Unfolded Cigarette Boxes (Flats) Packages Ltd Statistical Quality Management

Group members Abdul Rafeh Iqbal Asad Mujeeb

Table of contents

1. Executive Summary 2. Company Profile 3. Current Statistical Quality Control Systems 4. Application of Management Strategies 5. Eight Dimensions of Quality 6. Application of Descriptive Statistics 7. Statistical Methods Useful in Quality Improvement 8. Chance & Assignable Causes of Quality Variations 9. Magnificent Seven & Application 10. Control Charts for Variables 11. Control Charts for Attributes 12. Process and Measurement System Capability Analysis 13. Acceptance Sampling for Attributes and Variables 14. ISO Standardization 15. Application of Six Sigma Approach 16. Critique of the Quality Control System 17. References 18. Annexure / Appendix

4 5 6 6 7 9 12 13 14 19 21 23 26 29 29 30 31 32

Acknowledgements

Firstly we would like to thank Mr. Shahid Hafeez, Manager of the Industrial performance department for giving us the time to explain and make us understand all the various aspects of quality in the print industry, and then providing us complementary information on the Rivera Lemanic print line on which we based our Statistical Quality Management project Secondly we would like to thank Mr. Waqas Shuggaht, for also giving us a tour of the print line and explaining to us in detail all the functions and operations of the machines. We thank him also for giving us an insight into the SQM systems in packages and techniques used in Quality control Lastly we d like to thank Mr. Kamran Ijaz for providing us with the data on which we have performed the test and tasks required to give meaning and purpose to this project Thank you all

Executive Summary
Packages specializes in packaging using paper as the raw materials and covers a wide range of packaging materials starting from Cigarette boxes to tissue paper boxes, pamper covers to biscuit boxes. The partial project focuses in-depth quality management and statistical methods applied to interpret the current quality standards and variations in the product and machinery. The product that has been comprehensively spotlighted is Unfolded Cigarette boxes (flats). Being pioneers in the Packaging Industry, Packages observers strict measures to meet, ensure, and enhance Quality Standards by the use of advancing Quality Management Systems. Packages currently is guaranteeing Quality Assurance Systems and making head-fast implementations towards Quality Maintenance Systems to create a Material-Machine Relationship.

Company Profile
Established in 1956 as a joint venture between the Ali Group of Pakistan and Akerlund and Rausing of Sweden, Packages Limited provides premium packaging solutions for exceptional value to individuals and businesses. We are the only packaging facility in Pakistan offering a complete range of packaging solutions including offset printed cartons, shipping containers and flexible packaging materials to individuals and businesses world-wide. Our clientele includes illustrious names such as Unilever and Pakistan Tobacco Company, who have been our customers for over 50 years. We employ over 3000 people and had sales of over US $ 100 million in 2004. Listed on all three stock exchanges in Pakistan, Packages Limited has maintained a long-time credit rating of AA. Our joint ventures and business alliances with some of the world's biggest names reflect our forward-looking strategy of continuously improving customer value through improvements in productivity. Packages has always been at the forefront of new developments in packaging research and has pioneered several innovations, including the use of wheat straw as a raw material for paper and board manufacture. Our on-site paper and board mill, established in 1968, has constantly increased its production capacity. A new plant with even greater capabilities is planned for the near future.

Current Statistical Quality Control Systems

Packages considers Quality as one of their strengths and has thus since its inception in 1956 always focused on keeping Quality measures. Applying Quality Control Systems where checks were devised for each machine and product requirements for compliance and Standardization. Packages limited has Evolved from the systems of Quality control and Quality assurance and is now putting place a Quality Management System, which brings in new aspects such as customer complaint handling and Quality audits and new mind sets as written below The Quality management system looks to take the quality control manager from the end of the production line to the beginning, inputs to the machines are examined with far greater detail than before along with this processes of the machine are decomposed and output of one process is taken as the input of another. With this mind set, the QMS system believes that if one part makes an error, that error would be multiplied when out of specification input is given to the next process of the machines. With this decomposition of the process it makes it easier to pin point problem areas and eliminate incident and growth of errors. Packages believes the QMS will bring the defect rate down to 2% as it is smoothly incorporated in the complete firm.

