HAWASSA UNIVERSITY

INSTITUTE OF TECHNOLOGY

FACULTY OF MANUFACTURING

DEPARTEMENT OF INDUSTRIAL ENGINEERING

Statistical Quality Control and Reliability

GROUP MEMBERS ID NUMBER

YEABNEH ESHETAYEHU 1181/09

MEHERET KETEMA 0967/09

TESFAMARIAM TESHOME 0875/09

HUZEIFA MOHAMMED 0181/09

SADAM DALU 1552/08

SUBMISSION DATE MAY 16/2021

SUBMITTED TO MR. NEBIYOU G.

 Hawassa University Revenue Generating PLC

Table of Content
List of Figure........................................................................................................................I

List of Tables........................................................................................................................I

Declaration......................................................................................................................... II

Acknowledgement..............................................................................................................III

Abstract..............................................................................................................................IV

CHAPTER ONE

BACKGROUND OF THE COMPANY

1.1. INTRODUCTION........................................................................................................1

1.2. WHAT THE COMPANY DOES?............................................................................... 2

1.2.1. Hawassa University Enterprise.......................................................................... 2

1.2.1.1. Field of Work.................................................................................................. 2

1.2.2. Objective............................................................................................................ 3

1.2.3. Work Flow of the Company...............................................................................4

1.2.4. How does the working section look like?.......................................................... 4

CHAPTER TWO

BACKGROUND OF THE STUDY

2.1. INTRODUCTION......................................................................................................13

2.2. PROBLEM STATEMENT........................................................................................ 13

2.3. OBJECTIVE OF THE PROJECT..............................................................................13

2.3.1. General objective............................................................................................. 13

2.4. SCOPE OF THE STUDY.......................................................................................... 14

2.5. LIMITATION OF THE STUDY............................................................................... 14

2.6. METHODOLOGY.....................................................................................................14

2.6.1. Research Design...............................................................................................14

2.6.2. Source of Data..................................................................................................15

 Hawassa University Revenue Generating PLC

2.7. CONCEPTUAL PROJECT FRAMEWORK.............................................................16

CHAPTER THREE

LITERATURE REVIEW

3.1. INTRODUCTION......................................................................................................17

3.2. QUALITY IMPROVEMENT....................................................................................23

3.3. QUALITY CONTROL.............................................................................................. 26

3.4. The Seven quality control tools..................................................................................26

CHAPTER FOUR............................................................................................................. 28

RESULT AND DISCUSSION..........................................................................................28

4.1. INTRODUCTION......................................................................................................28

4.2. STATISTICAL PROCESS CONTROL TOOL.........................................................29

4.2.1. Pareto Chart......................................................................................................30

4.2.2. Process Capability Analysis.............................................................................32

CHAPTER FIVE

CONCLUSION AND RECOMENDATION

5.1. CONCLUSION.......................................................................................................... 35

5.2. RECOMMENDATION..............................................................................................35

References......................................................................................................................... 36
 Hawassa University Revenue Generating PLC

List of Figure
Figure 1 : Hawassa University Revenue Generating Enterprise PLC.....................................1
Figure 2 : Field of Work..........................................................................................................2
Figure 3 : Hawassa University Enterprise............................................................................... 3
Figure 4 : Mixer Machine........................................................................................................5
Figure 5 : Alcohol Tester.........................................................................................................6
Figure 6 : Density Test............................................................................................................ 7
Figure 7 : Lactic Checker........................................................................................................ 8
Figure 8 : Milk Chiller.............................................................................................................9
Figure 9 : Pre-Heater............................................................................................................... 9
Figure 10 : Pasteurization Process.........................................................................................11
Figure 11 : Final product and its storage...............................................................................12
Figure 12 : Log Book............................................................................................................ 15
Figure 13 : Framework.......................................................................................................... 16
Figure 14 : Guiding Objective for Good Dairy Farm............................................................18
Figure 15 : Milking Hygiene................................................................................................. 19
Figure 16 : Nutrition..............................................................................................................20
Figure 17 : Animal Welfare...................................................................................................21
Figure 18 : Environment........................................................................................................22
Figure 19 : Socio-economic Management.............................................................................23
Figure 20 : Pareto Chart of the Given Data...........................................................................31
Figure 21 : Concept of process capability............................................................................. 33
Figure 22 : Influence of location on process capability ...................................................... 33
Figure 23 : Influence of variability on process capability.....................................................34

List of Tables

Table 1 : 4 Month Defect Data..............................................................................................28

Table 2 : Defect Type............................................................................................................29
Table 3 : Pareto Analysis Table............................................................................................ 31

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Declaration

We hereby declare that this Project is the result of our work which has been carried out in
the Hawassa University Revenue Generating Enterprise Plc. All the ethics procedures
and guidelines have been followed properly while preparing this written Project.

Name of Students Signature ID

Yeabneh Eshetayehu _____________ 1181/09

Meheret Ketema _____________ 0967/09

Tesfamariam Teshome _____________ 0875/09

Huzeifa Mohammed _____________ 0181/09

Sadam Dalu _____________ 1552/08

This final project document has been submitted for examination with my approval as
Project advisor.

