QS626 Phase II Short Form by a2302339

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									                     QS626 Phase II
                     Short Form
              Presented to: Dr. John Sinn
                      Spring 2004

Assessment of Hirzel Canning Company Quality System
Utilizing the Industrial Technologist’s Toolkit for Technology
     Management System and Applicable ISO Standards

                       James Hale
                      Josh Seigley
                      Dennis Doren
          Short Form Content
•   Team and Project Information
•   Undergraduate Team Information
•   Toolkit 15 Summary
•   Toolkit 16 Summary
•   Toolkit 17 Summary
•   Phase I Summary
          Short Form Content
•   Phase II Work
•   Undergraduate SDA Information
•   Toolkit 18 Summary
•   Toolkit 19 Summary
•   Toolkit 20 Summary
•   Conclusions
•   Recommendations
                  Team: QS626
Team QS626 is comprised of graduate students and
  professional instructors from various industry sectors.

Through ongoing consultation, our team will rely on
  experience and knowledge to develop a working
  model of a Quality Management System for the
  Food Industry while utilizing the forms and
  procedures of the ITTTM Toolkit System.
           Project Description
Our team will use ITTTM Toolkit System to develop a
preliminary quality management model for Hirzel Canning
Company located in Walbridge, Ohio. The model will
utilize the ISO system as the foundation to be built upon.
Incorporating various food industry standards and policies
will be required and developed into the new model.
          Project Objectives 1 - 2
1. Complete six toolkit assignments, assessing four
   SDAs in each toolkit against comparable elements
   of a (real or simulated) organizational quality
   system, or modifying tools to enhance
   organizational quality system, presenting findings,
   recommendations as phase reports.
2. Assess Hirzel Canning Company’s quality system
   to determine extent of compliance with appropriate
   ISO 9001 standard and HACCP principles to show
   clearly how quality is maintained in their product.
         Project Objectives 3 - 5
3. Develop team portfolio reflecting 24 SDAs and 4
   continuously improved RCAs in ―grand‖ forms
   addressing main elements of appropriate ISO 9001
   standard and HACCP principles.
4. Conduct on site visits to Hirzal Canning Company
   and gather appropriate data to support the new
   quality management model.
5. Guide and mentor the undergraduate teams as they
   utilize the toolkits to achieve their project goals.
          Problem Statement
Due to recent issues in the Food Industry, there is a need to
develop a quality management system that can provide the
necessary support that traditional methods lack.


           Purpose of Study
The purpose of this study is to develop a quality
management model for the Food Industry to cover Food
Quality, Food Safety, and Food Security Issues.
       Assumptions/Limitations

• Understanding that the scope of this project as a whole is
  extremely large and is quiet an undertaking. The goal or
  purpose of this team is to develop the underling model that
  will support the new Quality Management System for the
  Food Industry based on the ISO 9001 standard.
               Methodology
•   Research data and process insight were gathered
    by working on toolkits 15-20 from The
    Industrial Technologist’s Toolkit for
    Technology Management (Dr. John Sinn, 2003).

•   On-line meetings were held weekly to discuss
    and evaluate the progress of the project, with
    guidance from Dr. Sinn, using meeting agendas
    and summaries.

•   On-line discussion board was used to archive
    findings and share our work.
Undergraduate Structures
Undergraduate Structures
       Team #1
                                          Ferhan Ozadali
                                         Director R&D / QA
                                              at Hirzel



                      John Sinn                                   Errol Samuel
                  Professor: QS 626                             Professor: QS 326
                        BGSU                                          BGSU

                    Dennis Doren
                  Mentor / Facilitator



   Josh Seigley                       James Hale
  Team #1 Mentor                    Team #2 Mentor




                                            David Luth                            Team #2
                                          Team #1 Leader

                      Ben Pigman
                    Assistant Leader


      Subgroup #1                 Subgroup #2                  Subgroup #3           Subgroup #4
  Retail / Food Service         Industrial / Bulk               Traceability            Labels
  Containers / Closures       Containers / Closures        Internal Shop Orders     Standardization

       David Luth                  Jesse Brotje              Justin Bayham            James Rutti
      Jason Grubb                  Justin Dean                Ben Pigman             Curtis Hudberg
       Undergraduate Structures
              Team #2
                                                            •Ferhan Ozadali
                                                          •Director R&D / QA
                                                           •Hirzel Canning Co.

