IMPLEMENTATION OF QUALITY TOOLS IN SMALL MEDIUM INDUSTRY MIRZAN

IMPLEMENTATION OF QUALITY TOOLS IN SMALL MEDIUM INDUSTRY

MIRZAN AIDIF BIN MOHD SHAKHIR

A report in partial fulfillment of the requirements for the award of the degree of

Bachelor of Mechanical Engineering

Faculty of Mechanical Engineering

Universiti Malaysia Pahang

NOVEMBER 2008

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SUPERVISOR DECLARATION

“We hereby declare that we have read this thesis and in our opinion this thesis is

sufficient in terms of scope and quality for the award of the degree of Bachelor of

Mechanical Engineering”

Signature : ……………………………………..

Name of Supervisor : MR MOHD FADZIL ABDUL RAHIM

Position : ……………………………………..

Date : NOVEMBER 13th, 2008

Signature : ……………………………………..

Name of panel : ……………………………………..

Position : ……………………………………..

Date : ……………………………………..

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STUDENT DECLARATION

I hereby declare that this thesis entitled “Implementation of Quality Tools In Small

Medium Industry” is the result of my own research except as cited in the references.

The thesis has not been accepted for any degree and is not concurrently submitted in

candidature of any other degree.

Signature : ..........................................................

Name : MIRZAN AIDIF BIN MOHD SHAKHIR

ID Number : MA 05022

Date : NOVEMBER 13th, 2008

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Dedicated to my beloved Mother, Father, Sister and Brothers

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ACKNOWLEDGEMENTS

First I would like to express my grateful to ALLAH S.W.T. as for the

blessing given that I can finish my project. In preparing this paper, I have engaged

with many people in helping me completing this project. First, I wish to express my

sincere appreciation to my main thesis supervisor Mr Mohd Fadzil Abdul Rahim, for

encouragement, guidance, advices and motivation. Without his continued support

and interest, this thesis would not have been the same as presented here. Last but not

least I acknowledge without endless love and relentless support from my family, I

would not have been here. Father, mother, sister and brothers, you all have given me

the inspirations and encouragement until these days. Thank you all.

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ABSTRACT

Quality tools are one of the methods used to control and improve productivity by

many ways such as reducing the repetitive mistake. Quality plays such an important

role in the manufacturing industry in order to raise the profit of the company and also

the company’s name. SMI has many problems in their company specifically in the

processing line. This is because they just focusing in producing the products and not

taking the lack occur in the processing very well. This study is about to apply the

quality tools in the processing line in order to identify where the highest waste is

occur at and to give suggestion for improvement at the major waste involves in the

processing line. The selected SMI is producing spice which is one of important

ingredients in Malaysian food. There are four stages for producing spice, weighing,

roasting, grinding and packaging. Due to the interview there are two causes

contribute to waste, which are roasting and grinding process. From the data taken and

the analysis done, it shows the highest waste occur in the grinding process which

cause by four factors, expose to the moving fan, spices stick at the grind blade,

rotating gear and tupperware without lid. This shows that quality tools managed to

find the highest waste occur in the processing line. The company can reduce the

waste by put on the lid on the table used for cooling the spice, service the grinding

blade once after running three time to avoid the wet spices will attract more spices to

stick together, build a compartment at the rotating gear as obstacle and put on the lid

on the tupperware to ensure the spice will not getting away from the tupperware.

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ABSTRAK

Perkakas kualiti merupakan salah satu kaedah digunakan untuk mengawal dan

menigkatkan produktiviti dengan banyak cara antaranya mengurangkan kesilapan

yang berulang. Kualiti memainkan peranan penting bagi syarikat pembuatan untuk

meningkatkan keuntungan dan menaikkan nama syarikat. SSK mempunyai banyak

masalah di dalam syarikat mereka terutamanya di bahagian pemprosessan. Ini adalah

kerana mereka hanya fokus dalam penghasilan produk dan tidak mengambil

kekurangan di bahagian pemprosessan dengan baik. Pengkajian ini adalah tentang

menggunakan perkakas kualiti di bahagian pemprosessan untuk mencari dimanakah

berlakunya pembaziran yang tertinggi dan untuk memberi cadangan bagi

meningkatkan kawasan pembaziran major yang terlibat. SSK yang terpilih

menghasilkan rempah yang mana merupakan salah satu ramuan yang penting dalam

masakan orang Malaysia. Ada empat perigkat bagi menghasilkan rempah, timbang

berat, panggang, mengisar dan mempaket. Berdasarkan temubual ada dua penyebab

yang menyumbangkan pembaziran, yang mana adalah panggang dan mengisar.

Daripada data yang diambil dan analisis yang dijalankan, ia menunjukkan

pembaziran yang tertinggi berlaku di proses mengisar yang mana disebabkan oleh

empat faktor, terdedah kepada kipas yang bergerak, rempah melekat pada mata

pengisar, gear yang berpusing dan bekas tanpa penutup. Ini menunjukkan perkakas

kualiti berjaya mencari pembaziran tertinggi yang berlaku di bahagian pemprosessan.

Syarikat tersebut boleh mengurangkan pembaziran dengan meletakkan penutup pada

meja yang digunakan untuk menyejukkan rempah, servis mata pengisar sekali

selepas menggunakan tiga kali untuk mengelakkan rempah yang lembab menarik

lebih banyak rempah yang melekat, membina pengkotak pada gear yang bergerak

sebagai penghalang dan meletakkan penutup pada bekas bagi mengelakkan rempah

terkeluar.