Name of Advisor Signature Date

Mr. Nebiyou.G (MSc) ____________ __/__/____

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Acknowledgement

Firstly, of all, we would like to thank the almighty god for giving us this time to finish
this project. Then after we sincerely thank our quality control and reliability lecturer Mr.
Nebyou G. for giving us this kind of project in order to accumulate knowledge about the
quality control concept which help us to communicate with the working environment and
industries. We also thank the quality control manager of our hosting company that is
hawassa university revenue generating plc Mr. Tariku for his constructive advice which
made this work a reality. Without his guidance this project could not have taken the
present form. Special thanks go to the operators of our hosing company for their
guidance, encouragement, understanding and insightful support in the development
process.

Last but not least we would like to mention here that we are greatly indebted to each and
everybody who has been associated with our project at any stage but whose name does
not find a place in this acknowledgement.

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Abstract

The project was conducted in Hawassa university revenue generating plc. At dairy farm
of milk pasteurization. The organization used quality tool to develop the satisfaction
from the customers. Quality control in dairy industry reduces vulnerability to dairy fraud
and ensure the authenticity and standard of the ingredients. Auditing, testing and
inspection of the product at each stage verifies that it satisfies a wide range of national
and international food safety and regulatory requirements. The aim of study is to find out
the effective way of improving the quality and productivity of a pasteurized milk. The
objective is to identify the defect of the company and create a better solution to improve
the production line performance. Various industrial engineering technique and tools is
implementing in this study in order to investigate and solve the problem that occurs in
the production. However, 7 Quality Control tools are the main tools that will be applied
to this study. Data for the defects of pasteurized milk in the factory are collected, studied
and analyzed. The defect with the highest frequency will be the main target to be
improved. Various causes of the defect will be analyzed and various solving method will
be present. The best solving method will be chosen and propose to the company and
compare to the previous result or production. However, the implementation of the
solving methods is depending on the company whether they wanted to apply or not. The
guiding objective for good quality dairy farming practice is that safe, quality milk should
be produced from healthy animals using management practices that are sustainable from
an animal welfare, social, economic and environmental perspective.

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CHAPTER ONE

BACKGROUND OF THE COMPANY

1.1. INTRODUCTION

Hawassa University Revenue Generating Enterprise Plc. established based on higher

education institution proclamation No.650/2001 in accordance with Article 66 which
says that universities can establish their own income generating enterprise’.

The HU enterprise is organized as institution to operate inside an outside the university

on different sectors that can generate revenue by having legal trade license to engage in
various business sectors.

Thus, the enterprise works hard to achieve the university and its own vision by following
efficient, effective management and services that are competitive by price and quality.

Figure 1 : Hawassa University Revenue Generating Enterprise PLC.

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1.2. WHAT THE COMPANY DOES?

1.2.1. Hawassa University Enterprise

The enterprise head quarter is located in Hawassa city inside Hawassa university main
campus.it is scope of work is in places where various colleges are located and in other
cities of the country and will open branches abroad.

1.2.1.1. Field of Work

 University model hotel in main campus

 Crafts center in wondo genet college of forestry and natural resource
 Crafts center in college of agriculture
 Main campus farm center
 Poultry
 Dairy farm
 Beef cattle
 Modern abattoir
 Counseling water work project

Figure 2 : Field of Work

The enterprise works full capacity and necessary to meet quality standards by giving
services to collect revenue. Also the enterprise is engaging in other revenue generating
sectors and fulfills preconditions to begin work. These sectors are :-

 HU comprehensive hospital model public service.

 Printing press center.

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 Modern garage and gas station service service.

 Book stores.
 Milk processing and pasteurization center.
 Short term training service and consulting on construction.
 Modern stadium and its shops in main campus.
 Guest houses.
 Modern trade center in college of agriculture.

Figure 3 : Hawassa University Enterprise

1.2.2. Objective

The enterprise provides quality products and services to the local community and
national level by increasing values to the university revenue generating centers as well as
expending revenue sources and applying highly effective and efficient budget system.

Vision

In the year 2017 E.C.by expending different revenue sources, to see being enough
internal capacity and competitive with the same other enterprises.

Mission

Our mission is creating a reliable source of finance for the university by expending
income generating units, creating linkage with medium and large industries at local and
national level, formulating new projects that bring new revenue, strengthening research,
consulting and market development study activities and using effective and efficient
budget procedure.

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1.2.3. Work Flow of the Company

Pasteurization or pasteurization is a process in which packaged and non-packaged foods

(such as milk and fruit juice) are treated with mild heat, usually to less than 100 °C
(212 °F), to eliminate pathogens and extend shelf life. Milk pasteurization is the process
of heating milk (or milk product) to a predetermined temperature for a specified period
without re-contamination during the entire process.

The process is intended to destroy or deactivate organisms and enzymes that contribute
to spoilage or risk of disease, including vegetative bacteria, but not bacterial spores.

