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APPLICATION OF QUALITY CONTROL IN NIGERIA INDUSTRIES (A CASE STUDY OF MICHELIN PORT HARCOUT)

March 1, 2019 projecteasy Leave a comment

APPLICATION OF QUALITY CONTROL IN NIGERIA INDUSTRIES

(A CASE STUDY OF MICHELIN PORT HARCOUrT)

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ABSTRACT

It is generally believed that Nigeria are not satisfied with goods made in their country but are rather attracted to foreign made products. This state of affair attributed to the poor quality of products. This study seek to examine the various method used by different manufacturing organizations and also assess the effectiveness of the applications.

To achieve this objectives, a survey of Michelin Nigeria Limited, one of the manufacturing organization in Port Harcourt was undertook. A review of related literature was also undertaken. A sample survey techniques was developed and administered to the various Michelin manufactured products.

From the analysis of data collected, it was found that the application of quality management techniques ensure high quality products and that the two Michelin products were under control.

The analysis is such that will construct the statistical quality control chart for the products, the production process should continue.

It also recommend the maintenance of the machine should be encouraged by the management of every department rather than allowing the machines to go bad before maintenance can be checked.

TABLE OF CONTENTS

Title page ii

CHAPTER ONE

Introduction 1

Background of the study 1
Statement of the problem 7
Scope and limitation 0f the study 8
Justification of study 10
Relevant of study 10
Objectives of the study 11

CHAPTER TWO

Review of literature 12
Responsibility for quality 14
Customer responsibility 16
Supplier responsibility 16
The manufacturer 17
Policies of quality 17
Motivation for quality 20
Quality circle 22
Inspection 23
Where to inspect 24
How to inspect 25
Acceptance sampling 26
Attributes sampling plan 28
Variable sampling plan 29

CHAPTER THREE

Research methodology 30

Source of data 30
Population of study 31
Sampling procedure 31
Systematic random sampling 32
Data collection instrument 32
Data analysis technique 33
Presentation data 35
Definition of terms 36

CHAPTER FOUR:

Presentation and analysis of data 37

Introduction 37
Examination of research sample data 38
General analysis of sample data 38

CHAPTER FIVE

Findings recommendations and conclusion 45

Introduction 45
Findings 45
Conclusions 46
Recommendation 47

References 49

CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND OF THE STUDY

In the production of goods and services, statistics is applied in the analysis and control of quality. Most manufacturing firms in a bid to attain their primary objectives which include survival, efficiency and profitability, large market share etc, establishes quality control laboratories where the quality control officers are charged with the responsibility of advising the production department as well as the management on the current quality presents the products.

Since the task of control is to plan, organize and manage the use of available resources to accomplish specified, long-term goals. It then follows that there exist the need for management to make quality decision that will enhance the attainment of these goals.

Quality is the concept which concerns how well and low long a product or service meets customers requirement, in these respect, the assessment of the customers is the most reliable indicator of product quality.

Quality costs money. Wide (1980) says that with sufficient expenditure any product can be endured with high quality. Quality goods and services are expected to be produced at a minimum cost so as to attract customers by non-exorbitant cost. Manufacturers are thus not faced with the problem of producing them at a low cost. There challenges have also been a intensified by the advances in technology changes in customers tastes and then stiff competition in the market place.

Competitions is continually intoning, the customer is having more knowledge about the goods he buys. This has been greatly encouraged by different organization. Government policy on prices and incomes have sort of enlightened the customers more or how to spend his money.

Okwu Anyia (2005) says that statistics deals with figures 9including real and integer – valued quantities) the decision is friendly with statistical approach to the solution of most management, (quality management) and other related problems. To this end, statistics involves the following.

Collection of data in figures
Organisation and presentation of data
Analysis of the data
Interpretation of the results (of the data); Analysis
Drawing conclusions on the results (or finding);
Making recommendations on the results and
Safety of the results conclusions and recommendations for immediate and future use.

Quality control and management in an organization should be a functional management discipline, responsible for defining and implementing developed programmes for quality improvement. These programmes range from training new employees to inspecting current products and services, conducting quality, improvement, performing design review and assisting the finance department in calculating the cost of quality.

