12/22/2013

Submitted by:

Kavita Krishna Moorti(10225)

Zainab Khan (9849)

Raisa Asghar Ali (13700)

Sundus Javed (8927)

Asif Sheikh ()

Submitted to : Sir Noman Nasir

Contents

EXECUTIVE SUMMARY ....................................................................................... 2

Shan Foods (Pvt.) Ltd ................................................................................................ 3

Specialties .......................................................................................................... 3

Headquarters ...................................................................................................... 3

Mission .................................................................................................................. 4

Company Overview ........................................................................................... 4

SHAN SHOOP NOODLES ...................................................................................... 7

PURPOSE OF THIS REPORT: ............................................................................ 7

Quality checks for raw material of Shoop: ....................................................... 7

Analysis for X bar chart: .................................................................................. 14

Analysis for X bar chart: .................................................................................. 16

Analysis for X bar chart: .................................................................................. 18

Analysis for R chart: ......................................................................................... 19

Analysis for R chart: ......................................................................................... 20

Analysis for R chart: ......................................................................................... 22

Pareto Diagram .................................................................................................. 23

Work Flow Diagram .......................................................................................... 24

Process Work Flow .............................................................................................. 24

Cause & Effect Diagram ......................................................................................... 26

C auses F or V ariation I n W eight /T aste /L ength : .............................................. 27

Conclusion ............................................................................................................... 29

Recommendations ................................................................................................... 29

EXECUTIVE SUMMARY

The purpose of this report is to use the SPC tools in order to detect and amend the issues of variation in weight, size and taste that Shan Shoop comes across during its production. Through the use of suitable PC tools, variations were identified that are denting the quality of the productivity and propose measures to tackle them.

Shan Foods (Pvt.) Ltd is a renowned & fast growing FMCG company. It stands as one of the most reputed food company and a powerful global brand with presence in more than 60 countries through delicious food solutions of Premium Quality under brand categories of: Recipe Mixes, Plain Spices, Paste, Pickles, Whole Spices, Rice, Salt and Desserts.

The product that has been chosen to be studied is ‘Shoop’ and based on this the following SPC have been applied to improve the quality and production.

1. Process Charts.

2. Pareto Diagram.

3. Process flow diagrams.

4. Cause and Effect diagram

The sample size we took for the study of the report were of 150 units, for studying the variation in ph and weight of the packets, we have found the possible causes behind it and suggested some recommendations.

The study recommends proper training of the employees, proper handling of the machine, and improvement in visual controls process for checking the raw material and equipment should be installed in production area which controls moisture effect on product.

Shan Foods (Pvt.) Ltd

Shan Foods (Pvt.) Ltd is a renowned & fast growing FMCG company. It stands as one of the most reputed food company and a powerful global brand with presence in more than 60 countries through delicious food solutions of Premium Quality under brand categories of: Recipe Mixes, Plain Spices, Paste, Pickles, Whole Spices, Rice, Salt and Desserts. With a vision to become a global food company, Shan is not only operating in Pakistan but also have started International Operations with manufacturing facilities in UAE and Saudi Arabia. Shan success attributes are to identify and respond to the changing consumer needs and delivering the consumers unmatchable Taste and Quality. Shan doesn't offer products, it offers enriching food experiences.

Shan have more than 1000 people who share the same vision that is aligned behind a clear strategy expressed in a simple road map. Our ambition for Shan Foods (Pvt.) Ltd is to be recognized as the world’s trusted leader in taste, quality and to be the main point of reference for outstanding financial performance in our industry.

Specialties

Food Products

TypePrivately Held

Company Size

1001-5000 employees

Website

http://www.shanfoods.com

Industry

Food Production

Founded

1981

Headquarters

Plot # 29, Sector 23, Korangi Industrial Area, Karachi. Karachi, Sindh 75300 Pakistan

Mission

To continuously develop and produce quality products that meet the customers and markets demands, compatible with applicable regulatory requirements.To be a consumer oriented company with keen insigne of food products ensuring quality, consistency and authentic taste to operate with state of the art technology to obtain optimum results and retain highest quality standards thriving on efficient and motivated human resource and inculcate in them a sense of participation for personal goals and development.