Application of Management Strategies

Packages considers Management Strategies a means for Quality Improvements and focuses towards defects & wastages in applying its Quality Managing Strategies. Packages with its immense packaging lines and unique packing types has specialized each separate procedure and item as it can so to keep clarity & efficiency in execution of work. The following are the quality improvement measures; y y y y y Information for Quality Targets Wastage reduction Defective reduction Overall-Equipment-Efficiency (OEE) Complaint Reduction (Internal & External)

These specialized unique units of the Quality Improvement Strategy are quite comprehensive and entail objective descriptions with them. Furthermore they also encourage creative solutions and incentives are

based on the amount of quality improvement in terms of immediate change that they bring. So, while a set of rules are being applied, there is always room for more efficiency.

8 Dimensions of quality Product Unfolded Cigarette boxes (Flats)

Performance: The purpose of the product is to fold neatly into a box with functions performed at the PTC manufacturing plant. In order for that to happen the product must have consistence and equal cut lines and since each flat is cut from a big sheet on which 21-27 flats may be printed, the cutting needs to be exact so as to not include part of another flat and compromise the structure and appearance Features: The flat should have the specified features, the different colors on the flat should not overlap each other, the colors used should be in conformity with the shades required by the brand, the embossing should be exactly on the text required and not deviated and the text or drawing should not be smudged Reliability: Since each flat has to be put through a machine, each flat should be within invisible specification of grammage, caliper and tensile strength to successfully make it out of the machine otherwise it could cause obstructions and cause a stoppage of the machine which would be very expansive and time consuming to restart Conformance: Since this is not a finished a product the flats have to still meet specification of the clients machines which fold it into a box. The clients specification are regarding firstly grammage which is the number of fibers per square meter, then Caliper which is the thickness of the board and tensile strength which the strength of the paper board vertically and horizontally Durability: The flats first have to be transported and they have to deal with different levels of humidity and wetness in regards to different location of PTC factories, thus they need to remain in their original shape. Each Flat has a certain amount of curve towards one side which is required by the machines at PTC and humidity can take that away or worsen it thus conditions of transportation need to be taken into regard. Lastly the machines pull, push and exert pressure on the flats thus regarding tensile strength specifications need to adhere to. Serviceability: Since the product is just a length of board with printing an embossing, if created out of speciation it cannot be repaired. Out of specification flats sent back by PTC cannot be repaired individually because they are not of the nature which would be conducive to input them into the original machine but with the nature of the industry, Packages limited can recycle it completely bleach the wood fiber and put it into another paper board reel which can be used for another batch of flats.

Aesthetics: Pakistan Tobacco Company has certain brands, and these brands carry certain logos, designs and specific colors, the products (flats) need to adhere to all of these things if the company is to create a brand relation with their customers. Another major aspects is the colors used in the printing they should be in conformity with the shades requires by the company. All of these characteristics of a brand are very important for consumer to draw bond with the brand Perception or perceived Quality: Even thought the cigarette box is not a product of Pakistan tobacco company, people who smoke their cigarettes will draw conclusions from their experience as a whole which includes the experience they have with the box, Thus lack of quality in the box may have the customer thinking that the cigarettes contained in the box are also of low quality, thus it is of high importance for PTC and Packages to have a good relationship and produce a quality product

Application of Descriptive Statistics

Aspect of Product chosen: Grammage: This is the amount of grams per square meter of fibers which
are left in the form of paper after almost 90% of the water is taken out from the pulp
Da e

6107-c

6142-c

7/8/2007

6763-c

1 1 1 2 2 2 1 1 1 2 2 2 1 1 1 2 2 2

(a (b (c (a (b (c (a (b (c (a (b (c (a (b (c (a (b (c

) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) )

Shown Above is part of the sampling spread sheet in which the daily data is stored, from every reel there are 2 sets of samples. Each reel is up to 1500 meters of cardboard paper, the first set of samples are taken from around 1100 meters and the second from around 450, finished flats come of three parallel conveyer belts which are denoted by (a)(b) and (c), and supporting is the grammage data from the Packages paper labs

Grammage base board coating finished

lower limit 180 18 196

target 188 20 208

upper limit 196 22 218

Shown above are the specification of the Flats (unfolded cigarette boxes) required by the Pakistan tobacco company, we will use this to analyze the descriptive statistics

