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(A CASE STUDY OF BENOK CERAMICS AND TRADING INDUSTRY ONNE, ELEME IN RIVERS STATE)
Abstract
This research work is proposed on application of statistical quality control in industry. (A case study of Benok ceramics and Trading Industry Onne, Eteme in Rivers State). The main aim to this study is to show the extent to which the application of statistics in quality control has helped to improve the economic and industrial sector; to find out if the defective production and distribution of ceramic tiles of Benok Ceramics and Trading Industry Onne was as a result of poor implementation of statistical quality control in the industry; to suggest possible methods to the observed problem facing the application of statistics in quality control. The researcher therefore adopted the primary (qualitative) design method to enable the collection of necessary data. The data was presented in a tabular form whereas the control chart for number of defects per unit (C- chart) and control chart for fraction of defectives (P-chart) was used to analyze the process. Conclusively,, the findings of this research shows that none of the points fell above or below the specification limits, and thus the process was in state of statistical control or simply in control. Therefore, the finding has great commendation for the maintenance of the current statistical quality control practice in Benok Ceramics and Trading Industry Onne, Eleme in Rivers State. Defectives products abound in Nigeria due to poor implementation of statistical quality control in manufacturing industries. Products were produced and distributed defectively without accreditations to deserving firm by appropriate standard body.
Table of contents
Cover Page i
Certification ii
Dedication iii
Acknowledgements iv
Abstract v
Table of contents vi
List of Tables viii
CHAPTER ONE 1
1.0 INTRODUCTION 1
1.1 STATEMENT OF PROBLEM 2
1.2 AIMS AND OBJECTIVES 2
1.3 SIGNIFICANCE OF STUDY 2
1.4 SCOPE OF STUDY 3
1.5 LIMITATION OF STUDY 4
1.6 DEFINITION OF TERMS 5
CHAPTER TWO 7
LITERATURE REVIEW 7
2.0 HISTORY OF STATISTICAL QUALITY CONTROL 7
2.1 THE THEORY OF QUALITY CONTROL 7
2.2 INTERNATIONAL STANARDS AND SPECIFICATION 8
2.3 QUALITY AUDIT, COMFORMITY AND CERTIFICATION 10
2.4 CONTROL CHARTS 11
2.5 CAUSES OF VARIATION IN A CONTROL CHART 12
2.6 PREVIOUS STUDIES IN QUALITY CONTROL 13
2.7 PREVIOUS STUDIES ON CONTROL CHART FOR C 16
2.8 PREVIOUS STUDIES ON CONTROL CHART FOR P 17
CHAPTER THREE 19
RESEARCH METHODOLOGY 19
3.0 INTRODUCTIONS 19
3.1 RESEARCH DESIGN 19
3.2 POPULATION STUDY 20
3.3 DESIGN EXPERIMENT/DATA COLLECTION 20
3.5.2 Control Charts of Attributes: 26
CHAPTER FOUR 30
DATA ANALYSIS/ RESULTS 30
4.0 DATA PRESENTATION 30
4.1 DATA ANALYSIS 30
4.2 RESULTS 35
CHAPTER FIVE 37
DISCUSSION, CONCLUSION AND RECOMMENDATIONS 37
5.0 INTRODUCTION 37
5.1 DISCUSSION 37
5.2 CONCLUSION 38
5.3 RECOMMENDATIONS 38
REFERENCES 40
List of Tables
TABLE 4.0: Reports the Number of nonconformities on ceramic 30
Table 4.2: Data Analysis Using P-Chart 33
TABLE: 4.1: Data Analysis Using c-chart 31
List of figure
Fig: 4.2. P-chart 34
Fig: 4.1. C-chart 32
CHAPTER ONE
1.0 INTRODUCTION
Manufacturers stock raw materials with poor quality and thus lead to production of defective products because the quality control measures were not affected on the noted production batch or lot.
This research on the topic “The Application of Statistical Quality Control in Industry”, which ought to cover all industries in Nigeria but due to some constraints like; finance, and some other uncontrolled factors and with the intention to coordinate the activity effectively was restricted to Benok Ceramics and Trading Industry, Onne, Eleme in Rivers State. Having once bought the economic tiles of Benok Ceramics and Trading Industry, I found out that some of their products were produced and distributed defectively. Therefore, numbers of non-conformities on ceramic tiles were taken in Ten (10) samples of size hundred (100) each from a lot to show if the defective products were as a result of poor implementation of statistics in quality control, and to show the extent to which the application of statistics in quality control has improved the economic and industrial sector.
