final quality management and productivity analysis(1)

8/13/2019 Final Quality Management and Productivity Analysis(1)

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QUALITY MANAGEMENT ANALYSISPakistan Tobacco Company

Group Members:

Hiba Mujeeb

Imtisal-e-noor

Arooj Fatima


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In 1947 took over the businessof the Imperial Tobacco

Company of India and became

part of the British AmericanTobacco Group

Remarkable supporter of social

responsibility

Vital role in development andprogress of the industrial and

agricultural sector

Leading Tobacco Companywith the highest market share

and the highest tax payer

Pakistan TobaccoCompany

First multinational in Pakistan


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Mission Statement

Transform PTC to perform with the speed,

flexibility and enterprising spirit of an

innovation, consumer-focused company


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Why We Chose PTC?

1stmultinational

company inPakistan

Tobaccoindustry

works at amega scale

Internationalimpact

Dataavailability


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First choice

Transform PTC to perform

with the speed, flexibility

and enterprising spirit

Regain volume leadership by

positioning viable brands

Drive W/C standards in products ,

Processes and services.

Strive to meet stakeholder expectations


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Business Principles

Mutualbenefit

ResponsibleProduct

Stewardship

GoodCorporateConduct


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Brands Offered


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Factory Layout

The factory is:

A state of the art manufacturing wonder

Certified by ISO-9001

Boasts the title of being the only 5-S certified

company

Plant area is divided into two main parts:

Primary Manufacturing Department (PMD)

Secondary Manufacturing Department (SMD)


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Over All Manufacturing Process

Manufacturing process main objective:

maximum productivity

maintaining quality

Each step is monitored by

computers

human eye

The manufacturing process is divided into two

parts, PMP and SMP.


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Primary Manufacturing Process

Primary Manufacturing Process


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Check Points

There are two quality check points in primaryprocess :

After conditioning tobacco where continuously

monitored Temperature

Moisture level

And at the end to assure quality five samples are

taken and examined in laboratory for: Moisture

Particle size


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Secondary Manufacturing Process

Secondary

Manufacturing Process


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Check Points

Each filter rod is inspected using high speed computerizedequipment called the Quality Testing Modules (QTM).

The MCBs from PMD are scanned for bar-codes, if the bar code is amatch with the maker machine, it means that the tobacco blend isfor the same brand that is currently being made on this machine.

All cigarette making machines are also equipped with QTM whichvisually inspects cigarettes for defects and if found any, cigarettesare discarded and sent for recycling.

Packets are then monitored visually by machines and humans.Faulty packets are discarded and sent for recycling

In between the PMD and SMD there is a small department calledthe Ripping department. Here all the discarded cigarettes areripped using rippers and tobacco is separated from the paper andfilters.

Moisture and temperature of ripping department is also monitoredand controlled.


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QUALITY MEASURES IN

PRACTICE AT PTC


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Pakistan Tobacco Company

Quality Policy

Following the quality standards set by BritishAmerican Tobacco Group International

Zero defects resulting in zero accidents

Customer satisfaction comes first

Carefully evaluating and maintaining qualitymeasures.


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Parts Of Quality

Their policy helps them to divide their

definition of quality into two parts,

product quality

method and manpower quality


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Product Quality

The extent to

which the finishedproduct meets the

expectations ofcustomers and the

specifications


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Physical

Attributes

Moisture

Fill Value

Particle Size

Pressure

Drop

Smoke Yield

Visual Attributes

Brand

Markings

Appearance Of

Packet &Cigarette

Ends Fall Out

Circumference

Tip Ventilation

Product Quality Attributes


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Major Tools For Quality Checking Frontline quality checking measureIMIIncoming Material

Inspection

Ranking of quality parametersCOPSContinuous OptimizationOf Primary Process

Database of all the quality based dataQUISQuality InformationSystem

Identify problems with pictorial representationEQUATAExhibit QualityTraining Aid

Measures all the quality parametersQTMQuality Testing Module

Measures quality of the finished productFPI Final Product Inspection

Deal with the problem of mixing of brandsPI & T - Product Integrity AndTraceability

Manages and monitors the suppliers of PTCC- Track System


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Possible Defects

All possible defects are classified into three

categories on the basis of their prominence

A-Rank: Obvious to all. 100% rejection of product

B-Rank: Noticeable by quality conscious only. Stop

production and rectify

C-Rank: only experts can identify. Continue

production and maintain machinery to removefault


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An exercise is conducted once a month which isused to check the quality and effectiveness ofmethods

Internal Audits Of

SMD And PMD

Quality circle meeting are attended by a group ofQuality related personnel.

Quality Circle

Meetings

This is an approach used at PTC to achieve zerodefects in terms of Machines, material, methodsand manpower related defects.

Approach To ZeroDefects

All the work force, including the workers,

machine operators, Quality Assurance personneletc are properly trained for their tasks.

Training And

Refresher Courses

This is another step taken by PTC to make theirwork force able to do their task right at the first

time with zero defects and being safe.

Fsep -Foucused Skill

Enhancement

Program


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KAIZEN: Continuously Looking For

Improvements

PTC has award winning quality measures but still

they are not sleeping over it.

They are constantly looking for improvements and

new methods of increasing quality. Continuously looking for better suppliers who supply

high quality raw materials.

This the reason why PTC does not make long term

contracts with its suppliers.


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Quality

ManagementAnalysis

tools appliedat PTC

Paretoanalysis

Process flowchart analysis

Cause andeffect

diagramanalysis

Benching themark

Statisticalprocesscontrolcharts

analysis


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Pareto Analysis Of PTC

One of the most effective cost-analysis tool.


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Process Flow Chart Analysis Process has been designed very carefully and

is integrated with QUIS system.

There are several quality check points after

every main process

Quality is tested on selected parameters


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Cause And Effect Diagram Analysis

The cause and effect diagram is used for

tracing back problems to their causes

A problem caused by the 4 Ms is detected.

The 4 Ms are:

Machine

Manpower

Material

Method


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Benchmarking

The process of benchmarking in PTC is done

internally. It compares the practices and

performance of similar business units or

business process that are already being used


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Statistical Process Control

SPC Charts are used to assure that products

are made according the specifications

If the process goes out of the pre-defined

limits, the manufacturing process is halted

immediately and the problems are identified

and solved

The Control Limits and the average values for making these charts were not.


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Quality Function Deployment : House

of quality

House of quality, These factors impacts the

overall quality

Moisture

Quality of tobacoo

Pressure drop

Particle size

Fill value

R & D and Manufacturing Quality Index


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Recommendations contd

Establishing direct connection between filter

making and cigarette making process

Taking proactive measures for reduction of

wastage


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Conclusion

PTC has state of the art quality assurance and

quality control measures.

However there is no end to improvements in

Quality the concept of kaizen which implies

gradual and continuous improvement is still

valid.


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Disclaimer

We do not condone smoking in any way.

Smoking is injurious to health

Video hyperlink


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