Company Overview

Traditional Recipes: 

Shan Foods Recipe Mix is a mouthwatering treat for every taste bud. It brings its customers way a perfect blend of recipes that are cooked to help them make an aromatic and tantalizing dish.

Shan Oriental Recipes:

offer the true taste of the orient; taking consumers through the food destinations of four countries, that is, Chinese, Malaysian, Indonesian and Filipino Cuisines.

Magical Arabic Recipes:

 Shan now takes this opportunity to explore delicious Arabic Cuisines by launching a wide range of Arabic Recipes that will bring a True Arabic Taste to your Table.

Delve Desserts:

gives you an experience of sweetness like never before. Discover the world of Delve Desserts where a wide variety of rich, creamy and flavorsome desserts are ready to delight its customers with an indulging Delve experience that is simply awesome. Delve Desserts are available in enticing variants of Custard, Jelly and Pudding.

Shan Shoop noodles: 

The fast food revolution has left kids with very few healthy food options. That is why your favorite company Shan Foods, came up with a simple but brilliant idea of making noodles tasty and nutritious. Available in six exciting flavors such as Chicken, Masala, Spicy Lemon, BBQ, Ketchup, and Bombay Biryani, Shoop Noodles have 50% more wheat protein than ordinary noodles making it a healthy and scrumptious choice.

SHAN SHOOP NOODLES

PURPOSE OF THIS REPORT:

The requirement of this report was to use the TQM tools in catering to issues enabling quality that surpasses excellence.

In this case, the method used to apply TQM tool is control charts for X Bar and R bar charts. In order to fulfil this purpose, 300 packets were checked in 30 days. By using this information we found out the averages and ranges in grams and PH. Then we determined the trail central line and control limits.

The analysis for this control chart is to carry out to find out the assignable causes. The following SPC tools would be used to:

 

1. Process Charts.2. Pareto Diagram.3. Process flow diagram.4. Check sheets5. Cause and Effect diagram to find out root cause.

Quality checks for raw material of Shoop:

Flour Testing

Quality of Shan noodles start right from raw material. Critical checking of raw material is needed to ensure high quality finished good. All the noodles quality depends on Flour and spices therefore stringent checking and inspection is done for Flour that includes physical testing, gluten and elasticity.

Visual inspection include checking flour visually for possible insects, foreign particles and its particle size

Gluten and Elasticity more required in noodles making therefore flour with high gluten and elasticity content is preferred for noodles making.

Taste Maker

Spices choose for taste maker is to procure as fresh as possible right after drying. Spices after drying are procured and the maximum requirement for clearance after drying is to not reach more than one to one and half weeks otherwise Aflatoxin presence chances will be manifold.

Quality checks for finished products :

Baked Cake

Tests include weight and Peroxide value. Weight of baked cake should be of 50gms ±2. Tolerance defined includes ±2gms.

Peroxide Value

Detection of Peroxide gives the initial evidence of rancidity in unsaturated fats and oils. Other methods are available but peroxide value is the most widely used. It gives a measure of the extent to which an oil sample has undergone primary oxidation.

The double bonds found in fats and oils play a role in autoxidation. Oils with a high degree of unsaturation are most susceptible to autoxidation. The best test for autoxidation (oxidative rancidity) is determination of the peroxide value. Peroxides are intermediates in the autoxidation reaction.

Autoxidation is a free radical reaction involving oxygen that leads to deterioration of fats and oils which form off-flavours and off-odours. Peroxide value, concentration of peroxide in an oil or fat, is useful for assessing the extent to which spoilage has advanced.

The peroxide value is defined as the amount of peroxide oxygen per 1 kilogram of fat or oil. Traditionally this was expressed in units of milliequivalents, although if we are using SI units then the appropriate option would be in millimoles per kilogram 

Peroxide values of fresh oils are less than 10 milliequivalents /kg, when the peroxide value is between 30* and 40 milliequivalents/kg, a rancid taste is noticeable.

Tastemaker

PH of taste maker check by makes a 10% solution of taste maker in water. The PH should be in-between 4 to 4.5, towards acidic side. If it’s above or below from defined PH, the whole batch discarded because of the evidence of bacterial growth.

