Total Quality Management and Quality Assurance in Salt Production and Processing

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Total Quality Management and Quality Assurance
in Salt Production and Processing

• Presentation by
• Lorenzo Locatelli-Rossi

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INTERNAL AND EXTERNAL QA

• Internal QC- are the procedures used by the
  producer/processor to ensure that their product
  consistently meet internal requirements and
  government and industry standards.
• External QC- periodic inspection by government
  regulatory body that confirm that products and
  procedures meets standards

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DEFENTION OF QUALITY ASSURANCE

• QA is a wide-ranging concept which covers all
  matters which individually or collectively
  influence the quality of a product.
• It applies to equipment, product design, supplies
  and logistics, management and human resources
  development.
• All elements designed to ensure that products are
  of the quality required for their intended use.

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TOTAL QUALITY MANAGMENT

• TQM is a management strategy to embed
  awareness of quality in all organizational
  processes (quality thinking).
• QA through statistical methods is a key
  component.
• Overall quality management influences company
  profitability.

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PROFITABLE BUSINESS

• No business can succeed if the product has no
  quality and guaranteed consistency.
• Consistent quality guarantee is closely linked to
  affordability.
• No one can afford inconsistent, bad quality and
  no guarantee. It is too expensive!

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W. Edwards Deming (1900-1993)
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STANDARDS

• In order to have quality we need Standards
• Standards are
• An accepted or approved example of something
  against which others are judged or measured.
• Guideline
• Point of Reference
• Ensures Consistency in the Product
• Guarantee of Quality

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TQM- AREAS OF INTEREST

• 1- Prime Requirements
• 2- Processing Technology
• 3- Production TQM and QA
• 6- Packing Iodized Salt
• 7- Warehousing and Dispatching
• 8- Marketing and The Consumer

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1- PRIME REQUIRMENTS

• 1a- People
• 1b- Factory
• 1c- Technology
• 1d- Salt (Raw Material)
• 1e- Iodate
• 1f- Spare Parts
• 1g- Packing Material
• 1h- Auxiliary Supplies

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1a- PEOPLE

• Every person
• Is an important investment
• Must know why their job is important
• Knowledgeable about the and product
• Given an opportunity to suggest ideas
• Ownership of his/her place of work
• Importance of participation

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1b- FACTORY

• Designed to be practical and economical
• Must be people friendly
• Allocate clearly defined spaces
• Proper place for resting/eating and lockers
• First Aid kit and person trained
• Emergency and fire points
• Kept clean all places at all times

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1c- TECHNOLOGY

• Appropriate Technology
• Vacuum process
• Washing/Refining process
• Rock Crushing process
• Re-Packing process
• 1- Investment Costs
• 2- Running Costs
• 3- Maintenance Costs
• Final Product Costs

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Technologycontinue

• Each process has a different
• 1- Investment Costs
• 2- Running Costs
• 3- Maintenance Costs
• These costs influence the
• Final Product Costs

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SALT 1d-

• The salt must
• Meet the Standards
• Stored in an appropriate place
• All the above factors have a cost implication.

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1e- IODATE

• Meets standards
• Stored in appropriate place
• Control of issuance of the product
• Always in stock sufficient quantities
• Avoid over supply (frozen capital)

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1f- SPARE PARTS

• Properly Stored
• Catalogued
• Control over issuance
• Know your supplier
• Replace immediately
• Spares cost money as a part and as in
  production

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1g- PACKING MATERIAL

• Supplied with bag/packs as per order
• Quantity
• Printing Quality
• Quality plastic/carton
• Proper size
• Tapes and glues
• Proper issuance procedure
• Hold appropriate quantity in stock
• Supplier keeps stock?

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1h- AUXILIRY SUPPLY

• Proper maintenance of all electrical equipment
  and cables
• Caution against danger
• Proper electrical links
• Stand-by generator (if appropriate)
• Appropriate stock of extra fuel
• Water Leakages

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What about the Prime Materials

• They all carry an investment cost
• Some are short term other long term investments
• They are all equally important and any
  additional cost must be avoided.

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How to Control costs/quality

• TQM applies principles of controlling the quality
  
• of machine-based factories operations to
• controlling the quality of people-based
• management operations

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2- PROCESSING TECHNOLOGY

• What ever the process, daily production data must
  be recorded. Data must include
• Time of start/stop and eventual breakdowns
• Specific reason/s for breakdowns and solutions
  adopted.
• Maintenance daily report list of areas requiring
  work.

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Processing Technology

• Plan for weekly, monthly and yearly maintenance
  program.
• TQM aims to do things right the first time rather
  than need to fix problems after they emerge and
  cause more problems.
• A bad or non existent maintenance plan is a
  costly business. There is no savings!

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Processing Technology

• Tally daily production with number of packs/bags
  issued.
• Tally the end of the month consumption of iodate
  and iodized salt production.
• Calculate plant capacity efficiency by comparing
  hours over tons of iodized salt

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PRODUCTION TQM and QA

• We focus on Iodized Salt
• 1- The processing equipment
• Tanks, pipes, pumps and nozzle or dozers daily
  check-up to ensure that are they clean and in
  good working order.
• Monitor even during production.
• If dry mix or a solution is the mix well
  prepared?
• 2- Iodization
• At the start, titration must be done continuously
  until standard has been achieved.
• After which, minimum once every hour.

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PRODUCTION TQM QA .

• Keep an hourly record every day
• Base your findings on titration not on the rapid
  test kit
• Chart the results
• Share the Results
• Make a monthly report
• Follow-up on issues that have been raised

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Charting Daily Iodizing Progress
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Packing Iodized Salt

• Guaranteed production of iodized salt needs to be
  packed and sealed in order to retain its
  guaranteed quality.
• Ensure that seams and seals can withhold
  transport/handling.
• Maybe a small pin-prick hole avoids problems
• Bag the packed salt in an orderly fashion

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WAREHOUSING AND DISPATCHING

• Goods to be protected from water, dust and other
  pollutants.
• Goods to be placed off the floor (on pallets) and
  away from the wall.
• Practice the First In Last Out (FILO).
• Ensure that trucks carrying the product have
  clean trailers and goods are covered

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MARKETING AND THE CONSUMER

• Iodized Salt pack/bag must have full details of
  the production company.
• It must indicate a Customer Care contact incase
  of product dissatisfaction.
• Prepare a complaints handling procedure.
• Product must state type and quantity of iodine.
• Interact with wholesaler/retailers if and when
  possible
• The customer is always right!
• Customer confidence builds business

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SUMMARY OF TQM / QA PRINCIPLES

• Set quality standards
• Monitor and record plant efficiency
• Plan for good maintenance program
• Involve/interact with workforce
• Measure iodization output against standards
• Define corrective action for non-compliance
• Focus on quality - TQM

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INCREASING AVAILABILITY OF IODIZED SALT

• Consumer education / awareness
• Prohibit the production, import and sale of
  non-iodized salt.
• Production facilities should interact with MoH
• Zero rated import duties on iodate
• Some form of tax rebate for producers as iodized
  salt is of national importance.