CP 320

QUALITY CONTROL IN CHEMICAL

AND FOOD INDUSTRIES

Course Instructor:
Divina D. Kaombe, PhD
Tel. 0788 999689; Email: [email protected]
 Objectives
• The course objective is to impart knowledge
to student on application of quality control
principles in chemical and food processing
industries.
 Learning Outcomes
At the end of the course students will be able to:
• Define the term quality, food quality and food
safety
• Explain why quality is important and the
consequences of poor quality
• Identify the determinants of quality
• Describe the costs associated with quality
 Learning Outcomes …
• Describe TQM, GMPs, SOPs, SSOPs, HACCP,
and ISO 9000 and 21000 series.
• Give an overview of problem solving
• Give an overview of process improvement
• Describe and use various quality control tools
• Explain how to implement statistical tools to
improve quality.
• Use sampling procedures to make decisions
and solve problems
 Pre-requisite
• Engineering Mathematics (MT 271)
 Mode of Delivery
• Lecture: 2 hours per week
• Tutorial: 2 hour per week
• Total hours: 60
• Credits: 8
 Course Assessment
The course will be assessed as shown below:
• Continuous Assessment (Tests, Quizzes and/or
Homework): 40%
• University Examination: 60%
 Course Contents
• Chapter 1: Introduction to concepts of quality,
food safety, quality assurance and quality
management; objectives, importance and
functions of quality control. Current
challenges to food safety.
 Course Contents . . .
• Chapter 2: Principles of quality assurance,
total quality management (TQM) – good
manufacturing/management practices, good
hygienic practices, good lab practices, general
awareness and role of management practices
in quality control.
• Chapter 3: Quality programs
• Chapter 4: Food safety management,
applications of HACCP in food safety.
 Course Contents . . .
• Chapter 5: Statistical quality control in
chemical and food industry.
– Statistical tools used in quality control
(histograms, Pareto charts, cumulative probability
functions, Six-sigma).
– Process capability.
– Application of control charts in process industries.
– The role of sampling in quality control: Sampling
and sample management techniques; Acceptance
sampling.
 Recommended Textbooks /
References
1. Merton R. Hubbard, Statistical Quality
Control for the Food Industry
2. Mark Clute, Food industry quality control
systems
3. George B., Gwilym M. J. and Gregory R.
(2006) Time Series Analysis: Forecasting &
Control (3rd Edition),
4. Hans-J. L, Peter T W, and Wolfgang S. (2008)
Frontiers in Statistical Quality Control.
 Chapter 1
Basic Quality Control Concepts as
applied to Chemical and Food
Industries

Introduction to concepts of quality,

quality assurance and quality
management; objectives, importance
and functions of quality control
 Definition of Quality
• Consider a food product.
– If foreign matter is found in a food,
– If the product is discolored or crushed or
– If causes illness or discomfort when eaten.
• The consumer reacts with anger, fear, and sometimes
mass hysteria (i.e. panic, madness, emotion).
• The offending product is often returned to the seller, or a
disgruntled letter is written to the manufacturer, or at
worst, an expensive law suit may be filed against the
company.
• The reaction is almost as severe if the failure is a difficult-
to-open package or a leaking container. There is no
tolerance for failure of food products.
 Your conclusion about this
product?

Good product!!!
Buy this product again!

Recommend to friends!

??? Quality of the Product!!!

 Definition of Quality
▪ Quality in its broadest sense
– Merriam Webster’s Collegiate Dictionary,
10th Edition(1994) defines quality as
“an inherent feature; degree of excellence;
and superiority in kind

Quality is a result
Quality is the result of a comparison between what was
required and what was provided. It is judged not by the
producer but by the receiver.
 Definition of Quality
▪ Some definitions that have gained wide acceptance
in the business world
▪ “Meeting or exceeding customer expectations”
▪ Juran, one of the quality qurus, defined quality
as;
▪ Fitness for Use
▪ That is, Quality is the extent to which
something is fit for its purpose.
 Definition of Quality
▪ Based on Juran‘s definiton, Quality therefore
does not only have to be perceived by the
customer, but the customer experience of
quality of a product or service is more
important.
▪ It places emphasis on the consumer aspect
of quality.
▪ It emphasizes that requirements and
specifications translate fitness for use into
measurable quantities.
▪ Quality does not mean an expensive product
 Definition of Quality
• Quality is conformance to requirements
or specifications.
– This is the definition used by Crosby who suggests
that in order to manage quality adequately, we
must be able to quantify and measure it.
 Definition of Quality
• Quality is inversely proportional to variability
– Customers value consistency and predictability

• Thus, quality improvement is the reduction of

variability in processes and products
 Definition of Quality
• Quality is the totality of features and
characteristics of a product or service that bear
on its ability to satisfy given needs.
– In this definition if you replace the word given with
stated or implied you have the ISO definition.
– This definition implies that quality is an attribute of
a product.
– A product is a quality product if it meets all the
requirements established for it; that is, it is a defect-
free product.
 Definition of Quality
▪ In quality management, quality is defined as;
▪ The totality of features and characteristics of a
product or service that bears on its ability to
satisfy customer’s stated and implied
needs.