Ree No. Sa p e No.

a ge g/ 219 218 215 219 217 222 216 213 220 217 217 218 217 211 221 214 215 220

Descriptive Statistics (sample of 12 reels, 6 samples each) Central Tendency

Mean: 219.83 Median: 219 Both the mean and median appear to be out of the limits, the reason from which will be discussed later as we discover the inter-relationship and relative importance of a group of variables

Dispersion
Range: 24 Standard Deviation: 6.19 Q1: 215 Q3: 222.75 The range is larger than the difference of the upper and lower limit which is 20, so this shows that there are flats being produced which go beyond the limits of the specifications, which is clearly evidence of assignable variation. The standard deviation is not that bad because from the mean the deviation allowed is 10 but this is a decent figure of 6.14 which shoes that the machine is capable, but It s capable at the wrong mean value, and this is evidently clear from the first and third quartile

Graphical Representation 1. Histogram

Histogram of Grammage
20

15 Frequency

10

0 210 215 220 225 Grammage 230 235

10

As shown above the Histogram of the distribution shows that the data set is symmetrically skewed with the mean and median being almost the same, however there are more classes above the mean, but with comparatively less frequency, thus the graph may now look exactly normally distributed. A matter of concern however is that the Mean of the distribution is even higher than the upper limit of the specifications.

2. Stem and left

Stem-and-leaf of Grammage N = 72 Leaf Unit = 1.0

3 10 19 28 (12) 32 21 17 15 11 9

21 21 21 21 21 22 22 22 22 22 23

111 2222233 444444555 666666777 888899999999 00000001111 2223 45 6667 89 000011

As shown above and hinted from the histogram table, the date distribution of Grammage is symmetrically skewed, with the median at 219, which is a really high median to have when we look at the specification of the required product

3. Box and whisker plot

Boxplot of Grammage
235

230

Grammage

225

220

215

210

11

The above figure shows the Box and whisker plot, which basically depicts the same information as shown above but in this plot we can see the unnecessarily large range of the grammage that the company is currently providing.

Statistical Methods useful in Quality Improvement

Packages incorporates many different statistical methods which it finds useful in improvement of Quality , 2 of the most popular and usual are mentioned below 1. Process Capability 2. Control charts But apart from these techniques packages pays a lot of heed to quality in matters of product in terms of machinery, in terms of employee efficiency and the quality of the firm as a whole. These include, the QM Matrix, QA Matrix, and YY Analysis & YYBecause Logic The QM Matrix is a tool that has been designed to measure the quality not only from the linguistic point of view, but also from the functional- technical point of view of the product. Therefore its audience is multiple: PM, TPM, vendors, Linguists, customers and anyone interested in monitoring the quality of the localized products. The QA Matrix consists of two separate sheets: y Review- sheet, which includes the "Review Comment" of the reviewer y Evaluation- sheet, which includes the "Results" tables The two sheets will be combined into one file when a reviewer evaluates the translation quality.

The YY analysis is a technique which simply focuses towards the root problem, and can be applied to products, machines, employees and etc. it is famously pronounced the 5 Why analysis. When multiple Why s are asked, each question leads to an answer and each answer leads towards another question and thus that is how the root cause of the problem is reached.

12

Chance and Assignable Causes of Quality Variation

Chance of random variation can be caused from a variety of sources, some of which are mentioned below. 1. Un-even heating and cooling of the machine can produce expansion and contraction in the parts of the machines which may cause minor variations in their performance causing random variation 2. Variation in the viscosity of the ink used in the print line 3. Fluctuations in the specifications of the Card board supplied by the packages paper mill. We are talking about the in-range specifications, (e.g. Grammage UL=218, LL=196) these minor fluctuation cause random variations in the final flats produced Assignable causes of variation are as follows 1. Power surges are a major cause in the assignable causes of variation, for they may make the machines behave in an unusual manner for that time phase, the parts of the machines may not be in proper Sync for that time, and may result in out of specification flats being produced 2. Where there are patches of card board in the reel which have specification out of range, these patches may cause problems to the machines which are designed to perform with set rules and room for flexibility, Thus these out of specification patches create errors in most of the process and cause flats made to be out of specification and deformed( smudged and un-cut)

