Quality intro for leather professionals (Think locally & act globally)Jul 15, 2015Abdul SattarKonsultant at Self -Employed

It is the PROFIT that improves the lives of owners and employees enjoy full and profitable. So every company work hard to maintain their quality so every organization’s aim is to;

To enhance its productivity.

Be Cost effective.

Be Consistent in quality.

Be Accurate in delivery.

Be Safe for people to work in.

High in morale.

By analysing the inputs and out puts of the production process in detailed ways, company has an opportunity to look closer into its operations and identify further opportunities to,

Optimize the production process.

Use resources more efficiently

Close flows of materials and substances (through reuse/recycling)

Address economic and environmental “weak points”.

The inputs and outputs of the production process refer to sum of the inputs and outputs of all the different direct and indirect production steps.

For the analysis of inputs, most of needed data might already be available in administration or accounting department the consumption of raw materials, auxiliaries, water and energy used per year and the amount of products produced during one year is usually data that can easily be collect or estimate.

But the out puts are difficult to analyse, therefore, detailed analysis of out puts at each and every step is needed to get/estimate output of waste (material, energy, and water waste and air emission)

The advantages of doing in detailed analysis at each and every production step is that one can obtain a differentiated and more complete view of production process which makes it much easier to identify opportunities to optimise the production process

Quality Understanding by definitionQuality of the product is;

The characteristic

The Measure of its standard of excellence.

Quality Understanding by brands A car is a product; BMW is a brand.

A watch is a product; Rolex is a brand.

A hotel is a product; Marriott is a brand.

A car is a means of transportation; a BMW is a symbol of exclusivity.

A watch tells time; Rolex tells who you’re.

Quality Control? Process -To ensure a certain level of quality in a product or

service

Action - To ensure that the product meet the specific requirements

 Quality asks to control three areas; Products or Services

Processes

Peoples

Difference between Q uality Control & assurance : Quality control is concerned with the product

Quality assurance is process–oriented.

Stages in Quality control Pre-Process :To ensure all arrangements are fit Before

process In- Process: To ensure process is going in right way. Post- Process:To ensure perceived quality conformance,

reliability, durability, and so on.Methodology (How to Measure the Quality)Basic Quality tools: Fundamental methods for gathering/analyzing quality-related data.

Fishbone diagrams

Histograms

Pareto analysis

Flowcharts

Scatter plots

Run charts

Control charts.

And many more etc.

Quality Standards:ISO 9000 -the European standard for quality that has been expanded worldwide. ISO stands for Organization for

International Standards. it covers the quality like that:

Quality Inspection/testing -Acceptable quality level (AQL) The maximum percentage or proportion of non conformities

in a lot or batch that can be considered satisfactory as a process average.

Acceptance sampling Statistical quality control technique used in deciding to accept or reject a shipment of input or output.

 Quality objectives (Guidelines):From Customer point of view

Thickness =to be 100% accurate.

Color matching =to be 100% or as per the tolerance limits provided by the customer.

Looseness = Maximum 2%.

Temper = as per the criteria approved by the customer.

Grade/Cutting Value = as per the criteria approved by the customer.

From Process Control point of view Process faults (Dye patches, Run marks, Scuff, Dye bleeding,

color matching, etc) = within 2% rejection.

Leather damages by mechanical = within 1% rejection.

Reworking/Reprocessing = within 5% rejection.

Factory Returns (Customer complaints) = within 2% rejection.

Extra issuance of raw leather = within 5% rejection.

Extra issuance of chemicals. = within 2% rejection.

Handling =to be kept good.

Actual process cost for final product not to be more average cost than the previous average cost.

continual improvement for Quality 

Reasons of poor quality in product /Process Rejection

High chemical cost.

High labour cost.

High indirect cost. (Energy ,

High maintenance cost.

Low production.

Improper handling.

Inappropriate housekeeping.

Mistaken calculation

Area loss.

Rejection & High sale returns:Man:Untrained and non-calibrated selectors

Improper decision

Material:Raw material with low selection.

MachineMechanical Damages

Method:

Poor Process (Damages)

Improper handling

Wrong Mechanical operation

High Chemicals cost:Man :Untrained and non-calibrated technician.

Improper decision

Material:Use of expired chemicals

Use of costly chemicals

Machine:Loss of chemicals due to non calibrated machinesMethod:Use of chemicals in excess quantity

Wastage of leftover chemicals

High labour cost:Man:Untrained and non-calibrated technician.

Use of unskilled labour

 Improper selection of labour and its use on non-productive work

Material:Damage of product due to labour

Machine:Use of labour instead of machine.

Method:Use of extra work / rework

Poor quality checks

High In direct cost:Man:Electrical / mechanical breakdown.

Wear and tear cost due to negligence

Use of unskilled labour

Material:Damage of product due to labour

Machine: Use of labour instead of machine.

Misuse of machines

Method:Misuse of resources (Water, Electricity, Steam etc)

Excessive use of consumable material.Use of extra work / rework

High maintenance cost:Man:Negligence during work

Use of unskilled labour

Unnecessary usage of machines

Material:Damage of product due to labour

Machine: Use of labour instead of machine.

Misuse of machines

Excessive electrical break down

Method:Misuse of resources/Uneven and excessive load on machine

Excessive use of consumable material.Use of extra work / rework

Low Productivity:Man:Increase in over head

Use of unskilled labour

Unnecessary usage of machines

Material:

Damage of product due to labour

Machine:Use of labour instead of machine.

Excessive electrical break down

Method: Delay in order completion