INTRODUCTION:

The evolution of large multinationals as a result of the appearance of new market demands shows that the companies having a specific market demands, are shown to possess certain characteristics. The rise of international competition has stimulated the industries to compete under price, quality and assortment along with timely delivery of goods. In today’s situation these three factors leads to market success. Now those days are gone when the manufacturer used to sell whatever types of goods he produced. Customers were not conscious about the product nor there any competition in the market. Gradually the situation changed due to the introduction of communication media like television, the percentage of literacy, the availability of products and the customer’s awareness increased. The mass advertising on television, news paper, magazine and on public places resulted in increase of sales of the product.

Now the situation rapidly changed stiff competition in the national and international market level and customer’s awareness requires production of quality goods and services for survival and growth of the company.

As a result, the companies are under pressure to improve the quality of the product. To stay in the competitive market the organisations have to adopt modern technology, and undergo upgradaton of the system for achieving the quality of the product.

DEFINATION OF COMPUTER:

A general-purpose machine that processes data according to a set of instructions that are stored internally either temporarily or permanently. The computer and all equipment attached to it are called hardware. The instructions that tell it what to do are called "software." A set of instructions that perform a particular task is called a "program" or "software program."

USE OF COMPUTERS IN QUALITY CONTROL SYSTEM:

The quality control system involves testing, inspection, auditing and analysis. The variation is the enemy of quality control. To reduce the variation various Statistical Process Control tools can be used.

Statistical Terms: Most measurements in testing consist of a set of repeated measurements that have been made on a number of identical individuals constituting a sample taken from the bulk of the material. Certain statistical measures are used to describe the average of the results and their spread.

Arithmetic Mean or Average: The arithmetic mean is the measure most commonly chosen to represent the central value of a sample. It is obtained by adding together the individual values of the variable x and dividing the sum by the number of individual’s n.

Standard Deviation: The standard deviation is most widely used measure of the dispersion or spread of results about the mean value. The symbol σ is used for the standard deviation of the universe (population) containing all the possible measurements that could be made of the variable in question. The symbol s is generally used for the estimated value of the standard deviation from a sample, which has been taken from the universe. The units that the standard deviation is measured in are the same as those of the mean.

Coefficient of Variation: The coefficient of variation (CV) is often used as a measure of dispersion, it is the standard deviation expressed as a percentage of the mean. The formula is defined follows.

C.V. =Standard deviation X I00 / mean

Calculation of Test Results: The samples received from each stage from raw materials to finished product are tested in quality control laboratory. It involves complex calculation, which is tedious manually. Risk of accuracy in results can be predicted by manual method. The manual calculation is a time consuming job. The employee feels the tardiness, fatigues ness by the manual calculation. That results in increasing stress on employees

Analysis of Quality Data: Analysis is the heart of quality control system. The performance of product cannot be known unless and until the analysis is done. In textile industry there are various processes involved. The factual figures help the shop floor department for their forecasting.

Help of gages, measuring devices and the testing apparatus. The two major parts of computer aided quality control are computer aided inspection (CAI) the planning, quality, productivity and on time delivery of the product. With the help of data analysis report they take the preventive measures for reducing the non-standard product, thus increasing the profitability of the organisation. In quality control department a system approach is adopted for –

a. Systematic collection and recording of accurate data.

b. Analysing the data for corrective and preventive action.

c. Analysing the data for setting quality standards.

d. Executives reports generation

Documentation - Automation of the Test Procedure:

The testing procedures as per ISO 9001:2008 system are atomised in quality control department. The documents are ready and can be retrieved as and when required. The test procedures are prepared as per the class of material. The materials are in the form of chemical, dyes, fibres, yarn , fabric and packing material. As per the test in the respective form of the material were prepared.

The use of the computers for quality control of the product is called as the computer aided quality control or CAQC. The two major parts of quality control are inspection and testing, which are traditionally performed manually with the (CAI) and computer aided testing (CAT). CAI and CAT are performed by using the latest computer automation and sensor technology. CAI and CAT are the standalone systems and without them the full potential of CAQC cannot be achieved. The main objectives of the CAQC are to improve the quality of the product, increase the productivity in the inspection process and reduce the lead times in manufacturing. The implementation of CAQC in the company results in the major change in the way the process of quality control is carried out in the company.

RESULTS:

ANALYSIS # 1 REDUCTION IN TIME FOR THE RECEIPT OF TEST REPORT TO PRODUCTION DEPARTMENT AFTER COMPUTERIZATION:

The data was collected from the senior staffs of production department involved in quality about the receipt of test report from quality control department. The data was analysed and tabulated which is shown in Table No. 1.

From the analysis in Table No. 1, it was observed that –

1. The production department were received the test report of single / double yarn count, TPI test after one day before computerisation. After computerisation, the test report has been received within day in second half to the production department.

2. The production department were received the test report of full yarn test after two days before computerisation. After computerisation, the test report has been received after one day to the production department. There is a reduction of one day time for the receipt of test report from quality control department.

3. The production department were received the test report of recombing final tops test after half day before computerisation. After computerisation, the test report has been received in less than half day to the production department.

From the observations 1 to 3, it is interpreted that by the use of computers in quality control system, quality control department is able to give the test report early to the production department. This helps the production department to take immediate action in processing in case deviation in the material found.