                               •Dr. John Sinn                                     •Errol Samuel
                               •Professor 626                                    •Professor 326
                                   •BGSU                                             •BGSU

                                •Denny Doren
                             •Lean Manufacturing
                                  Facilitator

         •Josh Seigly                                  •James Hale
       •Team 1 Mentor                                •Team 2 Mentor



         •Team 1                                       •Team 2


                                                      •Jim Gallagher
                                                      •Team Leader


                                                      •Teri Jo Wise
                                                     •Assistant Team
                                                         Leader

   •Bulk Ingredients                            •Rest of the Ingredients                      •Traceability
    •Process Team                                   •Process Team                            •Process Team
•Corn syrup, vinegar, etc.                                                           •Paper and accountability trail in
                                          •Tomatoes, peppers, cabbage,
                                                                                          the processing flow.
                                          etc
     •Jim Gallagher                                 •Marc Thomas                              •Teri Jo Wise
     •Marc Rairden                                    •Eric Fritz
    Completed Phase I Toolkits:
• Toolkit 15 - Statistical Foundations for Data-Based
  Improvement, Lean, Six Sigma Solutions

• Toolkit 16 - Attribute Data, the Obvious Starting
  Point for Lean, Six Sigma, Service

• Toolkit 17 – Variable Data, Comparisons to
  Attribute Charting for Six Sigma, Lean Service
                  Toolkit #15
• Overview of new TS 16949 Quality Standard.
• Quality Management System, Management Responsibility,
  Resource Management, Product Realization, and
  Measurement, Analysis, and Improvement.
• Basic Statistical Principles.
• Techniques in SPC, including random sampling,
  acceptance sampling, histograms, frequency charts, and
  run charts.
                    Toolkit #16
• Statistical principles in quality—more basic definitions
• Normal curve, variation, and standard deviation as
  foundations, six sigma
• Additional perspective: attributes and check sheets as pre-
  control
• Attributes, checklists and charting, and more for lean,
  service
• Quality characteristics, accurate data and variable charting
  introduced
• Team based problem solving, six sigma variation reduction
  for lean
                    Toolkit #17
• Organization wide understanding of data types and uses for
  each type, attribute and variable.
• Various charts utilized for each data type.
• Sampling program developed to minimize cost, but
  effectively represent the population.
• Cp and Cpk used to determine if process is in or out of
  control.
• SPC allows operators to adjust process on the fly.
• Attribute data is judgmental, therefore, varies between
  operators.
• DOE’s used to refine process only after it is in control.
    Completed Phase II Toolkits:
• Toolkit 18 - Basic Measurement, Geometric
  Relationships, Broader Data-based Issues

• Toolkit 19 - Gauge Repeatability And Reproducibility
  (R & R): Inspection And Measurement As Critical
  Services For Lean

• Toolkit 20 – Capability, Charts And Quality
  Characteristics Analysis: Transitioning Six Sigma and
  Lean
         Undergraduate SDA’s
• The following slides represent a suggested course
  for the undergraduate team to follow with respect to
  SDA selection and implementation. It is dually
  noted that the SDA’s represented are only
  suggestive, and it is up to the individual
  undergraduate team to identify which SDA’s they
  wish to complete that will yield the best information
  on their project scope.
      Undergraduate Recommended SDA’s
        Retail / Food Service Containers


• Toolkit 18 – ROI & MMA

• Toolkit 19 – CEAS & SOGA

• Toolkit 20 – CTTIC & SOGA
      Undergraduate Recommended SDA’s
          Industrial / Bulk Containers


• Toolkit 18 – ROI & MMA

• Toolkit 19 – CEAS & SOGA

• Toolkit 20 – CTTIC & SOGA
      Undergraduate Recommended SDA’s
      Traceability for Internal Shop Orders


• Toolkit 18 – ROI & MSTTIC

• Toolkit 19 – CEAS & SOGA

• Toolkit 20 – CTTIC & SOGA
      Undergraduate Recommended SDA’s
             Label Standardization


• Toolkit 18 – ROI & MSTTIC

• Toolkit 19 – CEAS & SOGA

• Toolkit 20 – CTTIC & SOGA
      Undergraduate Recommended SDA’s
               Bulk Ingredients


• Toolkit 18 – MMA & MSTTIC

• Toolkit 19 – GRARS1 & GRARS2

• Toolkit 20 – A-VCS & CACES
       Undergraduate Recommended SDA’s
            Other Ingredients Teams


• Toolkit 18 – MSAE1

• Toolkit 19 – CEAS

• Toolkit 20 – CC & SOGA
       Undergraduate Recommended SDA’s
              Traceability Process


• Toolkit 18 – ROI

• Toolkit 19 – GRRTTIC & SOGA

• Toolkit 20 – CTTIC
                    Toolkit #18
• Introduction of basic metrological principles and tools
• GD&T is a language for communicating mechanical
  engineering design specifications
• Hand held measurement devices include rules, calipers,
  micrometers, dividers, small hole gages, and telescoping
  gages.
• Basic measures are useful in industry to help give
  meaning, through standard values, for inspection.
                    Toolkit #19
• Lean systems with respect to Gage R & R
• Variation reduction can be made by reducing measurement
  error
• Inspection procedures are essential to providing optimum
  quality
• In-process inspection completed on all products, processes,
  and production phases, including equipment
• Certification should include all pertinent test data,
  sampling plans, and final inspection results
                    Toolkit #20
• Capability analysis provides a set of statistical tools to
  determine the capability of a system.
• Capability is the comparison between the system’s ability
  to perform and its specification limits.
• Control charts indicate the stability of the system.
• Unstable systems produce unreliable information and poor
  product.
               Conclusions
• In the development of the QS Management Model,
  there were several areas that were found to be
  important.
   – Attribute Vs. Variable Systems
   – Sampling
   – Evaluation of quality characteristics--
     HACCP, ISO/QS, NFPA
   – General Capability Issues
   – Training
   Attribute Vs. Variable Systems
                        Checklists Or
                        Check sheets
                         For Tracking



