ift2003-the need for continuous improvement

8/8/2019 IFT2003-The Need for Continuous Improvement

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The Need forContinuous Improvement

Jeffery CawleyNorthwest Analytical


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Continuous Process Improvement

CPI - Continuous Process Improvement What is CPI?

What are the Implications of CPI?

Why use CPI?

How do we achieve CPI?


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CPI - What is it?

A way of doing business - not an isolated project Goal - stable processes

Goal - capable

Means - process monitoring & control

Means - process improvement projects

Continuous variation/waste reduction


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Why Process Control?

The best business model

Enables successful inspection systems

Business necessity

Economic production Risk reduction

Supply chain considerations

Simplify audit

Vendor certification


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Statistical Process Control is the term for statisticalanalysis methodologies developed by WalterShewhart and popularized by W. Edwards Deming.

Monitors process stability - alerts to excessiveprocess variation

Evaluates the process capability to meetspecifications

SPC - The Tool for Process Control


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Control Chart


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Process Capability


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Process Capability


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Process Capability


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Inspection & Process Control

Different ViewsYou only get the quality you inspect for

vs..

You only get the quality you build in

Appropriate roles


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Appropriate Use of Inspection

Process not capable of producing perfect product

Production of defective product has serious consequences.

Process not capable of meeting customers needs andrequirements.

Little process history is known


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Inspection Caveats

Inspection is never 100% effective

Cannot inspect quality into a product


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HACCP & SPC

FSIS has concluded that statistical process controltechniques will provide experience in ``process thinking'' (acentral tenet of HACCP), develop an historical record of

performance, and permit evaluation of the long-term stability ofa process and determination of process capability (that is, howthe process is actually working), and track the effectiveness ofprocess improvement actions.

Federal Register, v.62, #92, May 13, 1997, p. 26213


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HACCP & SPC

The emphasis of food safety regulatory agencies must continueto be on prevention, reduction, or elimination of foodbornehazards along the food production, processing, and distributioncontinuum, rather than on inspection of the end product.

Statistical Process Control linked to continuous improvementmust be part of food safety regulations. The concept of

continuous improvement is central to food safety.

Excerpt from Summary Findings

Scientific Criteria to Ensure Safe FoodNational Academies of Science


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HACCP & SPC

SPC enabling successful HACCP program

Process control monitoring provides early alert toproblems.

High capability process enabling production of acceptable

product even when system stressed


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The Faces(?) of the Enemy


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http://www.nwasoft.com/press/mag_haccp.htm


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Risk Management

Recalls

Food Safety

Fill Weight/Portion Control


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ConAgra - Portion Control

Drivers

Regulatory Cost Avoidance Supply Chain Requirements

Giveaway Reduction

CPI

Implementation Results

www.nwasoft.com/appnotes/conagra.htm


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Food Processors Product Recall

Risk Management

The Hartford

http://mb.thehartford.com/view_industry/tips_food.asp

Risk Management


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SPC - Necessary for Business

CPI

Within Enterprise Reporting

Multi-Location, Complex Organizations

Benchmarking Best Practices

Supply Chain Quality Reporting

Contractually Required Deliverables

Vender Certification

Bid Requirement


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Vendor Certification - USDA AMS

http://www.ams.usda.gov/lsg/cp/beef/beef_whatsnew.htm


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Vendor Certification - USDA AMS

Quality ControlProgram Approved

by AMS

Process AssessmentStatus

20 Consecutive Lots

ProcessCapable?

IneligibleSupplier/Contractor

ProcessCapable?

Conditional Status ProcessAssessment of 20

Consecutive Lots within 30production days

NO

NO

YES

YES

AMS PROCESS

REQUIREMENTSFLOW CHART


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CPI

The Best Model for Long-termCorporate Success

Vendor/Customer Relations

Risk Management

Profitability

Survive/Thrive Question


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The concept of

continuous improvementis central to food safety.

National Academies of Science


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Northwest Analytical, Inc.

519 SW Park Ave.

Portland, OR 97205USA

1-503-224-7727www.nwasoft.com

[email protected]

[email protected]

ift2003-the need for continuous improvement

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