The plant has different sections working together for pasteurization of the desired. The
company has several sections; the major sections mentioned as follows:-

 Quality control room

 Chilling section
 Pre heating section
 Clarification section
 Standardization stage
 Homogenization stage
 Heating section
 Holding section
 Cooling and chilling section

1.2.4. How does the working section look like?

Raw Milk storage

Milk and milk products should be stored in clean conditions at appropriate temperature
and humidity to prevent deterioration or permit maturation. Never add milk of a cow
with mastitis to cans for delivery to the MCC or DPU. Also, do not deliver colostrum or
any milk produced by a cow less than 5 days in lactation. Although there is no reason to
consume this milk in the processing plant it will give problems. NEVER! Deliver milk of
a cow treated with antibiotics, this milk is dangerous even for home consumption.
Withdrawal period of milk of animals treated with

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1. Quality control room

Quality control room is responsible for giving required information about the quantity,
quality, hygiene, composition, water content of the raw milk. In addition to this it is also
responsible in inspection and testing of the final product.

Hygienic and Quality Milk Production

The milk process is started from the hygiene. Everyone before entering to the production
center must disinfect there shoes by copper sulphate solution. This is used for removing
bacteria or fungus from shoes.

Milk is the main output of a dairy farm and it is source of income and nutrition for the
farm owner. Thus, dairy farmer must ensure that milk produced in clean and hygienic
way to improve his/her benefits from the farm. Otherwise, wider ranges of issues are a
rising such as:- From the public health point out of view, milk is a very good media for
bacterial and other microorganisms development so that can easily be predisposed by
infected milk during production, handing, transporting and marketing.

Milk sampling at collection centers

After the milk has left the farm where it is produced, the first control takes place when it
arrives at the milk collection center. First the collected milk from different suppliers is
balanced. To know how much litter of raw milk is taken from supplier.

Figure 4 : Mixer Machine

Then after the required information about the quantity, quality, hygiene, composition,
water content of the raw milk is checked by different quality parameters. There is no

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need to test the whole quantity of milk, only a small sample is tasted to check the quality.
Accurate sampling, however, is essential for a proper quality control system. The quality
parameters are:-

 Alcohol test
 Lacto meter or density test
 Lacto scan or lactic check

Alcohol test

The alcohol test is used for rapid determination of an elevated acidity of milk. The test is
carried out by mixing equal quantities (2 ml) of milk and of a 68% or 70% ethanol
solution in a test tube. Alcohol gun is the best alternative for advanced farms/collection
centers. If the milk contains more than 0.21% acid, this results in coagulation of the milk
proteins and the milk is sour. The milk will clot and is not fit for any process which
involves heating, like pasteurization. This test is more sensitive to lower levels of acidity
and can therefore detect bad milk that may have passed the previous two tests. It also
detects milk that has kept for long without cooling, colostrum or milk from a cow with
mastitis. It is based on tendency of milk protein to get unstable as a result of disturbance
in the mineral balance of milk. Milk with high developed acidity, or having calcium and
magnesium compounds in greater than normal amounts, will coagulate when alcohol is
added. Increased levels of albumen (colostrum milk) and salt concentrates (mastitis) may
also results in a positive test. Because this test is quite sensitive, milk that passes this test
can keep for some hours (at least two hours) before it goes bad

Figure 5 : Alcohol Tester

If the milk contain more than 0.21% acid it will be rejected and back to the supplier.
Otherwise it will proceed to the next test, that is the lacto meter or density test.

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Lactometer or density test

The lactometer test is used to determine if the milk has been adulterated with added
water or solids. Addition of anything to milk can introduce bacteria that will make it
spoil quickly. The test is based on the fact that the specific gravity of whole milk, skim
milk and water differ from each other. With a lactometer the specific density of milk is
measured. The lactometer test is based on the fact that milk has a heavier weight or
density (1.026–1.032 g/ml) compared to water (1.000 g/ml). When milk is adulterated
with water or other solids are added, the density either decreases (if water is added) or
increases (if solids are added). If milk fat (cream) is added to milk, the density decreases.
Most lactometers are usually marked from “0” (representing density of 1.000 g/ml) to
“40” (representing density of 1.040 g/ml).

Figure 6 : Density Test

If the milk is normal, its lactometer reading will be between 26 and 32. If the lactometer
reading is below 26 or above 32, the milk will be rejected because it means that it has
been adulterated with added water or solids.

Lactoscan or lactic check

Lactoscan is a portable ultrasonic milk analyzer of fat, solids-non-fat, proteins, lactose,

added water, temperature, freezing point, pH solids, conductivity as well as density of
one and the same milk sample directly after milking, at collection and during processing.

Milk quality test by using lacto scan or lactic check at laboratory level is essential. The
laboratory should be able to control the following: ·

 Quality of raw milk during collection and at reception; various quality

aspects related to processing;

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 Quality of the finished milk products;

 Quality of the milk products during storage and distribution, Cleanliness
and hygiene at the milk processing plant.

Figure 7 : Lactic Checker

Ultrasonic milk analyzer performs measurement of fat and solid-non-fats content in milk.
The percentage of fat and solid-non-fat content is measured accurately and displayed
quickly on ultrasonic milk analyzer LCD for the convenient read-out by the user and the
milk producer. And it is used for equal distribution of fat in raw milk.