Sample testing

1 random test of both cake and taste maker is taken after every 1 hour for testing of PV, wt, and PH

STANDARD WEIGHT = 50 GM ±2GM

Weight Variation

Days 1 2 3 4 5Average Max Min Range

1 49 49 50 48 49 49 50 48 22 49 49 50 48 49 49 50 48 23 50 50 50 52 48 50 52 48 44 48 48 48 48 48 48 48 48 05 49 49 48 48 51 49 51 48 36 49 50 50 51 50 50 51 49 27 48 52 50 50 50 50 52 48 48 48 48 48 48 48 48 48 48 09 49 49 50 48 49 49 50 48 210 49 49 50 48 49 49 50 48 211 49 49 49 49 49 49 49 49 012 49 50 50 48 48 49 50 48 213 49 50 50 48 48 49 50 48 214 49 50 50 48 48 49 50 48 215 51 50 49 50 50 50 51 49 216 49 49 50 48 49 49 50 48 217 48 48 48 48 48 48 48 48 018 50 50 50 52 48 50 52 48 419 49 49 50 48 49 49 50 48 220 49 48 47 48 48 48 49 47 221 50 50 50 52 48 50 52 48 422 48 52 50 50 50 50 52 48 423 49 50 50 51 50 50 51 49 224 50 50 50 52 48 50 52 48 425 48 52 50 50 50 50 52 48 426 49 50 50 51 50 50 51 49 227 48 52 50 50 50 50 52 48 428 49 50 50 51 50 50 51 49 229 49 50 50 48 48 49 50 48 230 48 48 48 48 48 48 48 48 0

TASTE MAKER STANDARD PH 4-4.5

Days 1 2 3 4 5 Average pH Max Min Range1 4.5 4.4 4.6 4.5 4.5 4.5 4.6 4.4 0.22 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 03 4 4.1 4.2 4.1 4.1 4.1 4.2 4 0.24 4 4.1 4.2 4.1 4.1 4.1 4.2 4 0.25 4.3 4.1 4.2 4.2 4.2 4.2 4.3 4.1 0.26 4 4 4 4 4 4 4 4 07 4.5 4.4 4.6 4.5 4.5 4.5 4.6 4.4 0.28 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 09 4.3 4.5 4.4 4.3 4.5 4.4 4.5 4.3 0.210 4 4.5 4.1 4.4 4.5 4.3 4.5 4 0.511 4 3.9 4.1 4 4 4 4.1 3.9 0.212 4.5 4.4 4.6 4.5 4.5 4.5 4.6 4.4 0.213 4.5 4.4 4.6 4.5 4.5 4.5 4.6 4.4 0.214 4 3.9 4.1 4 4 4 4.1 3.9 0.215 4 4.5 4.1 4.4 4.5 4.3 4.5 4 0.516 4 4.5 4.1 4.4 4.5 4.3 4.5 4 0.517 4.4 4.4 4.4 4.4 4.4 4.4 4.4 4.4 018 4 3.9 4.1 4 4 4 4.1 3.9 0.219 4 4.5 4.1 4.4 4.5 4.3 4.5 4 0.520 4 4.1 4.2 4.1 4.1 4.1 4.2 4 0.221 4.3 4.1 4.2 4.2 4.2 4.2 4.3 4.1 0.222 4.3 4.1 4.2 4.2 4.2 4.2 4.3 4.1 0.223 4 4.1 4.2 4.1 4.1 4.1 4.2 4 0.224 4 3.9 4.1 4 4 4 4.1 3.9 0.225 4 4 4 4 4 4 4 4 026 4 4.1 4.2 4.1 4.1 4.1 4.2 4 0.227 4.5 4.3 4.4 4.5 4.3 4.4 4.5 4.3 0.228 4 4.5 4.1 4.4 4.5 4.3 4.5 4 0.529 4 4.5 4.1 4.4 4.5 4.3 4.5 4 0.530 4 4.2 4.1 4 4.2 4.1 4.2 4 0.2