                      Definitions Will
Attributes
                 Differ For Acceptability       Variables
 Defined         And Defective, Based On        Defined
                    Discrete Type Data



                       Non-conformities
                         For Ongoing
                        Improvements

            Variables And Attributes Defined As
         Tracking, Pre-control, Improvement System
                               Sampling
                                          Sample Size
                Lot Size      Normal     Tightened    Reduced

              2 to      50       5            13           5
             51 to      90       7            13           5
             91 to     150       11           13           8
            151 to     280       13           20           8
             281 to     500      16           29           8
             501 to 1200         19           34           9
            1201 to 3200         23           42           9
            3201 to 10000        29           50           9
           10001 to 35000        35           60           9
            35000 to 150000      40           74           9
           150001 to 500000      40           90           9
           500001 and over       40           102          9



Sample Sizes Of Normal, Tightened Or Reduced As A Function Of Lot Size.
Evaluation of quality characteristics--
      HACCP, ISO/QS, NFPA
• HACCP, ISO, and NFPA are the most
  commonly used standards in the food
  industry.
• Each tool kit utilized correlated to these
  standards.
• Tool kits used related directly to 1 or
  more elements in each standard.
         General Capability Issues
•    Design and construction, maintenance
•   Fixturing, tooling, gage capabilities
•   Variations among operators, others
•   Variations in tooling, materials, setups, SOPs
•   Method-feeds, speeds, flowrates, workrates
•   Environmental temperature, power, dust, etc.
•   Costs and implications of the problem?
•   Is it a problem or actually a symptom?
•   Is the problem improving? Others related?
•   Have cause/effect analyses been done?
•   Has documentation been provided?
                    Training
• Training is important to the when empowering
  team dynamics.
• Everyone must contribute to continuous
  improvement efforts.
   –   SPC
   –   Measurement Systems
   –   Gage R&R
   –   Data
   –   Capacity
                 Objective 1
• Six toolkit assignments were completed
  throughout the course. SDAs were assessed and
  fine tuned then given to the undergraduate 326
  course teams. Each toolkit was compared against
  elements of a real organizational quality system
  that will aid in the foundational develop of a
  quality management model for a seasonal food
  processing facility. This was completed at Phase I
  of the Food Quality, Safety, and Security
  Management System (FQSSMS) project.
                Objective 2.

• Throughout the course, team portfolios were
  developed reflecting continuously improved RCA
  project focuses, along with article reviews
  pertaining to the food industry. In conjunction
  with the undergraduate SDAs in a ―grand‖ form,
  main elements of the appropriate ISO 9001 and
  HACCP principles were taken. Not all SDAs
  applied to what to the overall model. This may
  have been because of the scope and limitations of
  the toolkits.
             Objective 3.

• Multiple visits were made to the Hirzel
  Canning Company’s facilities to determine
  the extent of compliance with appropriate
  ISO 9001 and HACCP principles. These
  visits gave clarity to how quality is
  maintained in their product, which was
  documented within the appropriate SDA’s.
               Objective 4
• Leadership and guidance for the two 326
  undergraduate course teams was limited due
  to expectations of the instructors. However,
  assistance was given in terms of the SDAs
  incorporated into the models and
  understanding of various project tasks
  identified by their instructor.
              Objective 5.

• Framework was provided for the continuous
  development of the FQSSMS project. The
  toolkits used for the spring semester were
  limited in terms of Data Tools, other tools
  throughout the ITT will definitely apply
  more solid substance to the overall model.
               Objective 6.

• A matrix was constructed of SDAs
  identified for statistical applications.
  Beyond the SDA’s identified, additional
  information was provided to support future
  FQSSMS progress.
                Recommendations
• Standardization Efforts
• Training
    –   Six Sigma
    –   Lean Manufacturing
    –   Gage R&R
    –   Etc.
•   Team Dynamics
•   Communication
•   Labeling Traceability
•   5S
                     Cont.
• Combine HACCP, assessment posting on
  –   5s
  –   Standardization
  –   Cultural Awareness
  –   Documentation Structure
  –   Etc.
• Toolkit for future student project
  management
                   Cont.,
• All assumptions based on learning through
  – Knowledge
  – Applications
  – Skills
                      Cont.
• Main concerns for project management in
  Manufacturing for undergrad students is lack of
  experience on the shop floor.
• For many this is the first time in manufacturing or
  using continuous quality tools.
• This our recommendation is revision of the ITTM
  and combination of assessment to assist walking
  through application
        Our Eecommendation
• Revision of the ITTM and
• Combinations of assessment
• Assist students in walking through
  application

								
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