EKOMILK-ULTRA: - Used for fast and cost effective analysis of the fat contents, non-
fat milk solids, milk density and added water to milk as well. Ekoweek acid is used for
cleaning purpose of the ultrasonic and Ekomilk machines.

Steps of Pasteurization

1. Milk chilling

Chilling is not a pasteurization process but it is a necessary step when dealing with large
volumes of milk. Milk leaves the cow’s udder at temperatures above the ambient, which
encourages rapid bacterial multiplication that speeds up spoilage. However, reducing the
temperatures to between 2° C to 5° C arrests bacterial growth and metabolism. This
provides a head start at keeping the quality before proper pasteurization commences.

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Figure 8 : Milk Chiller

2. Pre-heating (regeneration) and Standardization Stage

After bulking, the chilled milk is heated to about 40°C to facilitate easy separation of
butterfat during standardization. The system uses regenerative heating, i.e., it uses the
heat of the already pasteurized milk to heat up the incoming chilled milk. The chilled
milk, in a counter-current flow, cools down the pasteurized milk. The purpose of
standardization is to obtain a product with uniform content of butter-fat.

Figure 9 : Pre-Heater

3. Clarification stage

Clarification is essential for removing all foreign matter from the product. Large solid
particles are removed by straining the milk through tubular metallic filters. A centrifugal
clarifier (not the one used for standardization) is used to remove all soil and sediments

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from milk. The filters, usually fitted in parallel twins permits continuous processing as
one can be cleaned while the other is running. Clean the filters regularly (between 2 to 10
operational hours depending on the level of dirt) to avoid the growth of bacteria.

4. Standardization stage

It is important to standardize milk fat to ensure that you end up with a product of
consistent quality in the market. Different consumers prefer different products. There are
customers who will consume skim milk only while there are those who will take low-fat
milk. There are those who will take standardized milk while there are those who prefer
high-fat milk. Standardization is necessary to ensure that all the customers are catered for.
Again, it is during the process of standardization that you get to separate the butterfat that
is used for making cream and other fat-based products such as butter and ghee.

5. Homogenization stage

Homogenization is a physical process of breaking down the milk fat globules into tiny
droplets to discourage cream separation. Tiny droplets of fat do not rise in a milk column
since reducing their sizes also increases their density in the milk. A milk homogenizer
working at 100 to 170 bars splits all the fat globules into very tiny droplets that increase
the level of integration of the fat in the milk. As a result, the milk fat remains uniformly
distributed in the milk.

6. Heating section

Utilizes heat from steam to raise the temperatures of the milk from about 60°C to the
required 72°C that is effective to kill the Clostridium botulinum spores. The steam
exchanges heat with the milk across the PHE plates in a counter-current motion. In the
end, if this section, there is a temperature sensor, which controls the flow diversion valve.
Any milk that does not attain the required temperature is diverted back to the heating
section until it attains the required temperatures.

7. Holding section

After heating, milk flows into the holding tubes whose lengths have been calibrated with
the milk flow rate to ensure that milk takes at least 16 seconds in the tubes. All the milk
must maintain the required pasteurization temperatures at the end of the tubes. In case of
a breach, a sensor will trigger the flow diversion valve to take the milk back to the
heating section to bring the milk to the required temperature. Once the milk has attained

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the required temperatures at the end of the holding tubes, milk flows back to the
regeneration section to heat the incoming chilled milk while in itself being cooled down
to about 30°C.

8. Cooling/chilling section

After regenerative cooling of pasteurized milk, it moves to the cooling section of the
PHE where chilled water/PHE coolant lowers the temperature of pasteurized milk to 4°C.
The chilled milk is then pumped to the packaging machines for aseptic packaging and
subsequent storage in the cold room.

Figure 10 : Pasteurization Process

In most milk processing plants, chilled raw milk is heated by passing it between heated
stainless steel plates until it reaches 161° F. It’s then held at that temperature for at least
15 seconds before it’s quickly cooled back to its original temperature of 39° F. Here’s the
“cool” part: One way the dairy industry saves energy involves using the heat of the
heated pasteurized milk to warm the next batch of cold raw milk. Cold milk is then used
to cool the heated pasteurized milk. By doing this, the industry uses heating and
refrigeration energy more efficiently during the milk pasteurization process.

Packaging

In Hawassa University Revenue Generating Enterprise Plc. the pasteurized milk is

packaged by poly ethylene film in 500ml.

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Figure 11 : Final product and its storage

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CHAPTER TWO

BACKGROUND OF THE STUDY

2.1. INTRODUCTION

Our case study focuses on the Hawassa University Revenue Generating Enterprise PLC.
Its located in Hawassa University Main Campus. Hawassa University Revenue
Generating Enterprise PLC working areas in on Poultry, Dairy Farm, Beef Cattle,
Modern Abattoir and Counseling water work project.

From the areas of this enterprise we have focused on the quality and defect control on the
Dairy Farm. The aim of this project is to increase productive performance through
providing standardized food and decreasing the defects produced by this dairy farm.