Peroxide standard value 0-0.05Days 1 2 3 4 5 Average PV Max Min Range1 0.04 0.01 0.03 0.04 0.04 0.032 0.04 0.01 0.032 0.02 0.01 0.03 0.02 0.02 0.02 0.03 0.01 0.023 0.03 0.02 0.04 0.03 0.03 0.03 0.04 0.02 0.024 0.03 0.02 0.04 0.03 0.03 0.03 0.04 0.02 0.025 0.04 0.05 0.03 0.04 0.04 0.04 0.05 0.03 0.026 0.04 0.05 0.03 0.04 0.04 0.04 0.05 0.03 0.02

70.005 0.01 0.025 0.01 0.01 0.012 0.025 0.005 0.02

8 0.04 0.05 0.03 0.04 0.04 0.04 0.05 0.03 0.029 0.05 0.03 0.04 0.05 0.05 0.044 0.05 0.03 0.0210 0.02 0.01 0.03 0.02 0.02 0.02 0.03 0.01 0.0211 0.02 0.03 0.04 0.04 0.04 0.034 0.04 0.02 0.0212 0.01 0.01 0.02 0.03 0.01 0.016 0.03 0.01 0.0213 0.04 0.01 0.03 0.02 0.02 0.024 0.04 0.01 0.0314 0.04 0.01 0.03 0.02 0.02 0.024 0.04 0.01 0.0315 0.04 0.01 0.02 0.01 0.01 0.018 0.04 0.01 0.0316 0.04 0.02 0.03 0.04 0.04 0.034 0.04 0.02 0.0217 0.04 0.01 0.02 0.01 0.01 0.018 0.04 0.01 0.0318 0.04 0.03 0.02 0.01 0.02 0.024 0.04 0.01 0.0319 0.04 0.02 0.03 0.04 0.04 0.034 0.04 0.02 0.0220 0.04 0.03 0.04 0.02 0.02 0.03 0.04 0.02 0.0221 0.04 0.01 0.02 0.01 0.01 0.018 0.04 0.01 0.0322 0.04 0.01 0.02 0.01 0.01 0.018 0.04 0.01 0.0323 0.04 0.02 0.01 0.02 0.01 0.02 0.04 0.01 0.0324 0.04 0.02 0.04 0.03 0.03 0.032 0.04 0.02 0.0225 0.04 0.02 0.03 0.04 0.04 0.034 0.04 0.02 0.0226 0.04 0.01 0.03 0.02 0.02 0.024 0.04 0.01 0.0327 0.04 0.03 0.04 0.02 0.02 0.03 0.04 0.02 0.0228 0.04 0.03 0.01 0.02 0.01 0.022 0.04 0.01 0.0329 0.04 0.02 0.04 0.03 0.03 0.032 0.04 0.02 0.0230 0.04 0.03 0.04 0.02 0.02 0.03 0.04 0.02 0.02

Control Chartsstandard weight = 50gm ±2gms Standard ph= 4-4.5

Standard PV=0-0.05

DaysAverage Weight Variation

Average pH of Taste Maker Average PV

1 49 4.5 0.0322 49 4.4 0.023 50 4.1 0.034 48 4.1 0.035 49 4.2 0.046 50 4 0.047 50 4.5 0.0128 48 4.4 0.049 49 4.4 0.04410 49 4.3 0.0211 49 4 0.03412 49 4.5 0.01613 49 4.5 0.02414 49 4 0.02415 50 4.3 0.01816 49 4.3 0.03417 48 4.4 0.01818 50 4 0.02419 49 4.3 0.03420 48 4.1 0.0321 50 4.2 0.01822 50 4.2 0.01823 50 4.1 0.0224 50 4 0.03225 50 4 0.03426 50 4.1 0.02427 49 4.4 0.0328 48 4.3 0.02229 49 4.3 0.03230 48 4.1 0.03X double bar 49.16666667 4.233333333 0.02746667