Woof E. (1986) defines an audit as a process whereby the accounts of business entities, including limited companies, trusts and professional firms, are subjected to scouting in such details as will enable the auditor form an opinion as to their accurancy, trust and fairness. The application of statistical tool helps the auditor in arriving at t his opinion.

Quality management and control is also concerned with the establishments of standard on inputs and outputs. The pre-requisites to effective and efficient quality control are freedom from deficiency and minimum cost. These express management standard and attitude that non-conformance is not acceptable in order to reduce running cost. These cost include repair, rework, waste, replacement, warranty and the cost of detailed inspection. All these are expensive manufacturing problems that should not only be detected and resolved at the earliest time but if possible prevented.

Furthermore, to the established standard tolerance limits are set for every important quality. Variable these tolerance are limits of variation beyond which the variable will not be accepted it most satisfy the requirement customers will impose on the finished goods (products) because the organization must determine what qualities are needed by the users.

Meeting these quality needs by the users is the collective responsibility of all the functions of the organization. The market research will discover just what the needs are. Product development will create designs which are responsible to there needs. Subsequently, the planning decision of the organization will devise process which are capable of executing the product design in conjunction with the production decision which will regulate these processes to achieve the desired quality.

These inspection and testing section will prove the adequacy of the product, through stimulated use. The marketing section will sell the products for the prosper application. Finally, the customer service must follow the usage to remedy failure and discover opportunities for improvement.

All these sub-activities may collectively be seen as the quality function and so, the total management policy on quality is a collective efforts towards achieving a level of quality desired by both the organization and the customers.

2.1.1 HISTORY OF MICHELIN

When Edward Michelin came on the scene, factory activity was called “The silent”, one day when a cyclist was visited the factory in search of tyre repair equipment, Edward had the idea that the tyre could really be easier to repair. This is the beginning of a long story.

In 1889, a cyclist from the Auverregne region gets a flat tyre in Clermont Femand; unable to repair his English tyres, which are glued to the wheel rim, he enquires at the Michelin factory, already well known for its rubber products. Edward Michelin does the repair personally shows work followed by 6 hours drying time. He also discovers the incredible comfort offered by the pneumatic tyre. His research leads to the patenting of removable tyre. In 1894, the first horse draw carriage tyre appears. In 95, a car “the Elan” was designed, built and equipped with pneumatic tyres by Michelin.

In 1898, birth of pudendum, the Michelin man. He becomes the company’s unmistakable symbol and helps make Michelin known the world over. In 1990, Michelin Red Guide was produced by Michelin, 1903, the first Michelin was produced while in 1905 the first using Michelin “solid” tyres came in.

From 1955 to 1969, Michelin undertook considerable industrial investment by having 15 factories in 15 yrs. 12 factories are built in Europe while 3 factories are built outside Europe in which one of them is in Port Harcourt (Nigeria) and it was invested in 1962.

Michelin continued its development, monthly in the Eastern and western countries until in 2000; Alliance with the Gurman group WOCO and creation of WOCO Michelin AVS (Anti Viberation System), specialized at automobile responding to the requirements for innovation and world wide accompanion of manufacturers in the field of suspension and raw holding system.

1.2 STATEMENT OF THE PROBLEM

Although the success of every manufacturing organization depend greatly on the degree of its reputation for supplying quality products that will give customers satisfaction in the price range offered yet the realization of quality standard has been the search for a solution to this problem is the concern, which has led to a research of this nature.

It thus follows that for Nigerian manufacturing organizations to be successful, they must place great emphasis on the establishment, documentations and maintenance of quality policy of the company. It requires that every section of production must have its quality related activities well defined documented and maintained. The personnel responsible for quality function must be conversant with their activities. In all, quality management system, requires that quality procedure for each section be followed in order to achieve acceptable quality.

However, it is now common that Nigeria market are flooded with many products among which are of low standard. What immediately comes to mind is that these must be problem in the quality system of Nigeria manufacturers. What factors are responsible for this problem and what action must be taken to criminate or reduce their negative impact on the development of the characterized manufacturing section in Nigeria.