2.2. PROBLEM STATEMENT

In Hawassa Revenue generating plc of dairy products there are a lot of problems
regarding quality of raw and pasteurized milk. There are many recorded data that shows
products returned to the company because of different quality defects. Those are flavor
defect, odor defects and spoilage of milk before shelf life defects.

Distributing products with defect directly affect the company by making consumers to
lose confidence with their products and having a negative effect on the corporate product
or demand, the willingness to repeat purchase related to product will be cut and the
market value will decline. So this project is conducted in order to minimize these
defective items and to give solution and recommendations for providing quality products.

2.3. OBJECTIVE OF THE PROJECT

2.3.1. General objective

 General objective of the study is improving quality by identify and controlling the
defects produced in the dairy products.

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2.4. SCOPE OF THE STUDY

The scope of study will be Hawasasa University revenue generating enterprise plc. And
geographically it’s located in Hawassa Town Administration. Specifically in Hawassa
university main campus. The study will be focused on the quality and defect control on
the Dairy Farm. .

2.5. LIMITATION OF THE STUDY

The scope of the Project was conducted only at Hawasasa university revenue generating
enterprise plc on and also, even if broader projects that encompasses all Industries, will
give a more holistic view on the study; however, due to time and financial constraint the
study is delimited. Moreover, there can be difficulties in gathering information due to
effects of the covid-19 pandemic. Lack of sufficient information was our greatest
challenge in order to do this project because there was no documented file about the
overall process.

2.6. METHODOLOGY

This project uses a combination of both quantitative and qualitative methods. The
primary data have been obtained with the use of selected interviews (qualitative) for
possible qualification measures with the combination of quantitative (numerical) data
collection will be used.

2.6.1. Research Design

This study uses applied research design. Applied research is designed to solve practical
problems, rather than to acquire knowledge for knowledge's sake. Additionally, the goal
of these project is to identify the factors that reduce milk quality and propose techniques
or strategies to minimize defect time by using preventive maintenance method rather
than using only corrective maintenance method. Besides this explanatory study design
using quantitative method used to analyze the data collected from employees. This
design helped us in order to explain, understand and predicting the cause and effect
relationship between variables.

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2.6.2. Source of Data

In this project both primary and secondary sources of data was used.

1. Primary data: -We have used the following primary data collection methods.

 Observations: -by this method of data collection we looked about the overall
situations of the company like its pasteurization process, sampling method,
safety wears and etc.

 By conducting oral interviews: - this is done by asking quality control

department head, operators and everybody that concerns.

2. Secondary data: - are collected from both of published and unpublished data source.

 Logbook: - we gathered defective item information from this logbook which

is reported by shift leader.

 Internet: - this method helped my project in referring some facts related to

pasteurization of milk

 Recorded report papers: -these are daily, weekly and monthly reports
regarding defective item of pasteurized milk produced.

Figure 12 : Log Book

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2.7. CONCEPTUAL PROJECT FRAMEWORK

The purpose of the framework was to enable the company determine and reduce defects
produced for the dairy farm and to improve product quality.

Therefore, this project intends to investigate the applicability quality control in the
production process with a view to come up with a new framework that can be adopted to
increase quality in the system.

Figure 13 : Framework

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CHAPTER THREE

LITERATURE REVIEW

3.1. INTRODUCTION

Quality control in dairy industry reduces vulnerability to dairy fraud and ensure the authenticity
and standard of the ingredients. Auditing, testing and inspection of the product at each stage
verifies that it satisfies a wide range of national and international food safety and regulatory
requirements.

The guiding objective for good quality dairy farming practice is that safe, quality milk should be
produced from healthy animals using management practices that are sustainable from an animal
welfare, social, economic and environmental perspective.

To achieve this objective, dairy farmers should apply good practice in the following areas:

 Animal health;

 Milking hygiene;

 Nutrition (feed and water);

 Animal welfare;

 Environment; and

 Socio-economic management.

For each of these categories this Guide lists good dairy farming practices, and suggests measures
that can be implemented to achieve the desired outcome.

A) ANIMAL HEALTH

This Fact Sheet describes good dairy farming practice to ensure animals that produce milk are
healthy and there is an effective health care programme in place. However, not all of the

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practices are applicable in all circumstances and may be superseded by national, international or
market demands.

The suggested good dairy farming practices for animal health are set out under the following
headings:

 Establish the herd with resistance to disease.

 Prevent entry of disease onto the farm.

 Have an effective herd health management programme in place.

 Use all chemicals and veterinary medicines as directed.

Figure 14 : Guiding Objective for Good Dairy Farm

B) MILKING HYGIENE

Milking is the defining activity of dairy farming. Consumers demand high standards of milk
quality, so milking management aims to minimize microbial, chemical and physical
contamination. Milking management covers all aspects of the process of obtaining milk from
animals quickly and effectively, while assuring the health of the animals and the quality of the
milk.

Consistency in the day-to-day implementation of milking procedures is an important part of good

dairy farming practice for milking.

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This Fact Sheet describes practices that ensure milk is harvested and stored under hygienic
conditions, and that the equipment used to harvest and store milk is well maintained. The
suggested good dairy farming practices for milking hygiene are set out under the following
headings:

 Ensure milking routines do not injure the animals or introduce contaminants12 into milk.

