QCMS A quality control management system

Computers ind. Engng Vol. 19, Nos 1-4, pp. 495-499, 1990 Printed in Great Britain. All rights reserved

A QUALITY M.

0360-8352/90 $3.00+0.00 Copyright © 1990 Pergamon Press plc

QCMS CONTROL MANAGEMENT

SYSTEM

S. Eid and G. L o s i e r

School of E n g i n e e r i n g U n l v e r s i t ~ de M o n c t o n Moncton, New B r u n s w i c k Canada

ABSTRACT

to integrate our quallty control analysis system with a Management Information System that would a u t o m a t e the d a t a a c q u i s i t i o n , the quality control analysis results and the production of control charts, as well as generating m a n a g e m e n t reports.

Thls p a p e r p r e s e n t s the QCMS, a Quality Control Management System, was d e v e l o p e d for a p p l i c a tion in the q u a l i t y a s s u r a n c e area of i n d u s t r i a l p r o c e s s e s . QCMS is d e s i g n e d to h a n d l e the p r e p a r a t i o n of quality control documents a p p l i c a b l e to an o r g a n i z a t i o n , the a c q u i s i t i o n of d a t a r e l a t i v e to the q u a l i t y v a r i a b l e or a t t r i b u t e to be controlled, the transcription of the q u a l i t y data on the q u a l i t y control forms, the d e v e l o p m e n t of the q u a l i t y control charts, and the generation of m a n a g e m e n t reports. This system is b u i l t as a step toward an expert s y s t e m in q u a l i t y assurance that would provide quality diagnostics and p r e s c r i b e remedy recommendations. QCMS c o n s i s t s of d i f f e r e n t m o d u l e s that may be u s e d e i t h e r s e p a r a t e l y or as part of the i n t e g r a t e d system. The paper p r e s e n t s the QCMS w i t h its abilities thus far as well as of future extensions. The p a p e r also gives e x a m p l e a p p l i c a t i o n s of the QCMS to i n d u s t r i a l p r o c e s s e s . i.

2. L O B S T E R

OUALITY

REQUIREMENTS

Lobster fishing is a major i n d u s t r y for the C a n a d i a n M a r i t i m e Provinces. L o b s t e r is, as is the case w i t h m a n y e d i b l e products, a perishable food. Its q u a l i t y can be a f f e c t e d at any step d u r i n g its harvesting, transportation, processing, packaging, and marketing. They are subject to c o n t a m i n a t i o n by foreign matter and can also deteriorate by pathogenic microorganisms. The effect on q u a l i t y may be minimal not c o n s t i t u t i n g a health hazard but may make the product undesirable based on aesthetic and palatability considerations. The presence of foreign m a t t e r may also c o n s t i t u t e a health hazard resulting in food poisoning if p a t h o g e n i c organisms are present. Stringent quality control procedures are therefore mandatory.

INTRODUCTION

In an effort to enhance quality assurance in the fishing industry in g e n e r a l and the fish transformation industry in particular, the D e p a r t m e n t of Fisheries in the P r o v i n c e of N e w Brunswick, Canada, c o n d u c t e d a study of the q u a l i t y control n e e d s in this industry. The c o n s u l t a n t report Ill p r o p o s e d , among other recomm e n d a t i o n s , a set of forms for d a t a collection and quality control analysis. In the mean time, our team at the U n l v e r s l t 4 de M o n c t o n was a c t i v e in d e v e l o p i n g an automated system for the quality control a n a l y s i s and the p r o d u c t i o n of the n e c e s s a r y control charts. The D e p a r t m e n t of F i s h e r i e s report on the q u a l i t y control of lobsters p r o v i d e d us a g o o d start for trying

Q u a l i t i e s of i m p o r t a n c e in the lobster industry change depending on their step In the p r o c e s s chart. They range from the lobster condition before transformation (e.g., whether dead or alive}, to the wight d e l i v e r e d , the weight of sold packages, etc., to the b a c t e r l o l o g Ical and i n t r i n s i c q u a l l t y w h i c h is r e g u l a t e d by the Federal D e p a r t m e n t of F i s h e r i e s and O c e a n s standards. A P r o c e s s Flow Chart for Cold Pack Lobsters is d e p i c t e d in Figure i. Figure 1 g i v e s a l s o the d i f f e r e n t q u a l i t y control tests that are to be p e r f o r m e d and the d a t a collection forms to be u s e d as recomm e n d e d by The D e p a r t m e n t of Fisheries Study [i]. These forms, 495