However, in order to achieve these objectives, the application of some statistical concept in quality control to reduce the defect or error rate of products will be considered.
1.1 STATEMENT OF PROBLEM
The poor implementation of statistical quality control in Benok Ceramics and Trading Industry may result to:
i. Defective distribution of products
ii. Un-competitive market and
iii. Declining sales.
1.2 AIMS AND OBJECTIVES
The objectives of this research work are:
i. To show how some statistical quality control measure can be used to ensure total quality.
ii. To demonstrate the importance of some statistical quality control measure over the others.
iii. To monitor the stages of production process using control chart in order to ensure quality product.
1.3 SIGNIFICANCE OF STUDY
This study is concerned with the process through which information on the quality of product or services of an industry is collected, analyzed and conformity is ensured. The main motive of this study is to ensure that correct information is sourced and appropriate corrective measure take to avoid likely decline in business prospective. Also, this research project will be beneficial in understanding current, future customer’s needs, meets customer’s requirement. Since statistical quality control has to do with applying statistical methods or techniques with the goal of monitoring and maintaining conformity of the quality products. Quality has become a major business strategy for measuring productivity and gaining completive advantage.
Finally, statistical quality control come with numerous benefits in the sense that it also plays and integral in managements and process control. This study is based on the fact that no industry will operate and continue its existence effectively without primary concern given to the application of statistical quality control.
1.4 SCOPE OF STUDY
This research on the topic “Application of Statistical Quality Control in Industry” ought to cover all industries within Nigeria, but was restricted to Benok Ceramics and Trading Industry Onne, Eleme in Rivers State. Also, this project work consists of a great percentage of statistical techniques called “CONTROL CHARTS”. The various control charts within the range of this study are:
i. Control chart for mean (X-Chart)
ii. Control chart for range (K-Chart)
iii. Control chart for standard deviation (Ō)
iv. Control chart for fraction defectives (p-Chart)
v. Control chart for number of defectives (np-Chart)
vi. Control chart for number of defects (c-Chart)
However, because of the importance of some statistical techniques over the other in detecting defective items, the control chart for number of defects (C-chart) and control chart for fraction defectives will be applied.
The reason the above two techniques are:
i. The control chart for number of defect in this project will be applied to control the member of defects per unit of Benok Ceramics tiles.
ii. The control chart for fraction defective will be applied in this project work to control the percentage or proportion of defectives per sample of Benok Ceramic tiles.
1.5 LIMITATION OF STUDY
The greatest limitation was that the financial inadequacy, this therefore, hindered the range at which this project worked would have covered and the intention to co-ordinate the activities of this study to effectively, therefore, made me to restrict this study to Benok ceramics and Trading Industry Onne, Eleme in Rivers State.
1.6 DEFINITION OF TERMS
Quality control is a part of quality management (150 900:2005) focused on the fulfillment of quality requirements. It is a systematic process to monitor and improve the quality of product, e.g. manufactured article or service by achieving the quality of the production process and the product in plan. A list of basic terms and definitions in accordance with the 150 standard follows:
Product: A result of a process.
Defect: Non-fulfillment of a requirement related to an intended or specified use.
Measurement Process: A set of operation to determine the value of a quantity.
Key characteristics: A quality characteristic the product or the service should have to fulfill customer’s requirement and expectation.
Value: Value of key characteristics for several products a simple value is the desired quality level of a characteristics.
Nominal or target value: It is almost impossible to the next; consequently, it is nonsense for identical items having a key characteristics value. This need for flexibility is supported by the introduction of limit and tolerances.
Specification limit: This is the level of tolerance or conformance boundary, range specified for a characteristic.
Lower specification limit (LSL): Is the lower conformance boundary.
Upper specification limit (USL): It is the upper conformance boundary.
The following equation summarizes the relationship between these terms:
One sided tolerance: It relates to characteristic with only one specification limit.
Two sided tolerance: It refers to characteristics with USL and LSL.
Nonconformity: It is a non-fulfillment of a requirement. It is generally associated with a unit; a non-conformity unit, i.e., a unit that does not meet the specification.
Non-conforming product or service: A product or service with one or more non-conformities. A non-conforming product is not necessary defective I.e. no longer fit for use.
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