13

The Magnificent Se7en

1. Defect Concentration Chart

Defect Detection, concentration and identification

1. When the reel of card board is printed, each of the color(8) stations print a cross on the flat, in the end all the crosses should be over each other, and we can detect the colors which are not aligned properly 2. Every printed flat has a identification number , there are almost up to 21-27 flats on one sheet, if a defect is found, the defective, blade, color and emboss cylinder can be pin pointed 3. Gold Leaf has to be embossed on every flats, those whose alignment is out can be pointed with the identification number, and the defect can be counted and quantified, and analyzed later 4. Defect concentration can also be done using the 4 positions shown by the arrows with cuttings which have to fold, improper cutting due to blunt blades can cause section of un-cut 5. On the sides of the flat are lines along which the Flat is suppose to be cut, and this lines becomes a shorter and fatter with a difference of 0.5mm, to give an estimate of the deviation, as shown, defect concentration can also be used with this

1 2 3 4 5

14

2. Cause and effect diagram

Cause-and-Effect Diagram
Material Personnel

s i on dit c on

over condident

g ti n li gh x mi of

Above shown is the Cause and effect diagram for the causes and effect of increased Wastage

ong Wr s is on inc ce t an lac k

at i l eg de

pe pro Im

wrong shade(ink)

on

ts ien red ing

ink viscosity blunt razors

ego(non co-operation)

of os

or vi s per su

dly en fri too

lazy(repairs/replacements)

improper feed of paper inconsistant cooling wornout print cylinders

Increased Wastage

ge led ow r t kn - st a pre of

l t ro c on

at m

k l ac

changing humidity

Caliberation time

el nn so per g gin an ch
Imporper lubrication

water/ink spills

Environm ent

Machines

15

3. Pareto Chart
Exact Data on the number of errors was not available at packages limited, but they were aware of the 80-20 rule and they said that it was most likely be true for their processes, they provided us with hypothetical information which denoted Color sync, Wrong color shade, and wrong alignment as major problems which constituted almost 80 percent of their quality problems, below is a representation of all the errors in a pareto chart

P r to C ha rt 200 150 Count 100 40 50 0 ls 20

 

100 80

60

rs ou l co

nc

ng ro w
67 33.5 33.5

nm lig r

t en co

e /s ur lo em

ss os b

g on

t rc t Cum %

50 25.0 58.5

43 21.5 80.0

tti i cu pr r er p pe pr pr im im ir r 10 8 5.0 4.0 85.0 89.0

ti ul rf i

t ls

Ot

8 4.0 93.0

7 3.5 96.5

7 3.5 100.0

Errors
Color sync Emboss sync Wrong color/shade Wrong alignment Improper cutting Smudging Improper printing Irregular final stacks Total

frequency
67 10 43 50 8 7 8 7 200 16

P r

nt

   

4. Stem and leaf/ Histogram Histogram

Histogram of Grammage
20

15 Frequency

10

0 210 215 220 225 Grammage 230 235

As shown above the Histogram of the distribution shows that the data set is symmetrically skewed with the mean and median being almost the same, however there are more classes above the mean, but with comparatively less frequency, thus the graph may now look exactly normally distributed. A matter of concern however that is the Mean of the distribution is even higher than the upper limit of the specifications.

5. Stem and left

Stem-and-leaf of Grammage N = 72 Leaf Unit = 1.0

3 10 19 28 (12) 32 21 17 15 11 9

21 21 21 21 21 22 22 22 22 22 23

111 2222233 444444555 666666777 888899999999 00000001111 2223 45 6667 89 000011

As shown above and hinted from the histogram table, the date distribution of Grammage is symmetrically skewed, with the median at 219, which is a really high median to have when we look at the specification of the required product 17

6. Control Charts

Xbar Chart of Grammage

1

230

225 Sample Mean

UCL=224.52

220

_ _ X=219.83

215
1

LCL=215.15

6 7 Sample

10

11

12

Shown above is a simple X-bar chart of the grammage of the paper used, simple size was 6 and 12 samples were used, and this chart is helpful in showing that the process is out of control as shown by the red dots. A more detailed analysis of variables and attributes in done in the next section

7. Scatter plot (Variables for which data was provided were not related to each other , thus
were were unable to present any meaningful scatter plots)

