indian food specialities ltd

7/30/2019 Indian Food Specialities Ltd.

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Assignment 2

Operations Management I

Indian Food Specialties Limited

Section No. 5

Group No. AA1

Total Marks

Marks Obtained

Sr No. Name of Students Roll No

1

2

3

4

5


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1. Draw the R Chart and X bar for Mango Salt contentAns-

Sample size

X bar

chart R bar chartN A2 D3 D4

7 0.419 0.076 1.924

R' LCLr UCLr LCLx UCLx X''

0.865965 0.065813 1.666116 12.76445 13.49013 13.12729

0.00

0.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

2.25

2.50

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57

Range

Sample number

R-Chart

R'

LCLr

UCLr

R''


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2. What are your interpretations about the process, from each of the above charts?Comment on the specific observations and probable causes, if you find that the

process is not in control.

Ans- Process variability& average are clearly not in control& show that there are

some assignable causes which must be investigated to bring the process back in

control. Above charts show that process is not generating output, on average,

consistent with a target value set by the management for the process.

Probable causes are:-

Poor mango crop may have led to process variability getting out of control Workers may not be adhering to specific instructions given to them which

may have led to above issues

Chemical hazards such as aflatoxins, microbial hazards such as bacteria &physical hazards such as flint stones, hair etc might have led to the above

issues

12.25

12.50

12.75

13.00

13.25

13.50

13.75

14.00

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57

Average

Sample number

X-bar Chart

X'

LCL X

UCL X

X''


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As the process is out of control so as of now the company is having problem in

meeting specifications required by markets in UK & US

3. Draw the R Chart and X bar chart for Mango Acidity.Ans

Sample size X bar chart R bar chart

N A2 D3 D4

7 0.419 0.076 1.924

R' LCLr UCLr LCLx UCLx X''

0.140 0.011 0.269 1.573 1.690 1.631

1.250

1.500

1.750

2.000

2.250

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57

Average

Sample Number

X Bar Chart

x'

LCL

x"

UCL


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4. What are your interpretations about the process, from each of the above charts?Comment on the specific observations and probable causes, if you find that the

process is not in control.

Ans

R Chart

The process went out of the upper control limit two times. The process also exhibits a run pattern i.e. it is sloping continuously

downwards

Though the process is within the control limits for all other values, it showssome variability across the LCL and UCL

The company has been using the process from past when the qualityspecifications were not stringent.

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57

Range

Sample number

R - Chart

R

LCL

R'

UCL


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X Chart

The acidity content was above the upper control limit for the initial daysafter which it was under control for some time post which it went below the

lower control limit As observed from the chart, the level of acidity is out of control for most

part of the sampling process

This could be due to the fact that the company hasnt been stringent on thequality specifications front in the past. Thus, as the quality specifications

were implemented initially, the workers may not have been trained to handle

such quality checks and the acidity levels went above the upper control

limits

With the intention to bring acidity levels below UCL, the workers mighthave tried to lower down the content which could have resulted in the in-

control acidity for a short period

But again may be due to lack of training the process could have went belowLCL as workers must have tried to control the acidity and might have ended

up using low acids

A method to control these variations would be to train the workers in termsof quality. Since, they must have been used to the original quality and

composition standards from the past they need to be adequately trained.

Another probable cause could be an improper mixing process. The processshould be monitored so as to gauge the reason for any deviations from the

recently set standards

5. Is the process capable of meeting the acidity and salt specifications?Ans - To check if the salt and acidity is capable of meeting the process

specification we have to calculate the process capability index and processcapability ratio for both processes.

Salt Specifications:

Sigma


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(Ref:http://www.itl.nist.gov/div898/handbook/pmc/section3/pmc321.htm)

Where d2=3/(A2*sqrt(n))

Where A2 is 0.419

Sigma is calculated as 0.321

Xmean of mean=Grand Mean =13.13

Lower specification=12.5 Upper specification=13.5

Cpk=Min[(UpperSpecification-GrandMean)/(3sigma),(GrandMean-

LowerSpecification)/(3sigma)]

=Min[0.388,0.653]

=.388

A check for Variability

Cp=(13.5-12.5)/(6*.321)=.5192

The Value for Cpk is way below the critical limit 1(for a three sigma process and

the critical values need to get higher as we move towards better quality control

process like Five Sigma and Six Sigma). And going by the value of Cp we can say

that process variability is the main cause for the systems not being able to meet any

of the quality standards.


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Acidity:-

Sigma =

(Ref:http://www.itl.nist.gov/div898/handbook/pmc/section3/pmc321.htm)

Where d2=3/(A2*sqrt(n))

Where A2 is 0.419

Sigma is calculated as .05185

Xmean of mean=Grand Mean =1.63

Lower specification=1.50 Upper specification=1.70

Cpk=Min[(UpperSpecification-GrandMean)/(3sigma),(GrandMean-

LowerSpecification)/(3sigma)]

=Min[0.84,0.45]

=.45

A check for Variability

Cp = (1.70 -1.50)/(6*.05185)=.643

Even the acidity level shows that the process variability is extremely high to meet

any quality processes. Though the variability in acidity is lesser than in the salt

level its still below acceptable limits. The management should take measures to

reduce variability and run the test again to check for improvements.


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6. Mr Hemant Patil, QC manager is convinced with the idea of implementing SPCon the shop floor immediately, to control the process. What control limits

should he adopt? A qualitative discussion is sufficient.

Ans - As none of the processes meet any quality standard, we can start by applyingthe control limit for salt level (12.76-13.49) and for acidity(1.57-1.69). So using

this as the base we can reduce the causes of variability in this process. Once

significant steps are taken to reduce the variability, take another set of observations

and compute the value of CPk and Cp again.

SL NO Sigma Process CPk values

1 6 2

2 5 1.67

3 4 1.33

4 3 1.0

5 2 .67

6 1 .33

7. SPC is being followed, is it necesary to follow HACCP? Discuss.Ans -

The food industry cannot function completely based on statistics, apart from salt

and acidity levels there are certain other factors that are of more importance, likebacterial level, microbe level, and potential causes of health issues like food

poisoning. Here variability wont help much, since even one rare case could lead to

potential legal issues.


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As IFS has expanded abroad it has to be more stringent with regards to the quality.

HPCC would be essential since it would improve the overall hygiene, safety and

quality of their products. HPCC will also enable the system to identify various

risks and helps monitoring such activities. Managers should use HPCC to identify

various systems risks and examine the cases of failure. SPC would give us howmuch these measures have helped reduce the variability and improve the overall

consistency in the product.

indian food specialities ltd

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