Statistical Process Control for the Food Industry: A Guide for Practitioners and Managers

ISBN-13: 9781119151982 / Angielski / Twarda / 2019 / 200 str.

Jiju Antony; Sarina A. Lim

Spis treści

Preface xiii1 Quality Management in the Food Industry 11.1 Introduction 11.2 Definition of Quality Control 11.3 Quality Control in the Food Industry 21.3.1 Quality Control (Raw Material) 31.3.2 Quality Control in Production (Processes and End Product) 41.3.3 Issues Related to the Quality Control 61.3.3.1 Late Adopters 61.3.3.2 Difficulties Identifying and Prioritising Hazards (Microbiological and Chemical) 61.3.3.3 Lack of Scientific and Quantitative Method to Assess Critical Points 61.4 Quality Assurance 71.4.1 Current Good Manufacturing Practice (cGMP) 71.4.2 HACCP (Hazard Analysis of Critical Control Point) 81.4.3 ISO 91.4.4 British Retail Consortium 91.5 Quality Management System in the Food Industry 91.6 Statistical Thinking 101.7 Summary 122 Food Industry and its Contribution to the Global Economy 132.1 Introduction 132.2 What Is the Role of Food Industry in the Global Context? 142.3 Several Classifications of Food Industry from Several Sources 152.4 How is the Food Industry Different from Other Industries? 182.5 Customers and Consumers 192.6 Government Plan 202.7 Summary 203 Quality and Safety in the Food Industry 233.1 Introduction 233.2 Food Quality 253.2.1 Objective and Subjective Quality 253.3 Food Safety 273.4 Hazard Analysis and Critical Control Point (HACCP) 283.4.1 Concept 283.4.2 HACCP Principles 303.4.2.1 Principle 1 303.4.2.2 Principle 2 303.4.2.3 Principle 3 303.4.2.4 Principle 4 303.4.2.5 Principle 5 313.4.2.6 Principle 6 313.4.2.7 Principle 7 313.4.3 Hazards 323.4.3.1 Physical Contamination 323.4.3.2 Chemical Contamination 333.4.3.3 Microbiological Contamination 333.4.4 Documentation 343.4.5 Critical Control Point (CCP) 343.4.6 How to Do it? 343.4.6.1 Step 1: Develop HACCP Team 343.4.6.2 Step 2: Describe and Characterise the Product 353.4.6.3 Step 3: Construct the Process Flow Diagram 363.4.6.4 Step 4: Identify the Hazards Control 363.4.6.5 Step 5: Quantify and Analyse the Hazards 363.4.6.6 Step 6: Identify Control Requirements, Targets and Tolerances 373.4.6.7 Step 7: Identify CCPs and Assess Existing Controls 373.4.6.8 Step 8: Establish a Monitoring System for Each CCP 383.5 Good Manufacturing Practice 383.5.1 Personnel 393.5.2 Plant and Grounds 393.5.3 Sanitary Operation 403.5.4 Sanitary Facilities and Controls 403.5.5 Equipment and Utensils 403.5.6 Processes and Controls 403.5.7 Raw Materials 403.5.8 Warehousing and Distribution 413.6 Food and Drug Administration (FDA) 423.7 Summary 424 An Introduction of SPC in the Food Industry: Past, Present and Future 434.1 Statistical Process Control: A Brief Overview 434.2 Quality Control in the Food Industry: Before SPC 444.2.1 Inspection! Inspection! Inspection! 454.3 The Evolution of SPC in the Food Industry 484.4 The Principle of Current Quality Control 504.4.1 Control in Raw Material 504.4.2 Control in the Finished Product 514.4.3 Control in Processing 514.4.4 The Practicality of SPC in the Food Industry 534.5 Future of SPC: Organisational Learning Through Statistical Methods Application 554.6 Summary 605 Tools in SPC 615.1 Basic Quality Tools 615.2 SPC Tools 615.3 Cause-and-Effect Analysis 625.3.1 What? 625.3.2 Why? 625.3.3 When? 625.3.4 How? 625.3.5 Where? 645.4 Pareto Diagram 665.4.1 What? 665.4.2 Why? 665.4.3 When? 675.4.4 How? 675.4.5 Where? 695.5 Process Flowchart 695.5.1 What? 695.5.2 Why? 695.5.3 How? 695.5.4 When? 715.5.5 Where? 715.6 Histogram 715.6.1 What? 715.6.2 Why? 725.6.3 When? 725.6.4 How? 725.6.5 Where? 735.7 Scatter Diagram 735.7.1 What? 735.7.2 Why? 735.7.3 When? 735.7.4 How? 745.7.5 Where? 745.8 Control Chart 745.8.1 What? 745.8.2 How? 755.8.3 Assumptions 755.8.4 Why? 755.8.4.1 Process/Product Monitoring 755.8.4.2 Process Prediction 765.8.5 How? 765.8.6 Types of Control Charts 775.8.7 Variable Control Chart 775.8.7.1 Xbar Chart and R Chart or Xbar and S Chart 775.8.7.2 ExponentiallyWeighted Moving Average (EWMA) Chart 785.8.7.3 Cumulative Sum (CUSUM) Chart 795.8.8 Attribute Control Chart 805.8.8.1 Proportion Defective Chart (p-Chart) 805.8.8.2 Number Defective Chart (np-Chart) 815.8.8.3 c-Chart 815.8.8.4 U-Chart 825.8.9 Run Chart 825.8.10 Interpreting Control Chart Signals 835.8.11 Rules for Interpreting a Control Chart 835.8.12 Where? 