 Ensure milking is carried out under hygienic conditions.

 Ensure milk is handled properly after milking.

Figure 15 : Milking Hygiene

C) NUTRITION (FEED AND WATER)

The quantity and quality of the feed and water provided largely determines the dairy animal’s
health and productivity, and the quality and safety of its milk.

This Fact Sheet describes good dairy farming practice for managing animal nutrition, both
feeding and watering. The suggested practices are set out under the following headings:

 Secure feed and water supplies from sustainable sources.

 Ensure animal feed and water are of suitable quantity and quality.

 Control storage conditions of feed.

 Ensure the traceability of feedstuffs brought on to the farm.

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Figure 16 : Nutrition

D) ANIMAL WELFARE

In essence, animal welfare is the application of sensible and sensitive animal husbandry practices
to the livestock on the farm. Animal welfare is primarily concerned with the wellbeing of the
animal.

In general, consumers perceive high animal welfare standards as an indicator that food is safe,
healthy and of high quality. Animal welfare standards have been incorporated into most on-farm
food quality and food safety schemes.

Many animal welfare codes list ‘five freedoms’14 that should underpin best farm practice in
relation to animal welfare. These five freedoms provide a comprehensive overall concept of
animal welfare.

This Fact Sheet describes good dairy farming practices for animal welfare. They are set out to
reflect the five freedoms:

 Ensure animals are free from thirst, hunger and malnutrition.

 Ensure animals are free from discomfort.

 Ensure animals are free from pain, injury and disease.

 Ensure animals are free from fear.

 Ensure animals can engage in relatively normal patterns of animal behaviour.

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Figure 17 : Animal Welfare

E) ENVIRONMENT

Increasingly, consumers are concerned that the production of food is sustainable and is
undertaken in harmony with the environment. To meet these concerns it is important that dairy
farmers produce milk in a way that meets the wider community’s expectations, by using natural
resources efficiently and minimizing any adverse impact on the environment.

Every dairy farmer can play a role in protecting their industry and the future of their enterprise
by adopting management practices that enhance the environmental sustainability of their farming
system.

The suggested good dairy farming practices for the environment are set out under the following
headings:

 Implement an environmentally sustainable farming system.

 Have an appropriate waste management system.

 Ensure dairy farming practices do not have an adverse impact on the local environment.

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Figure 18 : Environment

F) SOCIO-ECONOMIC MANAGEMENT

Being ‘socially responsible’ and ‘economically sustainable’ are integral to good dairy farming
practice as they address two key risks to the farm enterprise.

Managing and looking after the farm’s human resources is critical to the sustainability of the
enterprise. In many parts of the world this will primarily apply to the farmer and others living on
the dairy farm. However, dairy farmers must also consider the role their enterprise has in the
wider community; as an employer, consumer of natural resources and its potential impact on
neighbours.

Similarly, dairy farms are businesses producing a product, in this case milk, meat and livestock.
Like all businesses, dairy farm businesses must be financially viable to have a long term future.

The suggested good dairy farming practices for the socio-economic management of dairy farms
are:

 Implement effective and responsible management of human resources.

 Ensure farm tasks are carried out safely and competently.

 Manage the enterprise to ensure its financial viability.

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Figure 19 : Socio-economic Management

3.2. QUALITY IMPROVEMENT

Quality improvement is a way of life and the human aspect of it requires a great deal of
education and training at all levels. Improving quality is very often regarded as an activity which
is going to increase productivity. Quality Improvement Methods Within this broad framework,
managers, researchers, and consultants have identified several methods for ensuring and
improving quality. Today most organizations apply some or all of these methods, including
statistical quality control, the zero-defects approach, employee involvement teams, Six Sigma,
and total quality management.

A) Statistical Quality Control

It rarely makes economic sense to examine every part, finished good, or service to ensure it
meets quality standards. For one thing, that approach to quality control is expensive. In addition,
examining some products can destroy them. As a result, unless the costs of poor quality are so
great that every product must be examined, most organizations inspect only a sample. Looking
for defects in parts, finished goods, or other outcomes selected through a sampling technique is
known as statistical quality control. The most accurate way to apply statistical quality control is
to use a random sample. This means selecting outcomes (such as parts or customer contacts) in a
way that each has an equal chance of being selected. The assumption is that the quality of the
sample describes the quality of the entire lot. This view confuses the terms used in industry
concerning quality and grade. Improving or raising the grade of products relates to the use of
more expensive materials or processes to produce a product and will raise product costs. As
conclude improving quality means, among other things, making less faulty products with the

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same amount of effort or cost which usually gives a lower unit cost and results improve
productivity.

B) Zero defect approach

A broad view of process quality control is that everyone in the organization should work toward
the goal of delivering such high quality that all aspects of the organization’s goods and services
are free of problems. The quality-control technique based on this view is known as the zero-
defects approach. An organization that uses the zero-defects approach provides products of
excellent quality not only because the people who produce them are seeking ways to avoid
defects but also because the purchasing department is ensuring a timely supply of well-crafted
parts or supplies, the accounting department is seeing that bills get paid on time, the human
resources department is helping find and train highly qualified personnel, and so on.