R bar 2.233333 0.2267 0.023667

DATA COLLECTION

X BAR CHART

A verage wt variation Ph PV

N=30,n=5, A₂= 0.577, R bar= 2.2333 0.2267 0.023667

X double bar = 49.1666 4.2333 0.027467

CL= 49.1666 4.2333 0.0274673

UCL= 50.4552 4.3641 0.041123

LCL= 47.877 4.1024 0.01381

U2SWL= 50.0256 4.321 0.03657

L2SWL= 48.31 4.146 0.018363

U1SL= 49.6 4.2769 0.032019

L1SL= 48.73 4.189 0.02291

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 300

0.005

0.01

0.015

0.02

0.025

0.03

0.035

0.04

0.045

X bar Chart for PV

X-BarUclu2swlU1slClL1slL2swlLcl

Interpretation:

Analysis for X bar chart:The graph shows central lines and the trial control limits for X bar chart. The graph is showing variations in weight averages taken over thirty numbers of days.

Fall of samples under: Samples Comment

Outside Control lines 0 Bad

Control lines 0 Ideal

CL & 1SWL 0 Good

1SL & 2SL 13 Desired

2SWL & UCL 0 Bad

CL & 1LSL 12 Good

1LSL & 2LSL 0 Acceptable

2LSL & LCL 5 Bad

All sample weight average under control limits

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 303.7

3.8

3.9

4

4.1

4.2

4.3

4.4

4.5

4.6

X bar for Ph

Average pH Uclu2swlU1slClL1slL2swlLcl

Interpretation:

Analysis for X bar chart:The graph shows central lines and the trial control limits for X bar chart. The graph is showing variations in Ph averages taken over thirty numbers of days.

Fall of samples under: Samples Comment

Outside Control lines 15 Bad

Control lines 0 Ideal

CL & 1SWL 0 Good

1SL & 2SL 6 Desired

2SWL & UCL 0 Bad

CL & 1LSL 3 Good

1LSL & 2LSL 0 Acceptable

2LSL & LCL 6 Bad

The process is out of control

1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829300

0.005

0.01

0.015

0.02

0.025

0.03

0.035

0.04

0.045

X bar Chart for PV

X-BarUclu2swlU1slClL1slL2swlLcl

Interpretation:

Analysis for X bar chart:The graph shows central lines and the trial control limits for X bar chart. The graph is showing variations in PV averages taken over thirty numbers of days.

Fall of samples under: Samples Comment

Outside Control lines 0 Bad

Control lines 0 Ideal

CL & 1SWL 8 Good

1SL & 2SL 4 Desired

2SWL & UCL 4 Bad

CL & 1LSL 4 Good

1LSL & 2LSL 4 Acceptable

2LSL & LCL 6 Bad

R control chart

A verage wt variationPh PV

N=30, n=5,

D₄= 2.115, D₃= NA

UCL=

U2SWL=

U1SL=

CL=

L1SL=

L2SWL=

R bar= 2.2333 0.2267 0.023667

4.7234 0.47947 0.05005

3.893 0.3952 0.04126

3.0633 0.311 0.032456

2.2333 0.2267 0.023667

1.4032 0.1424 0.014864

0.5732 0.05818 0.006075

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 300

0.5

1

1.5

2

2.5

3

3.5

4

4.5

5

R Chart for weight

RangeUclu2swlU1slClL1slL2swl

Interpretation:

Analysis for R chart:The graph shows central lines and the trial control limits for R chart. The graph is showing variations in weight ranges taken over thirty numbers of days.

Fall of samples under: Samples Comment

Outside Control lines 0 Bad

Control lines 0 Ideal

CL & 1SWL 1 Good

1SL & 2SL 0 Desired

2SWL & UCL 8 Bad

CL & 1LSL 16 Good

1LSL & 2LSL 0 Acceptable

2LSL & LCL 5 Bad

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 300

0.1

0.2

0.3

0.4

0.5

0.6

R chart PH

RangeUclu2swlU1slClL1slL2swl

Interpretation:

Analysis for R chart:The graph shows central lines and the trial control limits for R chart. The graph is showing variations in PH ranges taken over thirty numbers of days.

