Lesson 8 - Quality Management End of Unit SAQ

***Apply the concept of continuous improvement to the activities of both quality assurance and quality control to illustrate the differences between the two approaches to quality management.

Response:

Quality Control (QC) deals with the activities of analysis, inspection quarantine, rework, and rejection. The application of continuous improvement to QC would bring about an improvement in each of these areas. Continuous improvement is an iterative process and hence would achieve improvements in a stepwise manner. In analysis this would be the improvement of the repeatability and reproducibility of analytical methods through training, sharing of best practice, and improvement in the accuracy of calibration of analytical equipment. Lab proficiency schemes could also be used in this regard to benchmark the lab against the best of its peers. This would lead to more accurate and precise data and increased confidence in lab performance. The data from the lab will then provide a reliable metric for use in process improvement projects which would be undertaken as part of QA. Lab facilities, layout, and design could be reviewed, and improvements in ergonomics and workflows in the lab made. Sampling and inspection would be improved by developing data and statistically analysing it to determine the most effective and efficient sample size for properly reflecting variation in the output of the production process. This would lead to improved detection of defective product allowing it to be quarantined and reworked. The ultimate goal in continuous improvement of quality control activities is that all defects and quality failures are detected, and no defective product ever reaches the customer.

Quality assurance involves all areas of the business and it seeks to improve quality by improving the systems used to operate the business and produce beer. In quality assurance, continuous improvement is applied to all activities, often through the Plan – Do – Check – Act cycle. Continuous improvement is a planned activity, undertaken as a project, where a problem is identified, its root cause established, and then a project to implement the improvement which removes the root cause is carried out. Looking at process level, this could be out-of-spec gravities from the Brewhouse, or at system level this could be an improvement in planning to prevent high residence times in BBT. Improvements in training and communication will reduce errors and hence defects. Improved relationships with suppliers lead to better raw materials and timely delivery of goods and services, both of which improve quality within the brewery.

Statistical process control can be used as a tool for continuous improvement with the tightening of control lines on the process control chart for a given process. As quality can be defined as conformance to specification, a product or process which varies lacks quality. The reduction in variation from the optimised process therefore drives an improvement in the quality of the output from the process. The quality assurance tool Six Sigma gives another statistical basis for improvements. Six Sigma projects are undertaken at process and system level to bring about improvements in DPMO and hence quality. As each project is completed, quality is further improved. Six Sigma projects would use DMAIC in place of PDCA; DMAIC involves a process of defining, measuring, analysing, and controlling the aspect of production being improved. The ultimate goal in continuous improvement of quality assurance activities is that the process and systems of production are improved to the point where no defective product is produced and hence ever reaches the customer.