8. Check sheet (the appropriate information was not available from packages limited to create
this sheet)

18

Control Charts Variables

X-Bar Variable: Grammage

This is the amount of grams per square meter of fibers which are left in the form of paper after almost 90% of the water is taken out from the pulp. Samples: 34 Sample size: 6

Control Chart : Grammage

1

230

225 Sample Mean

UCL=224.84

220

_ _ X=218.34

215 LCL=211.85
1

210 3 6 9 12

15 18 21 Sample

24

27

30

33

The x-bar chart presents 30 such samples means which remain within the Control limits (Upper & Lower) but there are 4 sample means which are going beyond the Control limits and thus make the process Out of Control.

19

R-Chart Variable: Grammage

This is the amount of grams per square meter of fibers which are left in the form of paper after almost 90% of the water is taken out from the pulp. Samples: 34 Sample size: 6

70
1

60 50 Sa ple Range 40 30 UCL=26.94 20 10 0 3 6 9 12 15 18 Sa ple



21

The representation of the R-Chart shows 2 distinct results, though the process is undoubtedly goes out of control once. The value which goes beyond the UCL is called assignable variation and is due to a short-failure of the electricity for micro-seconds, this causes the range for the certain sample to be out of control. Apart from this detail, most of the samples come out to be below the Central line = R-bar. This means that according to this feature, the process is again out of control.



Control Chart : Gra

age

_ R=13.44

LCL=0 24 27 30 33

20

Control Charts- Attributes

P-chart
Variable: Cut to Print Depending on the job there could be 21 or 27 flats printed on one sheet, they need to be cut and separated, but they need to be cut exactly on lines which divides each individual flats from the other, if the cut is along the wrong lines then one flats will contain parts of another and the design of the pack will not complement the shape once it is folded, Thus the print cut can only deviate 0.5 mm from the ideal center where the cut should ideally be. Samples: 34 Sample size: 6

Control Chart : Cut to Print

1

0.5 UCL=0.4622 0.4

Proportion

0.3

0.2 _ P=0.0980

0.1

0.0 3 6 9 12 15 18 Sa ple 21 24 27 30 33

LCL=0

The P-Chart clearly shows out of control process, with 17 samples on the LCL and 1 sample beyond the UCL.

21

C-chart Variable: Cut to Print

Samples: 34

Control Chart: Cut to print

3.0 2.5 2.0 1.5
1

UCL=2.889

Sample Count

1.0 0.5 0.0 3 6 9 12 15 18 Sample 21 24 27 30 33 _ C=0.588

LCL=0

The C-Chart is a representation of the same P-Chart but used in the purpose where un-equal sample size are available. So the, result is the same, the process is out of control.

22

Process Capability Analysis

Process capability analysis was carried out on the variables Grammage and Caliper as discussed earlier

Grammage
lower limit base board coating finished 180 18 196 target 188 20 208 upper limit 196 22 218

P o en ial i hin C apabili y Cp 0.75 C PL 1.52 C PU -0.03 C pk -0.03 C C pk 0.68 O v e a ll C apabili y Pp P PL P PU P pk Cp 0.60 1.23 -0.02 -0.02 0.28
& # & 0 & )( & &

204
& $ '# 3# # %

216
$ '# 3#

228
E xp. PP PP PP

240
#

252
$ '# 3#

264

The process capability analysis was done with 269 samples from 45 card board reels .The Cpk index indicates whether the process will produce units within the tolerance limits. A Cpk index of 1 means that a process is exactly capable of meeting specifications, while less than 1 means that the process is not meeting specification limits, In the case of Grammage, the Cpk value is -0.03 which means that the current process is nowhere near capable of meeting specification and producing units within the tolerance level, it is plainly evident just by looking at the distribution that more than half the values lie 23

&

&

&

Ob PP PP PP

e v ed P e o a n e <LS L 0.00 >U S L 496296.30 To a l 496296.30

E xp. Wi hin P e o a n e 2.41 PP <LS L PP >U SL 535486.67 535489.08 PP To a l

O v e a ll P e o a n e <LS L 113.39 >U S L 528627.36 To a l 528740.75

'

"

Da a LS L 196.00000 Ta ge 208.00000 USL 218.00000 S a ple ean 218.43704 270 S a pleN S D ev i hin 4.90670 6.08518 S D ev v e all
& 0 %% $ # 0 # & )( 2 1( & ' ' # & &

P o e

"

LSL

Ta g e

USL Wi hin Ove all

44

Process Capability of Gra

age

beyond the upper limit, there appears to be a strong need for improvement in the current process which shows a considerable amount of variability and inconformity with the desired specifications.