Total Quality Management

Bringing together aspects of other quality control techniques, many organizations have embraced
the practice of total quality management (TQM), an organization- wide focus on satisfying
customers by continuously improving every business process for delivering goods or services.
Thus, it is not a final outcome but an ongoing commitment by everyone in the organization.
Today most companies accept the basic idea of TQM that everyone in the organization should
focus on quality.

C) Quality Control Plans

As with the other responsibilities of supervisors, success in quality control requires more than
just picking the right technique. The supervisor needs a general approach that leads everyone
involved to support the effort to improve quality. a) Prevention versus Detection It is almost
always cheaper to prevent problems from occurring than it is to solve them after they happen;
designing and building quality into a product is more efficient than trying to improve the product
later. Therefore, quality-control programs should not be limited to the detection of defects.
Quality control also should include a prevention program to keep defects from occurring. One
way to prevent problems is to pay special attention to the production of new goods and services.
In a manufacturing setting, the supervisor should see that the first piece of a new product is
tested with special care, rather than wait for problems to occur down the line. Also, when

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prevention efforts show that employees are doing good work, the supervisor should praise their
performance. Employees who are confident and satisfied are less likely to allow defects in goods
or services.

Using Control Chart

Control chart is the most populated quality tool. The main reasons of their popularity are :

i. A proven technique for improving productivity.

ii. Effective in defect prevention.
iii. Prevent unnecessary process adjustment.
iv. Provide diagnostic information.
v. Provide information about process capability.
vi. Problem Statement

Hawassa university revenue generating plc of dairy products specifically milk pasteurization
company in Hawassa wants to test their quality and productivity and wants to find the most
effective way of their quality testing.

Statistical process control

SPC use of various methods to measure and analyze a process, either in manufacturing or non-
manufacturing situations. SPC also help us identify variation in some quality characteristic of the
product or process. First identify what types of defect are there when measuring quality. Then we
will be able to identify specific tools used for minimizing defects.

Objectives of SPC:

 Improve quality of process output

 Reduce process variability and achieve process stability

 Solve processing problems

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3.3. QUALITY CONTROL

The systems and procedures that are used to achieve the right quality is quality control.
Companies that have their product/service quality based on quality control approaches believe in
looking for the defects and mending them (Quality digest) Quality control also needed a
transformation.

According to the main reason for the “origin of the term Total Quality Management (TQM)
could be a substitution in the previously used term of total quality control (TQC), the word
„control‟ by „management‟ with the reasoning that quality is not just a matter of control, it has
to be managed”. Organizations realized they needed systems not to „check‟ the defects but to
eliminate the root cause of the defect. For this they required techniques that would indulge in
continuous quality improvement.

The 7 QC tools (Histogram, check diagram, Pareto analysis, cause and effect diagram, scatter
diagram, control chart and graphs) and other Statistical procedures played an important role in
the forming a base for Quality Assurance. Japanese are under the belief that 95 percent of the
problems in an organization can be solved by simple quality control methods such as the seven
quality control tools.

3.4. The Seven quality control tools

Seven QC tools are fundamental instruments to improve the quality of the product. They are used
to analyze the production process, identify the major problems, control variations of product
quality, and provide solutions for the defects and rejected products. These tools use statistical
techniques to measure and analyze the data.

In productivity improvement or quality improvement process, it is need to know what the main
problem is, the causes of the problem before they propose the solutions. However logical and
systematic method should be applied to make the job easier by locating and eliminating the root
or cause of the problem. There are many techniques available in problem solving, ranging from
simple and easy to use methods to relatively complicate and control tools.

The 7 quality tools are easier to apply and understand and yet proven scientific management
tools.7 quality control tools can be used in all process. They form the fundamental foundation for

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all problem solving and quality control activities. These 7 quality control tools also known as
total quality management (TQM) tools. These seven quality control tools are listed below;

 Control chart

 Histograms

 Scatter diagram

 Check sheets

 Pareto charts

 Cause and effect diagram.

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CHAPTER FOUR

RESULT AND DISCUSSION

4.1. INTRODUCTION

This section deals with the analysis of data that obtained from different reports and documents of
the Hawassa revenue generating plc of diary product specifically pasteurized milk is analyzed.
The following table shows the amount of pasteurized milk retrieved due to appearance of defect
before shelf-life. The shelf life of 500ml of pasteurized milk is 6 days. If the consumer finds any
defect between these days it has a guaranty to return the product to the company.

Table 1 : 4 Month Defect Data

Observation period Quantity produced Quantity of defective

pasteurized milk per month
in litter

1st 6419 litter 1814 litter

2nd 7012litter 2026 litter

3rd 5420 litter 1360 litter

4th 8096 litter 2354 litter

Total 26947 litter 7554 litter

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Table 2 : Defect Type

Types of January February March April Total

defect

Spoilage 640 litter 860 litter 960 litter 940 litter 3400 litter
before shelf-
life(>6days)

Flavor defect 800 litter 1010 litter 100 litter 750 litter 2660 litter

Taste defect 300 litter 110 litter 150 litter 502 litter 1062 litter

Odor defect 60 litter 26 litter 140 litter 140 litter 366 litter

Other 14 litter 20 litter 10 litter 22 litter 66 litter

Total 1814 litter 2026 litter 1360 litter 2354 litter 7554

According to this table the spoilage of pasteurized milk before shelf-life (>days) is the critical
defect.