496

Proceedings of the 12th Annual Conference on Computers & Industrial Engineering

FLOW PROCESS CHART - COLD PACK LOBSTER

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all starting with the letter "L" denoting lobster, are classified into three series. Series i00, ii forms, relate to terms specific to a species. Series 200, 6 forms, are generic forms covering many species. Finally, Series 300, 5 forms, are generic relating to the product and its recall situation. Figure 2 gives Form LID2 as an example.

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Eid and Losier: QCMS

3. QCMS- THE O U A L I T Y C O N T R O L MANAGEMENT SYSTEM B e c a u s e of the n a t u r e of the product, a perishable item, any effective quality control must be ba s e d on timely reports allowing management appropriate actions• Now that m i c r o c o m p u t e r s are available at r e a s o n a b l e p r i c e s and that a p p l i c a t i o n s of m i c r o p r o c e s s o r s are multiplying at low cost, such a control is p o s s i b l e . The QCMS is d e s i g n e d to i n t e g r a t e the d i f f e r e n t tasks of q u a l i t y control starting from the data acquisition, data analysis, i n f o r m a t i o n r e t r i e v a l and the g e n e r a t i o n of d e c i s i o n reports. Figure 3 gives the different m o d u l e s of QCMS• 4. U S E OF QCMS The S y s t e m is user f r i e n d l y and is easy to use. It requires no knowledge of any programming languages• It is m e n u d r i v e n w i t h responsibilities for m a s t e r files housekeeping, checking for the different tiers of a u t h o r i z a t i o n , and permitting the analysis to those a u t h o r i z e d p e r s o n n e l . Users of QCMS w o u l d have an ID n u m b e r i n d i c a t i n g their d e p a r t m e n t , level of a u t h o r i t y , and a p e r s o n a l code. Only the QCMS manager or his a u t h o r i z e d p e r s o n n e l have the right to add a n e w user, d e l e t e a user, or edit the p e r s o n a l i n f o r m a t i o n of a user on the system. Only Quality d e p a r t m e n t p e r s o n n e l are a u t h o r i z e d to a c c e s s d a t a and p e r f o r m q u a l i t y control analysis. A QCMS user is therefore denied access to unauthorized information and/or analysis. 5• E X A M P L E QCMS A P P L I C A T I O N LOBSTER INDUSTRY

497

a c q u i s i t i o n device, such as scales and other m e a s u r i n g Instruments, to automatically feed in the data. F u t u r e e x t e n s i o n s are e n v i s i o n e d to p r o v i d e it w i t h d e c i s i o n tools and h e n c e m a k i n g it take the form of an expert system. REFERENCES

7•

1. R E P O R T ON THE D E V E L O P M E N T OF OUALITy CONTROL PROCEDURES E N S U R I N G THAT R E G U L A T O R Y C R I T E R I A A R E MET, a report p r e p a r e d for the D e p a r t m e n t of F i s h e r i e s and O c e a n s b y The A t l a n t i c Q u a l i t y C o n c e p t s Ltd., D F O File # FDB G R 87-28 and DSS File # 0 0 1 X A R . F P 3 0 - 7 - 8 0 3 7 , Moncton, N. B., Canada• 2. F r e d e r i c k W. W h e a t o n and Thomas B. Lawson, P R O C E S S I N G A O U A T I C FOOD PRODUCTS, John W i l e y & Sons, N. Y., 1985. 3• J• M• Juran, Q U A L I T Y C O N T R O L HANDBOOK, M c G r a w -Hill, N• Y•,1979.

TO THE

The QCMS was a p p l i e d to the q u a l i t y control of lobster transformation us i n g e l e c t r o n i c s p r e a d sheets for forms LIOI, LI02, L307. Figures 4a, 4b . . . . give d i f f e r e n t screens of the QCMS showing its d i f f e r e n t options. The same c o u l d be a p p l i e d to other i n d u s t r i e s once the appropriate data forms are provided.