Caliper
lower limit base board coating finished 260 5 265 target 280 5 285 upper limit 300 5 305

Process Capability of Caliper

LSL
P ro ess Data LS L 265.00000 Target 285.00000 USL 305.00000 S a pl M ean 285.20000 270 S a pl S tD ev (Within) 4.45433 S tD ev (O v erall) 9.25274
5 8 7 6 7 6

Target

USL Within Overall

P otential (Within) C apability Cp 1.50 C PL 1.51 C PU 1.48 C pk 1.48 C C pk 1.50 O v erall C apability Pp P PL P PU P pk Cp 0.72 0.73 0.71 0.71 0.72

262.5 270.0 277.5 285.0 292.5 300.0 307.5

5 6 5 6

O bserv ed P erfor a n e P P M <LS L 7407.41 P P M >U S L 29629.63 P P M Total 37037.04

5 6

E xp. Within P erfor an e PP M <LS L 2.88 PP M >U SL 4.39 PP M Total 7.27

Exp. O v erall P erfor an e P P M <LSL 14512.89 P P M >U S L 16181.19 P P M Total 30694.07

The process capability was done using 269 samples from 45 card board reels .The Cpk index indicates whether the process will produce units within the tolerance limits. A Cpk index of 1 means that a process is exactly capable of meeting specifications; while a Cpk of less than 1 means that the process is not meeting its specification. In the case of Caliper the Cpk value is 1.48 which is more than 1 thus the process can be deemed more than capable to produce units within the tolerance level, thus in the case of caliper there exists no dire need of improvement, but there is always rooms for improvement, we

24

should not forget that sample values have exceeded limits from both sides, the process can be improve to produce all the units with the in wide range of 265 to 305.

25

Acceptance sampling for Variable (Grammage)

Customer: Pakistan Tobacco Company
Sampling information Packages limited Packs the flats in pellets each containing a lot of 100,000 flats Pakistan Tobacco Company takes around 20 samples from each pellet, if 2 samples of this twenty is found to be critical, then PTC starts a dialogue or a discussion with packages limited. A lot of a 100,000 flats is never really out rightly rejected. A flat in a sample in found to be critical when it is not worthy to be fed into PTS s production machines, especially with regard to Grammage, if the sample has grammage outside its limits, it may cause stoppage in production lines As said before a lot of never out rightly rejected, but it subject to manual sorting by personnel of packages to remove the lot of critically defected items, thus this constitutes a Single Sampling Plan

Acceptance sampling and the OC curve of Variable: Grammage

Lot size = 100,000 Sample size = 20 Reject able Quality level (RQL or LTPD) = 10% Acceptable Quality level (AQL) (assumed) = 6.5% this usually also includes major or minor defect, which are not detectable by the normal consumer and does not hinder machine performance

1.0 ptance 0.8 0.6

B

Probability of A

0.4 0.2 0.0 0 10 nt

9 A @9 9 9@ 9

20 Lot P r

30 f tiv

Operating Charact ristic (OC) Curv Sample Size = 13, Critical Dist nce = 1.10174
D 9

C B

40

50

26

USL=218 and LSL=198

Sampling plan according to ANSI/ASQC Z1.9 N=100,000

Inspection level = N Sample size= 100 Using AQL of 0.065, k= 2.14

Using k USL= 221.01 and

208(2.14)(6.08)

LSL= 194.98

This is suggest that the limits should slightly widened and that the sample size need to be significantly be increased from 20 to 100

27

Acceptance sampling for Attribute (Cut to Print)

OC Attribute (Cut to Print)

1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 0.05 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.95