▪ Quality is those features of a product or

service that allows it to satisfy (or
delight) customers
 Definition of Quality . . .
▪ Freedom from deficiencies – refers to
quality of conformance
▪ Conformance to standards- ability of the
product or service to conform to the stated
and implied requirements of customers.
▪ Higher conformance means fewer
complaint and increased customer
satisfaction
Customer-Driven Definitions of Quality

▪ What is a customer?
▪ Anyone who is impacted by the product
or services delivered by an organization

▪ External customer- the end user

▪ Internal customer- other divisions of

the company that receive the processed
product.
Eight Critical Dimensions of Quality
▪ Quality framework for strategic analysis:
▪ Performance – measures to what extent a
product or service meets the expectations of
the customer (primary operating characteristics
of a product).
▪ Features – secodary aspects of performance;
supplemental to basic functioning/operating
characteristics.
Eight Critical Dimensions of Quality
• Reliability - degree of dependability and
trustworthiness of the benefit of the product for a
long period of time ( consistency in perfomance
within specifications)
• Conformance – measures if processes are carried out
the way they were intended to be carried out (meet
established standards).
• Durability – length of time that a product performs
before it deteriorates
Eight Critical Dimensions of Quality
• Serviceability - promptness , courtesy,
proficiency/competence and ease of repair.

• Aesthetics – subjective in nature(deals with

art, beauty and taste); a product’s impacts on
the human senses eg. How it looks, feels,
sounds, tastes, smells and so on ( personal
judgement and a reflection of individual
preference).
Eight Critical Dimensions of Quality
• Perceived Quality – perception of the quality
of the product in the mind of the consumer. It
is related to personal experience.
 Importance of Quality
Reasons why quality is a cardinal priority for most
organizations.
• The need for safety and reliability - as systems have
become more complex the reliability requirements for
suppliers of components have become more stringent as
well as safety.
• Desire to excel – quality at its best
• Competition - Higher level of customer satisfaction-
higher customer expectations are getting spawned by
increasing competition.
 Importance of Quality
• Liberalization and globalization – multiple
choice for customers.
• Meaningful Choice –customers want to
make best decisions in money spending.
Benefits of Quality Control in Industry
• Improving the quality of products.
• Increasing the productivity of manufacturing
processes.
• Reducing manufacturing and corporate costs.
• Determining and improving the marketability of
products.
• Reducing consumer prices of products.
• Improving and/or assuring on-time deliveries and
availability.
 What does quality apply to?
• Every product, service, process, task, action,
decision can either be acceptable or
unacceptable.
• Hence, there is an intrinsic quality in everything
that an organization does.
• Everyone must pay attention to quality, from the
chief executive to the shop-floor across all
functions in an enterprise.
• It is as important for support staff to pay
attention to quality as well as production staff.
 Who is responsible for quality?
• One can only be responsible for doing something
relative to quality.
• Hence a person can be responsible for:
– specifying quality requirements
– achieving quality requirements
– determining the quality of something
• A role of Quality Manager is to enable others to
achieve quality by providing encouragement,
leadership, training, tools, techniques and
performance data.
 How can quality be achieved?
• Several methods have evolved to achieve, sustain and
improve quality.
• They are known as quality control, quality
improvement and quality assurance
• They are collectively known as quality management.
• Quality management is not the task of one manager
but of all managers and members in the production
chain.
• Quality is achieved through a chain of processes, each
of which has to be under control and subject to
continual improvement.
 How can quality be achieved?

The chain starts with top management expressing a

firm commitment to quality, then:
1. establishing customer needs and expectations
2. developing and maintaining a management
system that will enable achievement of
customer needs and expectations - reliably,
repeatedly and economically
3. designing products and services with features
which reflect customer needs
 How can quality be achieved?

4. building products and services so as to

reproduce faithfully the design
5. verifying before delivery that products and
services possess the features required
6. preventing the supply of products and services
which possess features which dissatisfy
customers
7. discovering and eliminating undesirable features
in products and services
 How can quality be achieved?
8. finding less expensive solutions to customer
needs
9. making operations more efficient and
effective
10.discovering what will delight customers and
providing it
11.most importantly, honouring commitments
 How can Quality be achieved?
There are standards, philosophies, methodologies,
tools, techniques and measures used to meet
quality goals:
• Management systems / Standards
– ISO 9001, ISO 14001, ISO 21000, ISO/IEC 27001
• Philosophies
– Total quality management
• Methodologies
– Business process management, continual
improvement
 How can Quality be achieved?
• Tools and techniques
– Process charts, failure mode and effects analysis,
statistical process control, quality function
deployment
• Measures
– Quality awards, best value, ISO 9000 and Investing
in People