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The QCMS makes easy the data c o l l e c t i o n and a n a l y s i s for p r o d u c tion and/or quality control purposes. The m a j o r a d v a n t a g e is in p r o v i d i n g t i m e l y r e p o r t s and hence permitting appropriate actions regarding quality. QCMS may be p r o v i d e d w i t h a front end d a t a

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QC R e s u l t s

FIauT~ ~ OC Eystem MOdules

LIO1,102, . . L201,202, . , L301,302, . .

498

Proceedings of the 12th Annual Conference on Computers & Industrial Engineering

Figure 4: ExamPle o$ QCMS Output

Q u a l i t y Control Program (c)

1989

Monday 01/01/90

MAIN MENU

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Production Control Q u a l i t y Control Test Personnel Data Maintenance Backup databases f i l e s Exi,,t t o Dos

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Version : dBASE I l l PLUS Version 1,1 Disk space : 4536320 bytes Last update : 01/01/90

Q u a l i t y Control Program Ecole de 6enie U n i v e r s i t e de Moncton

Use cursors t o choose o p t i o n , then press RETURN

Figure 4a

Q u a l i t y Control Program (c)

QCMS Main Menu

1989

Monday 01/01/90

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RM - Lobster : Buying S t a t i o n / Inspection Form . . . . . . . . . . . . . . . . . . . Lobster : Raw M a t e r i a l Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Incoming Processing & Packaging M a t e r i a l s Inspection . . . . . . . . . IP Daily Q u a l i t y Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lobster : In-Process Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lobster : Holding Tank Operation Log . . . . . . . . . . . . . . . . . . . . . . . . . - Lobster : Holding Tank Storage Log . . . . . . . . . . . . . . . . . . . . . . . . . . . - Lobster : Cooking / Cooling Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - Lobster : C h i l l Room Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Freezer / Cooler Temperature Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - Weigh Scale Inspection Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lobster : Sealer Operators Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Employee Workmanship Performance Record . . . . . . . . . . . . . . . . . . . . . . FP Cold Pack Lobster Meat : Finished Product Inspection . . . . . . . . . - Freezing Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - Shipping Inspection : Finished Product . . . . . . . . . . . . . . . . . . . . . . . - Finished Product Inventory Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Return t o MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -

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Figure 4b

L 101 L 102 L 205 L 204 L 107 L 103 L I()4 L 105 L ic)6 L 207 L 206 L 110 L 111 L 108 L 201 L 203 L 202 QUIT

qCMS Request f o r Form AnaIEsis

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X-Bar & R-Bar Charts NP Chart P Chart C Chart Single Sampling OC Curve Double Sampling OC Curve Quit, return to l a s t menu

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Employee submenu Buyer submenu Supplier submenu Quit, return to mainmenu

PERSONNELSUBMENU

EMPLOYEE FILE SUBMENU

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: : : :

29 AMOUR MONCTON EIC3E8 ( )8574491

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LOBSTER KBS EID CONTAINERS JAN 1 1990 : MARKET SIZE

Fioure 4d

: 0.00 : 0.00 : 36.00 : 6.50 -

Personnel Module Outnut

Unemployment insurance Blue cross insurance Regular hour ( week ) Regular salary ( hour )

Oualitv Control Outouf

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- Last name : SMITH

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Others information : memo ( Ctrl-Pgdn to e d i t , Ctrl-Pgup to e x i t ) Overtime hour ( week ) : 0.00 Overtime salary ( hour ) : 0.00

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I Quality Control Program 1989

State : N.B.

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Social insurance number : Marital status : M ( S for single, M for maried ) Birth date : 06/12/50 Date started : 05/23/89 Account ( bank ) : SCOTIA BANK

Address City Zip code Phone no

DATA VERIFICATIONS

CHARACTERISTIC

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Id number : 02023489 - F i r s t name : JAMES C.

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Edit : Employees Database f i l e s

INPUT DATA # TO CHANGE, 0 TO CONTINUE ?

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Fiqure 4c

1. PLANT / DEP. NAME : 2. UNIT MEASUREMENT : 3. Q.C. ANALYST NAME : 4. PART NAME OR NO. : 5. DATE OF STUDY :

Examine an employee record I Add a new employee record I Delete an e x i s t i n g employee record I Edit an employee record I Sort employee records I Quit, return t o MAIN MENUi

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Production Control Quality Control Test Personnel Data Maintenance Backup databases f i l e s E x i t to Dos

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