ANALYSIS # 2 REDUCTION IN CALCULATION TIME OF TEST RESULTS:

The data was obtained from quality control employees about the calculation time for calculating test results. The data of calculation was based on before computerisation i.e. manual calculation and after computerisation in quality control department. The data was analysed and tabulated which is shown in Table No. 2.

Table No. 1 : Test Report Receipt Analysis for the Period 1994-2003

Type	Name of Test >	Single / Double Yarn Count, TPI Test Report	Full Yarn Test Report	Recombing Final Tops Test Report
Before Computerisation	Time Taken For Receipt of Test Report	After One Day	After Two Days	Above Half Day
After Computerisation	Time Taken For Receipt of Test Report	Above Half Day	After One Day	Less Than Half Day

Table No. 2: Reduction in Calculation Time Analysis for the Period 1994-2003

Type	Name Of Test >	Single / Double Yarn Count TPI Test	Full Yarn Test	Fiber Length Test	Recombing Final Tops Test
Before Computerisation	No. Of Samples Tested Per Day	11	5	8	14
Before Computerisation	Total Calculation Time Required	50 Minutes	30 Minutes	35 Minutes	25 Minutes
After Computerisation	No. Of Samples Tested Per Day	15	7	13	17
After Computerisation	Total Calculation Time Required	15 Minutes	8 Minutes	8 Minutes	8 Minutes
Savings	Time Saved Per Day	35 Minutes	22 Minutes	27 Minutes	17 Minutes
	Time Saved Per Month	1050 Minutes	660 Minutes	810 Minutes	510 Minutes
	Time Saved Per Year	12600 Minutes	7920 Minutes	9720 Minutes	6120 Minutes

From the analysis in Table No. 2, it was observed that –

1. The calculation time required for single / double yarn count test results before computerisation was 50 minutes for 11 samples. However after computerisation, 15 minutes time has been taken for calculation of test results for 15 samples though there is an increase in number of samples tested. Hence 35 minutes per day, monthly 1050 minutes and annually 12600 minutes calculation time has been reduced.

2. The calculation time required for full yarn test results before computerisation was 30 minutes for 5 samples. However after computerisation, 8 minutes time has been taken for calculation of test results for 7 samples though there is an increase in number of samples tested. Hence 22 minutes per day, monthly 660 minutes and annually 7920 minutes calculation time has been reduced.

3. The calculation time required for fiber length test results before computerisation was 35 minutes for 8 samples. However after computerisation, 8 minutes time has been taken for calculation of test results for 13 samples though there is an increase in number of samples tested. Hence 27 minutes per day, monthly 810 minutes and annually 9720 minutes calculation time has been reduced.

4. The calculation time required for recombing final tops test results before computerisation was 25 minutes for 14 samples. However after computerisation, 8 minutes time has been taken for calculation of test results for 17 samples though there is an increase in number of samples tested. Hence 17 minutes per day, monthly 510 minutes and annually 6120 minutes calculation time has been reduced.

From the observations 1 to 4, it was interpreted that by using computers in quality control system, the calculation time has been reduced. It has been also interpreted that the number of samples tested has been increased, hence, increasing the efficiency of quality control employees.

ANALYSIS # 3 REDUCTION IN CALCULATION TIME OF TEST RESULTS – MANAGER / DEPUTY MANAGER OF QUALITY CONTROL DEPARTMENT STANCE:

The data was obtained from manager / deputy manager of quality control department about the reduction of calculation time after computerisation in quality control department. The data was analysed and tabulated as follows.

Opinion	Yes	No
Total %	100.00 %	0.00 %

The graphical presentation of data analysis is given below.

From the above analysis it was observed that –

1. Manager and deputy manager of quality control department were said that the calculation time of test results has been reduced.

2. None among manager and deputy manager of quality control department were said that the calculation time of test results has been not reduced.

From the observations 1 to 2, it is interpreted that by the use of computers in quality control system, calculation time of test results has been reduced.

From the analysis# 1, # 2, and # 3, it is concluded that by the use of computers in quality control system, calculation time of test results for the quality control department employees has been reduced. This helps the employees in doing more tests.

SUMMARY OF THE STUDY:

The comprehensive study has been done on the topic to study the reduction in time for the use of the computers in Quality Control System. The analysis has been done with the help of primary, secondary data. The use of computers in quality control system, following conclusions was emerged from the study -The calculation time for test results has been reduced. The annual savings is 117 man-days. Total saving on account of reduction in calculation time is approximate Rs.12, 87,000 /annum.

REFERENCE:

1. CAD/CAM: Computer Aided Design and Manufacturing by Mikell P. Groover and Emory W. Zimmers, Jr., Prentice Hall of India Private Limited.

2. The Essence of Total Quality Management, Prentice - Hall of India Publication, New Delhi By John Bank

3. National Centre for Quality Management Issues – Bombay

4. The Essence of Information Systems , Prentice - Hall of India Publication, New Delhi By Adrian Buckley / Chris Edwards / John Ward

5. Computer Architecture And Organisation McGraw-Hill Book Co. Singapore By John P. Hayes

6. Raymond Limited (Textile Division- Chhindwara) Quality Control MIS

Received on 16.05.2011 Accepted on 25.05.2011

Asian J. Management 2(3): July-Sept., 2011 page 94-97

INTRODUCTION:

Coefficient of Variation: The coefficient of variation (CV) is often used as a measure of dispersion, it is the standard deviation expressed as a percentage of the mean. The formula is defined follows.

Documentation - Automation of the Test Procedure:

No

Total %