Fall of samples under: Samples Comment

Outside Control lines 6 Bad

Control lines 0 Ideal

CL & 1SWL 0 Good

1SL & 2SL 0 Desired

2SWL & UCL 0 Bad

CL & 1LSL 19 Good

1LSL & 2LSL 0 Acceptable

2LSL & LCL 5 Bad

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 300

0.01

0.02

0.03

0.04

0.05

0.06

R cahrt for PV

RangeUclu2swlU1slClL1slL2swlLcl

Interpretation:

Analysis for R chart:The graph shows central lines and the trial control limits for R chart. The graph is showing variations in PV ranges taken over thirty numbers of days.

Fall of samples under: Samples Comment

Outside Control lines 0 Bad

Control lines 0 Ideal

CL & 1SWL 11 Good

1SL & 2SL 0 Desired

2SWL & UCL 0 Bad

CL & 1LSL 19 Good

1LSL & 2LSL 0 Acceptable

2LSL & LCL 0 Bad

Pareto DiagramPareto analysis is a statistical technique in decision making that is used for identification and

solution of the major problems that cause most of the problems. It is based on 80-20 rule, in

which it is supposed that 80% of problems are caused by 20% of causes. It is shown in the bar

chart where the problems with highest frequency are placed on left side of the chart while

problems with least frequency are at the right.

Pareto analysis is an important tool because it identifies all the major and minor problems or

causes, complaints or failures in any product or procedures. You can easily identify the most

critical problems by looking at their frequency of occurrence and you can find out the problems

that need immediate attention.

Pareto analysis is very creative tool and what makes it different from other tools is the ability to

find out one or two major problems that is root cause behind majority of the problems.

It does not only take into account the problems in the procedure, one can take complaints,

failures or causes on the x-axis. And on Y axis, there is frequency of occurrence, or amount.

Pareto Analysis of Shoop Noodles

We have used pareto analysis to find out major and minor problems in the product. Our objective

is to solve 20% of the major problems that can help reduce 80% of the remaining problems.

Ten samples of noodles were observed at three different times under the same environmental

conditions.

The problems that we have found are thinner noodles, acidic taste, oily, dark color, and improper

shape of the noodles. The frequency of the problems is as follows:

ProblemsFrequency

Cumulative frequency

As % of Cum freq

Weight 8 8 0.4Acidic 4 12 0.2Oily 3 15 0.15Broken noodle 2 17 0.1Dark color 2 19 0.1Improper shape 1 20 0.05

These problems can graphically be represented as follows:

Allow it to reach maturation

Weight Acidic Oily Broken noodles

Dark color Improper shape

0

1

2

3

4

5

6

7

8

9

A total of 150 packets of noodles were checked in which above problems were identified.

A total of 8 packets were found to have weight problem. Some of the packets have less weight, some were more acidic because of more quantity of the tastemaker. Few were more oily, 2 packets had broken noodles, while a few had darker noodles and one sample was found to have improper shape.

The measurements of each as per the weight of the dough, and because of the change in weight of noodle cakes, above problems are faced.

Now that we have identified the most critical problem, it is our job to control this weight issue and it must be equal in all the packets. If the packets would be of equal size, weight and thickness, then the tastemaker will be ok, and other problems like being oily, broken, darker and improper shape of noodles would also improve.

Work Flow Diagram

Process Work FlowDissolve salt and flavor in water

Then it is kneaded

Add flour to form a mixture

Cause & Effect Diagram

Moisture in the atmosphere

People Environment

PH Analyzer not analyzing the correct PH Value

Equipment

Cutting machine not cutting properly

Materials

EffectVariation in

Weight/ taste/

Length

Fishbone cause-and-effect diagram is the most prominent and widely accepted tool for Root Cause Analysis. It starts with the problem on the right and builds the causes to the left. It was created by Kaoru Ishikawa (1915-1989) in Japan. The fishbone diagram builds from right to left because the Japanese language reads from right to left. This method actually uses Ishikawa's convention by asking Why questions in the direction we read. The fishbone is widely recognized as one of the standard quality tools. Ishikawa was a pioneer with his approach. The fishbone cause-and-effect diagram is part of every six-sigma program.