4.2. STATISTICAL PROCESS CONTROL TOOL

The key statistical tools for investigating & controlling quality of processes include:

 Histograms

 Check sheets

 Pareto charts

 Cause and effect diagrams

 Control charts

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4.2.1. Pareto Chart

A Pareto chart is a graph is constucted based on the collected defect data in the Hawassa Dairy
Farm Revenue PLC.

Steps for constructing Pareto Chart :-

Step-1: Determine category (frequency, cost, or time);

Step-2: total the raw data in each category, then determine the grand total by adding the
totals of each;

Step-3: re-order the categories from largest to smallest.

Step-4: determine the cumulative percent of each category;

Step-5: draw & label the: 1) left-hand V-axis with the unit of comparison (freq./cost/); 2)
horizontal axis with the categories {list left to right in rank order}; & 3) right-hand V-
axis from 0 to 100%;

Step-6: begin with the largest category & draw bars for each;

Step-7: Draw a line graph beginning at the corner of the first bar to represent the
cumulative percent;

Step-8: Analyze the chart. Usually the top 20% of the categories will comprise roughly
80% of the total;

The Given Data is taken from Table 1 :-

Types of Spoilage Flavor defect Taste defect Odor defect Other

defect before shelf-
life(>6days)

Defects 6419 litter 2660 Lt 1062 Lt 366 Lt 66 Lt

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Table 3 : Pareto Analysis Table

Types of defect Number of Cumulative Percentile Cumulative

defect Total Overall Total Percentile

Spoilage before shelf- 3400 Lt 3400 Lt 45 % 45 %

life(>6days)

Flavor defect 2660 Lt 6060 Lt 35 % 80 %

Taste defect 1062 Lt 7122 Lt 14 % 94 %

Odor defect 366 Lt 7488 Lt 5% 99 %

Other 66 Lt 7554 Lt 1% 100 %

Total 7554 - 100 % -

Figure 20 : Pareto Chart of the Given Data

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4.2.2. Process Capability Analysis

a) Measurement of process capability analysis

Measurement of process capability analysis basically means quantification of the capability of a

stable process to produce parts within the specification limits.

These are:

CP = Process Potential Index

CPK = Process Performance Index

CPU = Upper Process Performance Index

CPL = Lower Process Performance Index

K = Process Centering Index

b) Basic concepts of process capability

Process capability is a statistical analysis tool. It requires collecting data from the process,
constructing a histogram, drawing a curve that fits in the histogram, and then finally finding out
what percentages of data goes outside the upper specification limit (USL) and lower
specification limit (LSL). For any part, upper specification limit, lower specification limit and
allowable process spread are of two important concern.

Traditionally, a process is called “capable” if the process spread 6σ is equal to the width of the

specification limit.

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Figure 21 : Concept of process capability

There are three ways in which a process can be judge not capable:-

 The process is not stable

 The process is centered too close to a specification limit (Figure 22)

 The process variability is excessive (Figure 23)

Figure 22 : Influence of location on process capability

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Figure 23 : Influence of variability on process capability

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CHAPTER FIVE

CONCLUSION AND RECOMENDATION

5.1. CONCLUSION

There are several approaches to choose from when the goal is to increase the quality and
productivity of the Pasturized Milk Production Farm of Hawassa University Revenue Generating
Enterprise Plc. In this paper only the quality tools have been used and tried to find the most
effective way of quality testing and improving productivity. These have given a better solution.
But if any one uses other technique of industrial engineering then he will get more benefit than
this paper. If it is decided to use the data in future studies it would be interesting .By this way it
may be possible to specify high quality and productivity. The quest for higher quality and
productivity will never stop and the project extreme Pasturized Milk Production will proceed. An
important suggestion for future work is to test if the findings are applicable to other products and
machines within the factory. A deeper understanding could possibly make the conclusions from
this study more understandable and easier to apply to other products.

5.2. RECOMMENDATION

In this paper, the most effective way of quality control and productivity improvement has tried to
find by experimenting on a manufacturing company. Using all quality tools and sampling plan is
an expensive procedure. For any industry, using the Pareto chart is the best way for quality
testing.

 The Plc needs to monitor and control machine operation, machine cleaning to improve
quality.
 The Plc needs to focus on critical identified s defects and their respective cause to
improve quality.
 The Plc should have to give training to the employees especially about the important of
quality.

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References

1. Dr. M. Ahsan Akter Hasin, Quality Control and Management (Bangladesh Business Solution,
Dhaka, Bangladesh).

2. Douglas C. Montgomery, Introduction to Statistical Quality Control (John Wiley & Sons, Inc.,
3rd edition, canada).

3. FAO Animal Production and Health

4. Global Journal of Researches in Engineering: G Industrial Engineering (Volume 14 Issue 3

Version 1.0 Year 2014 )

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