utilization of available resource at economic cost.
· Production: This is the
rate of units produced in terms of machines, labour, materials or any other
effective basis.
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