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TABLE OF CONTENTS

Page

TITLE PAGE i

SUPERVISOR DECLARATION ii

STUDENT DECLARATION iii

DEDICATION iv

ACKNOWLEGDEMENTS v

ABSTRACT vi

ABSTRAK vii

TABLE OF CONTENTS viii

LIST OF TABLES xi

LIST OF FIGURES xiii

CHAPTER 1 INTRODUCTION

1.1 Project background 1

1.2 Why SMI 2

1.3 Scope of Project 2

1.4 Problem Statement 3

1.5 Objective 3

CHAPTER 2 LITERATURE REVIEW

2.1 Definition of Quality 4

2.2. Seven Basic Quality Tools 5

2.2.1 Check sheet 5

2.2.2 Pareto chart 6

2.2.2.1 Weight Pareto chart 7

2.2.3 Cause and effect diagram 9

2.2.4Conclusion of Seven Basic Quality Tools 10

2.3 Implementation of Quality Tools in previous case 10

2.3.1 Seven Basic Quality Tools (Pareto chart) 10

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CHAPTER 3 METHODOLOGY

3.1 Introduction 12

3.2 Literature Review on the topic 12

3.3 Define the objective, scopes and problem statement 12

3.4 Find the small medium industry 13

3.5 Interview 13

3.5.1 Important finding from the interview 16

3.6 Find the major defects and start taking data 16

3.7 Analysis 19

3.8 Conclusion 19

3.9 Chapter summary 20

CHAPTER 4 RESULTS AND DISCUSSION

4.1 Introduction 21

4.2 Results 21

4.2.1 Results of 10 random spices 21

4.2.2 Results of 3 Kurma spice 25

4.2.2.1 Data 1 25

4.2.2.2 Data 2 26

4.2.2.3 Data 3 28

4.3 Important finding from 3 data taken 29

4.4 Discussion 30

4.4.1 Expose to wind (fan) 30

4.4.2 Spices stick at the grinding blade 31

4.4.3 Tupperware without lid 33

4.4.4 Rotating gear 34

4.5 Suggestion for improvement 35

4.5.1 Case 1; Expose to wind (fan) 35

4.5.2 Case2; Spices stick at the grinding blade 37

4.5.3 Case 3; Tupperware without the lid 37

4.5.4 Case 4; Rotating gear 38

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CHAPTER 5 CONCLUSION AND RECOMMENDATIONS

5.1 Conclusion 41

5.2 Recommendation 41

REFERENCES 42

APPENDICES

Appendix A Interview 43

Appendix B Check sheet of 10 random spices and Kurma spice 44-46

Appendix C Data of 10 random spices and Kurma spice 47-50

Appendix D Gantt chart of PSM 1 and PSM 2 51-53

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LIST OF TABLES

Table No. Title Page

3.1 Check Sheet for taking of 10 random spices 17

3.2 Check sheet for taking 3 data of the selected spice 17

4.1 Data for Beriani spice, Kari Daging, Opor spice, 22

Kurma spice and Nasi Dagang

4.2 Data for Satay spice, Soto spice, Gulai Kawah, Kari Ikan 22

and Rendang

4.3 Data of waste during the process in kilogram (kg) for 22

Beriani spice, Kari Daging, Opor spice, Kurma spice

and Nasi Dagang

4.4 Data of waste during the process in kilogram (kg) for 23

Satay spice, Soto spice, Gulai Kawah, Kari Ikan

and Rendang

4.5 Data of waste during the process in percentage (%) for 23

Beriani spice, Kari Daging, Opor spice, Kurma spice

and Nasi Dagang.

4.6 Data of waste during the process in percentage (%) for 23

Satay spice, Soto spice, Gulai Kawah, Kari Ikan

and Rendang

4.7 Data 1 for Kurma spice 25

4.8 Waste during the process (data 1) 25

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LIST OF FIGURES

Figure No. Title Page

2.1 Because it clearly organize data, check sheet is 6

the easiest way to track information

2.2 Typically the left y-axis is frequency of occurrence, 7

and the right y-axis is the cumulative percentage of the

total number of occurrence.

2.3 The most frequently occurring defects are wrinkles 8

and stains. Based just on this information, it can decide

to develop and improvement project and around reducing

wrinkles and strains.

on weld hardness

2.4 The most costly defects are scratches and dirt specs. Based 8

on this more informative data, it can decide that it is better

to develop an improvement project to reduce scratches and

dirt specs.

2.5 Fish bone diagrams display the various possible causes of 9

the final effect. Further analysis can prioritize them.

2.6 Pareto chart of grinding operations problems. 11

3.1 PJ FOOD Industries 13

3.2 Flowchart of processing spices 14

3.3 Weighing process 14

3.4 Roasting process 15

3.5 Grinding process 15

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3.6 Packaging process 16

3.7 Flowchart of methodology 20

4.1 Graph shows the waste value in roasting and grinding 24

process

4.2 Pareto Chart of Defects (Data 1) 26



4.5 Fish bone diagram of causes waste in grinding process 30

4.6 Spices expose to the moving fan 30

4.7 Spices stick at the grinding blade (front view) 31

4.8 Spices stick at the grinding blade (top view) 31

4.9 Spices stick at the grinding compartment 32

4.10 Spices stick at the grinding machine 33

4.11 The spices move out from the tupperware 33

4.12 The rotating gear 34

4.13 Spices stick at the grinding machine 35

4.14 Top view of the table 36

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4.15 Cross section of the lid 36

4.16 Top view of the tupperware lid 37

4.17 Top view of the gear compartment 38

4.18 Side view of the gear compartment 39

4.19 Front view of the gear compartment 39

IMPLEMENTATION OF QUALITY TOOLS IN SMALL MEDIUM INDUSTRY MIRZAN

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