Lot size = 100,000 n= 20 c=2 AQL= 0.042 Alpha= 0.04 Beta= 0.10 LTPD = 0.26

Sampling plan according to ANSI/ASQC Z1.4, ISO 2859

At inspection level normal for N=100,000, the code is N For this lot size the sample size should have been n=500 At the AQL of 0.04 Acceptance: 1 and Rejection: 2 According to the sampling plan, PTC needs to increase their samples to 500 and reject a lot of there are more than 2 defect or developed a manual sort plan in line with packages personnel , PTC could consider revising their current sample size and rejection criterion

28

ISO Standards
Packages Ltd having a clientele encompassing MNC s since 1960 s, inclusive of Unilever apart from Pakistan Tobacco Company (PTC), had always to work on high volumes with machine capacities having a bare minimum of 25,000 flats in the late 60 s. Keeping in mind their corporate strategies and their reputation as a National Leader, Packages Ltd incorporated the ISO 9000 and ISO 9001 standards. Furthermore they even acquired Certification by SGS Group in the early 90 s. Lemanic Print line, the machinery used for the manufacturing of flats had also during the process of ISO Certification been standardized. The ISO Standards include, process standardizations for Usage so that even if a new employee uses the machine, he follows a standardized set of steps from which he is not to derail to avoid quality inefficiencies. The standards also include defined processes for handling raw material and standards in case a flat print line is found faulty. The purpose of ISO standards on the Lemanic Print line were to Standardize the processes of the manufacturing process to avoid defective inputs and outputs and furthermore to standardize the errors so that they may be controlled to a certain extent. Packages Ltd also focused towards acquiring the standards of ISO 14000 series which is based on external purposes specifically the Environment.

6 Sigma Approach
Packages Ltd regards the Sigma approaches as, measures of how far can we go to control our processes . It has been the aim of the Quality Control Department since its inception in the Packages Division to increase their control over the manufacturing processes. Packages Ltd is one of the only companies in Pakistan to fully implement the 3-sigma approach in various processes. This includes selection of raw materials, machinery controls, manufacturing process, etc. Packages realize that the future belongs to those, who plan to reduce costs which seem uncontrollable today, who do not compromise on quality and perceive perfection in their processes. Thus Packages has directed its Quality Control Department to start R&D towards the practical and analytical implications of implementing the 6-Sigma Approach. In order to achieve a six sigma level of production we have to keep in mind that all process in the making of paper needs to be a six sigma, with the nature of card board manufacturing involving a lot of evaporation stages the process is very hard to monitor and maintain, but packages limited in working on process environment control and aim to achieve higher levels of quality in the future y y y Moisture control Temperature Control Dust free environment 29

Frequent cleaning and maintenance of machinery

Critique
During the course of our quality analysis of packages ltd we have learned a lot about the company and one of their major customer The Pakistan tobacco company. Throughout the project we have taken into account 2 main variables namely grammage and caliper, as you might have read the process with regard to grammage is not capable and is out of control, even though grammage is something the operators have to vary to keep the caliper within range we urge that effort should also be directed towards bringing grammage in control, especially taking into regard PTC s machines, which aim to fold the flats with a prescribed strength. If the grammage of the flat will be too thick the folding process will be interrupted and this is cause costly stops/starts of the manufacturing process. Since packages limited deals with a lot of companies, they have a huge variety of orders; they need to organize their orders in such a way that their machines can have longer operative runs, since it takes a while for the machine to acquire its rhythm and start producing at the set standards. Constant changes in orders, resetting of specification and condition higher a achievable higher level of quality Packages is a firm which acquired It s ISO certification in early nineties, and in recent times it has also been working toward acquiring a ISO 14000, and in line in that they have a installed a water treatment plant in their new factory in Kasur (bullah shah paper mills) , water is taken from all processes of the factory and collected at one location where it is brought to a constant temperature and then treated before it is used again the process, this will also bring in a higher level of control and consistence in water involved processes which are abundant in paper manufacturing. This is also a step towards social corporate responsibility for which packages limited can be applauded Lastly we would advise PTC to reconsider their acceptance sampling, they should consider taking up a larger sample size regarding both variables and attributes, this although would come at a cost but which would further ensure that critically categorized flats do not enter their manufacturing process which might be a source of interruptions or costly stops

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References

www.packages.com.pk Various handouts acquired from packages limited   Quality assurance ISO 9000 and ISO 14000

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Mini tab 15 (generation of OC curves) Packages Quality control department Packages Industrial Performance department

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