845.9 Common Mistakes 855.10 Summary 866 Team Formation, Team Dynamics and Training 876.1 The Team 876.2 Team Dynamics 886.2.1 Team Structure 886.2.2 SPC Team Characteristics 916.2.3 Team Maturity 936.3 Training 946.4 Consultant 976.5 Follow-Up in-House Training 976.6 Measuring Training Effectiveness 986.7 Summary 1007 SPC Readiness Self-Assessment Tool 1037.1 Ready...? 1037.2 Concept of Readiness 1047.3 History of the Readiness Concept 1057.4 An Approach to Assessing SPC Readiness in the Organisations 1077.5 Key Components of SPC Readiness 1087.6 Top Management Support 1097.6.1 Capable Measurement System 1097.6.2 Organisational Culture 1097.6.3 Employee Involvement 1107.6.4 Urgency to Change 1117.7 Identifying the Readiness Level 1127.7.1 How to Use the SPC Readiness Assessment Tool? 1127.8 Summary 1168 Critical Aspects in SPC Implementation Process 1178.1 Introduction 1178.2 Key Findings from an Empirical Study in the UK Food Manufacturing Industry 1178.3 CSF of SPC Implementation 1208.4 Gap Between the Importance of SPC and the Frequency of Actual Practice 1228.5 Common Barriers to SPC Implementation 1248.6 Process Performance Measurement 1268.7 Summary 1289 Roadmap for the Deployment of SPC 1299.1 A Cookbook Approach 1299.2 Phase Awareness: Sell the Program 1299.2.1 Step 1: Top to Bottom 1319.2.2 Step 2: SPC Awareness Sessions 1339.2.3 Step 3: SPC Training 1339.3 Phase Preparation 1359.3.1 Step 4: Corporate SPC Vision Create/Creating a SPC Corporate Vision 1359.3.2 Step 5: SPC Team Establishment 1369.3.3 Step 6: Develop Strategic Plans for the SPC Implementation 1379.4 Phase Initiation 1389.4.1 Step 7: Process Prioritisation 1389.4.2 Step 8: Process Description 1399.4.3 Step 9: Process Synthesis 1409.4.4 Step 10: Measurement System Analysis (MSA) 1409.4.5 Step 11: Control Chart 1419.4.6 Step 12: Establish Out-of-Control-Action-Plan (OCAP) 1439.4.7 Step 13: Process Capability 1449.4.8 Step 14: Reflection 1469.5 Phase Institution: Company-Wide Implementation 1479.5.1 Step 15: Communicate the Success of Initial Project 1479.5.2 Step 16: Company-Wide Training 1479.5.3 Step 17: Progress Evaluation Systems 1489.6 Phase Sustainability 1489.6.1 Step 18: Maintenance of In-house Expertise 1489.6.2 Step 19: Towards Learning Organisation 1499.6.3 Step 20: Reward System 1499.7 Summary 15010 Case Studies 15110.1 Application of the Control Charts in the Industries 15110.2 Case Study 1 Monitoring Fish Product Packaging (Grigg, Daly, and Stewart, 1998) 15210.2.1 Problem Statement 15210.2.2 Processes 15210.2.3 Sampling 15210.2.4 Type of Data 15310.2.5 Construction of the Control Chart 15410.2.5.1 Determine the Target Level 15410.2.6 Interpret x . R Chart 15410.2.7 Conclusion 15610.3 Case Study 2 Monitoring the Sausage Production 15610.3.1 Problem Statement 15610.3.2 Processes 15710.3.3 Sampling 15810.3.4 Type of Data 15810.3.5 Construct Control Chart 15910.3.6 Interpreting the p-Chart 16010.3.7 Conclusion 16110.4 Case Study 3 Controlling Microbiological Hazards on the Food Products 16110.4.1 Problem Statement 16110.4.2 Process 16210.4.3 Sampling 16210.4.4 Type of Data 16210.4.5 Construct Control Chart 16210.4.5.1 Modification of the Data 16210.4.6 Interpret the Charts 16710.4.6.1 The Individuals Chart 16710.4.6.2 The CUSUM Control Chart 16710.4.7 Conclusion 168References 169Index 181

O autorze

SARINA ABDUL HALIM LIM is part of the Faculty of Food Science and Technology, Universiti Putra Malaysia, Malaysia. Sarina is currently pursuing research on SPC implementation in the food industry. Sarina has also taught several modules on SPC and DOE for process analysis and optimization.JIJU ANTONY works at the School of Social Sciences at Heriot-Watt University, Edinburgh, UK. He is recognized as a leader in Six Sigma methodology for achieving and sustaining process excellence, and delivers training courses on quality management, process management, and Lean Six Sigma topics to numerous companies world wide.