Today, manufacturing organization in Nigeria which are serious about increasing sale and profitability, have to analyze and understand every aspect of their business in terms of customers needs. The improvements of the quality of products have become an important necessity in order for manufacturing companies to survive.

Besides, satisfying the needs of customers, planned quality improvement result to higher efficiency and productivity, lower costs and punctuality in delivery, but quality improvement is not something one can just attach to a product.

Quality is all embracing. In order words, every stage of the production of any product from raw materials to the end product as well as the built on services up to the point of delivery has to be taken into consideration with regard to quality improvement. This brings to focus the concepts of total quality management (TQM), Quality assurance or Quality control. These concepts must be completely internalized by every segments of any organization before it can became effective.

In this study we will be concerned with the examination of the quality management application and techniques (procedures) in Michelin. Nigeria Limited one of the manufacturing organization in Nigeria and their effectiveness in meeting the quality needs of the customers.

1.3 SCOPE AND LIMITATION OF THE STUDY

This research will concerned only the management of quality, its techniques and application within Michelin. It concerns only products, manufactured in Michelin.

However, because of finance and time constraints materials and information that would have added more light were not realized. Moreover, a research work of this sort cannot be error force because answers received from employees and company execution during interview might not be hundred percent (100%) correct. They may be hiding facts as they may be afraid of exposing the company policies and producers.

Lastly, since the saidly is done in the company (Michelin) it is limited to the Michelin locality.

1.4 JUSTIFICATION OF STUDY

This research on quality control will help in the examination of the quality management application in manufacturing organization in Nigeria and their effectiveness in meeting the quality needs of customers, for instance, in the case of Michelin, this study will help to whether its products are below standards and if so, adequate measure may be taken to improve on their quality.

Though the justification is that Michelin tyre has been considered long ago as the best tyre made in Nigeria. It is also chosen for its proximity, familiarity and cost related consideration.

1.5 RELEVANT RESAERCH QUESTION

To accomplish the purpose of this research, the following research questions will be answered to have solution to the problem which will led to the achievement of the objects of the study.

How are quality standard established?
What are the different techniques of quality management used in the organization?
Does the current techniques ensure high quality products?
What are the problems faced in the practice of quality management?
What are the prospects of solving the identified problem?

1.6 OBJECTIVES OF THE STUDY

The following are the objectives of this research

To facilitate management decision making in the form of efficient allocation of resources using quality control techniques.
To construct statistical quality control chart for the products.
To help to know the skills and techniques of quality control in an manufacturing industries
To know whether the industry maintains quality standard.

CHAPTER TWO

2.1 REVIEW OF LITERATURE

Human desire for quality goods and services had always exist since the dawn of history. In Nworah (1991) primitive man was concerned with quality and he did so as a manufacture, that is, when he manufactured what he used. He was responsible for carrying out his technological and managerial activities and was able to co-ordinate all these activities, ensuring that he produced item is of a quality acceptable by him.

Karmel and Polasuk (1989) discussed statistical quality control as the quality control as the quality of industrial products which can be measured in various ways but when one concerned with mass produced components, quality can generally be measured by a fairly simple character of the component under consideration.

Thirkettle (1980) discussed quality control as a method of estimating the quality of the whole from the quality of the sanities taken from the whele; the method is based upon the laws of chance. Also Lawrence (1979) discussed quality control as the means to achieve true reliability.

According to encyclopedia (1996) quality control as a system of inspection analysis and action applied to a manufacturing operation so that by inspecting a small portion of the product currently produced, an estimate of the overall quality of the products currently produced, an estimate of the overall quality of the product can be made to determine what changes must be made in the operation in order to achieve or maintain the required level of quality control of manufacturing operations.

According to Akpenji 1996): It is customer focused performance enhancing tooth which can be applied to any type of organization. It enhances the diverse element of business ie leadership, strategic planning human resources development management information system, external customer, employees and stakeholders and aligns them to achieve excellent business result/

Duncan (1974) insisted on a long period of training for apprentices and required that these evidence of their ability, such rules were in part, aimed at the maintenance of quality. In more modern time focus, factory inspection and research, food and drugs activities of operational scientists have all aimed at ensuring the quality output.