Causes For Variation In Weight/Taste /Length:

1. Equipment

a) The current cutting machine doesn’t cut the noodles equally due to which it

causes variation and the noodles have to be stuffed in the packing and as result the

noodles break into smaller pieces. As the noodles are not equal, during the frying

procedure they either take longer time to cook and if are shorter than standards the

noodles can burn. Therefore we can say that the variation in length and weight

causes variation in Time of frying.

b) PH value of Taste maker should stay in between 4-4.5 , if the PH value will vary

from the standard range this will cause a variation in taste of the noodles. This

problem is caused by poor visual inspection of PH indicator.

Materials

a) If the quantity of water and wheat are not in proper ratio. The dough will be

hard to knead if water is less and if the water is more in the mixture the dough

will be too soft to be given a proper shape.

b) The wheat is an essential ingredient in making the dough if the quality is not

good, the noodles will not be of very good quality. This condition can occur if

the supplier, supplies poor quality of wheat to the company, also if the wheat is

not utilized within the time frame mentioned by the manufacturer, the wheat may

Poor Visual inspection

Unskilled labor

Variation in Peroxide value

of oil

Cause and Effect Diagram to find out the causes for variation in thickness/Length/Taste of Shoop

Variation in wheat quality and quantity

Variation in quality of spices

rot, and cause a change in taste. The visual inspection should be improved to

avoid usage of such type of wheat and better taste of the product.

2. People

a) When the operator doesn’t set the machine on proper scale/standard there is a

difference in thickness, and length of the noodles.

b) The workers should be given proper training to use the machine so that ,they can

use the machine to its maximum efficiency ,and if the machine is used properly

the machine will not undergo a breakdown and the production time will

improve(as machine down time will decrease).

3. Environment

a) The Noodles have to undergo a procedure to extract moister out of them, If the

area is not properly sealed it decrease the efficiency of moister extraction process,

as a result a poorer quality noodles are made.

ConclusionOn the basis of X bar chart and R chart, we have found out the variation and range of three variables, i.e, weight of the noodles cake, Ph of the tastemaker and the Peroxide value in the noodles.

The weight of the noodles packet is mostly at the desired level, most of the samples are between U1SL and U2SWL, while 5 samples are very close to Lower control limit. So these should be monitored and improved so that it could be brought to good side of the limits.

There is huge difference in the Range of the samples, 8 samples are close to upper control limits while 5 samples are lower than U2SWL. Range going close to UCL and LCL shows that there are various unusual reasons behind the variations.

For the Ph value of the taste maker,

As for as the X bar chart of PV, there is so much variation but no one sample is outside the control limits. But the R chart is under control having values between U1Sl and L1SL. This shows that there is no unusual cause affecting the system. However there are some common problems that need to be solved in order to improve the process.

We have also used pareto diagram, Cause and effect as well as flow diagram to find out the problems and there are many reasons behind those problems and we have given some recommendations as given below.

Recommendations The TQM implementation process begins with senior management and most importantly the CEO’s commitment. If emphasis on implementation of TQM practices of the organization is not a dominant aspect of New Product Launch, failures in the market can have adverse effects on image of the company and brand loyalty.

Always test market the product first

Educate customers of product Innovation

Premium products need to be marketed accordingly

Value for money should stand out itself by the brand

Local manufacturing is always favorable for the company

Companies should plan & design according to the market standings and the country in which the product is being launched

Short term action plan for shoop noodles include achieving expertise in noodles making by training their staff and employees so there will be less variation in overall quality of product. Reduce the overall cost of product by cut down less value added activities /non value added activities and that can be find out easily by carefully analyse each and every process of noodles making from start to end user. Value stream mapping or blue print would help to identify non value added activities. Another cost saving and better quality product can be achieve by focus on

1) Equipment & Machinery

Should be properly and regularly maintained to avoid the breakdown of machinery that cause loss of manufacturing and generate scrape

2) Materials

High quality material should be used to reduce scrape chances and gain competitive edge by producing better quality product

3) People

Skilled workforce should be trained and hired experience and relevant field experts

4) Environment

They should initiate some environmental controlling measures. Equipments should be installed in production area which controls moisture effect on product.

Last but not the least is, the only solution of all problems is continuous improvement and the competitive edge only possible through achieving quality standard that rival can’t give to customer. It’s the only way to outperform in the market.