2.2 RESPONSIBILITY FOR QUALITY

According to Sakee (2004) the survival of every company depends on the income it gets from selling its products and services and the ability to sell is based on fitness for use. Hence, no single department is responsible for the broad quality function in an organization (Batuboo 200). All department have a role to play.

According to Furan (1980) deciding what should be a quality objective for a particular company is always a tailor made job. Since companies differ widely so do their level of performance in the various aspect of quality control.

According to Caplen (1972) the major activities through which fitness for use is achieved is known as the quality function. It is a company under management responsibility these activities relates to each other in an organization (Ajie 1996). Management is any organsiation considers quality primarily as a business problem or as a matter of marketability (Akyseiyi 1996). The needs of the society are met by the goods and services. This goods and services are paid for through purchase prices, taxes, interests. Etc companies comment offering terms. Also Nwachukwu (1980) said that with superior quality goods and service a company can secure higher share of the market, firmer prices, a higher percentage of successful bids, etc. quality costs money to built control and pay for failures involved. More so, higher quality of decegn means higher costs and higher value (Sakee 2000). Design of goods means a variation in specification for the same functional use. It could be variations in the life of product appearance, reliability factor of safety inter changeability, features, luxury features case of installation use, maintenance etc.

Quality of a product is a weapon of competition and can take manly forms. Juran (1980) says that opportunities to exploits quality in competition are many. He says that for these objectives to be accomplished every department msut participate fully because quality is a team work. It requires the participation of all major department of the company to choose the design as higher quality design costs more but higher quality of performance usually cost less.

According to Databo (2000) quality control is an effective system of co-ordinating the efforts of various groups. In an organization to enable production to operate at the economic level and allow for full customer satisfaction.

2.3 CUSTOMER RESPONSIBILTY

Great number of problem are cuased by the customer, Crosby (1982) claim that 80% of company’s problem are caused by non conforming purchase goods, also Ishikwa (1985) claim that at least 70% of the blame for this rests on the customers clearly, if the customer designs the products and issue drawing and specification to the supplier, the finished products may not work because of an unsatisfactory designs although argument may still develops over the attribution of responsibility.

2.4 SUPPLIER RESPONSIBILITY

According to Weiss and Gersslion (1989) is a duty to ensure that every product leaving the factory is known to conform to specified requirements, it is more important to ask how is this to be achieved, but is inadequate merely to respond with a statement that supplier should organizer the design.

2.5 THE MANUFACTURER

Bathbo (2000) define a manufacturer as a commercial scale using machinery, example in the manufacturing of tyre, plastic, electronics. In contrast with industries which do not make products but rather provide services example consultancy.

2.6 POLICIES OF QUALITY

The management sets the quality policies for the organization, always written, easily understood and the made available to everybody in the organization.

All objectives will be in line with the company polices and procedures. The total management policy on quality is supportive efforts towards achieving a level of quality desired by both, the organization and its customers (David 1981).

According to David (1981), there are two approaches to quality, they are the reactive and the probabtively philosophies. Top management decides whether it is to adopt a reactive approach to quality management.

Neiss and Gershon (1989), said that in the reactive or detection oriented approach its emphasis is on prevention of faulty work being passed on to subsequent scrap return or rejected products and non repeat business. Inspection is a reactive tool of quality management. This can be done only after a manufacturing task has been completed. It will identify poor workmanships but its of lower quality due to human error it does nothing to prevent it from occurring again but corrective action will be taken to avoid the recurrence side by Weiss and Gershon (1989). The objectives of this approach is to inspect completed work from part of the process to prevent faulty work from being passed on the neat stage of the process. It is usually carried out by staff outside the operations. Function and takes place between process stages or after a sequence of stages to filter out sub-standard work. This is then either scrapped or reworked to bring it to standard. Inspection stages are expensive and time consuming. The preventive oriented approach aims to allocate resources as to make products right at first time or more of the times side by David (1981). He said that this can be achieved by viewing the quality of both design and conformance in order to identify factors affecting these two quality. Quality management is then designed around this analysis.

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