ABSTRACT:
Every manufacturing organization is concerned with the
quality of their products. While achieving the targeted production in scheduled
time it is important that the finished product meet established standard
specifications, so as to satisfy customer needs regarding its quality and
services. Information or any feedback becomes an important source for quality
improvement. Earlier, the information system purely depended on the typewriter
and hand written memos, records and sending this information was cumbersome and
searching or reproducing them was time consuming job. With the advent of
computers the specified information management system has been developed to
improve quality and services.
KEYWORDS: quality, specifications, information system
Quality is the heart of any organisation
therefore it is very important to give more weightage
to quality control department actions by the management. The function of
department starts from the incoming raw materials, which includes dyes,
chemicals, auxiliaries, water, fibers, yarns, fabric and packing materials to
finished fabric, which includes suiting and furnishings fabrics. The department
has established process control parameters
of materials at various stages viz. Dyeing, Converter, Grey combing, Recombing, PV/Worsted Spinning, Finishing and Folding
department to take corrective action against ”deviation from quality” and to
certain extent facilitate Research and Development work.
Reporting System: Production department
need the result of tested material from quality control department. Test
results were fed and stored in computer. All the reports were checked by HOD
before releasing them to the concerned department.
USE OF COMPUTERS
IN QUALITY CONTROL SYSTEM:
The quality control system involves testing,
inspection, auditing and analysis. The uses of computers were mainly in the
area of testing, testing calculation; reporting of test results and analysis of
data, report generation of cuts and defect.
In Testing - In following table machine name and test
carried out is given in table 1
Table No. 1 Computerised
Testing Machine List
|
S.N. |
Machine Name |
Material |
Test |
|
1 |
Almeter |
Fibers/Sliver |
Length Distribution Of Fibres/Slivers |
|
2 |
Uster |
Slivers/Yarn |
Unevenness of slivers/yarn |
|
3 |
Statimat |
Yarn |
Elongation of yarn |
|
4 |
Tensile Strength Tester |
Fabric |
Strength of fabric |
Source: Own Source
In
Reporting:
a. Recording of test results data.
b. Calculation of test results.
c. Reporting of test results.
In Analysis -
a. Systematic collection and recording of
accurate data.
b. Analysing the
data for quality standards and performance.
c. Executives reports generation
Every manufacturing organisation
is concerned with the quality of its product. It is important that the finished
product meet established specifications, because customer’s satisfaction is
derived from quality products and services. Information plays an important role
in running any system. Prior to computer the information system depended on the
typewriter and hand written memos. Sending this information was the cumbersome
and time consuming. There was delay in getting quality report
from quality control department within time period. The evolution of computers
overcame these problems. At each stage of manufacturing process the quality
control is involved. With the help of computers testing was carried out,
results were reverted to corresponding department for their corrective action.
The analysis was done for product wise performance, rejection of reduction, and
testing analysis.
The study has been conducted on the suiting
fabrics. It included the testing and analysis parameters. The effectiveness of
reporting system, data analysis reports, reduction of time has been taken while
studying. The information is the product of data. The data is generated, gathered, collected
from testing, inspection, and auditing sources. To develop management
information system required an utmost skill. Software’s were designed for
development of management information system. Spinning wrapping test management
information system has been elaborated.
SPINNING WRAPPING
STUDY:
Purpose
of Wrapping: The purpose of the module is to deliver yarn
at its required count value i.e. fineness of the yarn. In spinning process the
gm/mtr (wrapping) value of material received from
earlier process is reduced by drafting. The weight of the material cannot be
reduced in single stage. It can be reduce step-by-step up to ring frame where
the desired yarn is obtained for the fabric. At each step the standard wrapping
value is defined. Unless and until this standard wrapping value is maintained,
the yarn with desired count value cannot be produced. At each stage the
wrapping value from deviating the standard value is checked. If there is
deviation, certain machine parameter is adjusted so that acceptable value is
obtained. At present, for controlling or checking the wrapping value, the
process runs at various stages viz. At gill box no.3, gill box no.4, ring
frame.
File Used and Its Description: The database use for wrapping is wrap.dbf and
its structure is displayed in table- 2.
Table No 2: Data
Base File Wrap. dbf
|
Name |
Description |
Type |
Width |
Decimal |
|
date |
test date |
date |
8 |
|
|
rpno |
report no |
n |
4 |
0 |
|
shift |
shift |
c |
3 |
|
|
section |
section |
c |
10 |
|
|
sr |
std. regain |
n |
4 |
2 |
|
dept |
department code |
n |
1 |
0 |
|
mc |
machine no |
n |
2 |
0 |
|
side |
side |
c |
1 |
|
|
shade |
shade number |
c |
4 |
|
|
lot |
lot number |
n |
4 |
0 |
|
dp |
dyeing plane no |
c |
6 |
|
|
count |
count value |
n |
2 |
0 |
|
wt1 |
1st lea weight |
n |
6 |
3 |
|
wt2 |
2nd lea weight |
n |
6 |
3 |
|
wt3 |
3rd lea weight |
n |
6 |
3 |
|
wt4 |
4th lea weight |
n |
6 |
3 |
|
wt5 |
5th lea weight |
n |
6 |
3 |
|
wt6 |
6th lea weight |
n |
6 |
3 |
|
wt7 |
7th lea weight |
n |
6 |
3 |
|
wt8 |
8th lea weight |
n |
6 |
3 |
|
wt9 |
9th lea weight |
n |
6 |
3 |
|
wt10 |
10th lea weight |
n |
6 |
3 |
|
yrwt |
yarn weight |
n |
6 |
4 |
|
ctwt |
yarn count weight |
n |
7 |
4 |
|
cntwt |
container weight |
n |
7 |
4 |
|
blend |
blend code |
n |
3 |
0 |
|
spdl |
spindle number |
c |
7 |
- |
|
wheel |
wheel no |
n |
3 |
0 |
Source: Own source
Formulae Used:
The formulae used in wrapping study are as follows.
Count at Spinning Condition:
I.] For
pv ring frame
Count = 64.8 / actual reading
Ii] For
pw ring frame
Count = 100 / actual reading
Iii]
For worsted ring frame
Count = 90 / actual reading
Iv] For
worsted fly frame
Count = actual reading / 4
V] For
worsted gill box
Count = actual reading
Count at mr. minimum,
maximum, mean is calculated from the ten readings.
Standard Deviation:
s.d. =
(ĺ
(xi - x^)2 / (n - 1))1/2
xi = observations 1,2,.........,n
x^ = mean
n = no of reading
Coefficient of Variation:
cv %
= (standard deviation. * 100) / mean
Moisture Regain:
Yarn weight - (container +
yarn container Weight)
mr % =
-------------------------------------------------------------* 100
( Container. + Yarn container weight
– container weight)
Factor:
Factor = (100 + standard regain) / (100 +
moisture regain)
Count At Standard Regain:
Minimum = minimum at count at mr / factor
Maximum = maximum at count at mr / factor
Mean
= mean at count at mr / factor
Standard Error:
Std errs. = (s.d. / [ n - 1 ]1/2 )
n = no of reading
Total Value:
Total value = (mean of count at mr wrapping limit) / std err.
95 % Confidence Range:
+ Range = mean of count at mr + (1.96 * std err)
- Range = mean of count at mr - (1.96 * std
err)
Processing Logic:
Record key: - report no
The program offers a menu from which user
can select the required option depending on the requirement of user. The option
includes were -
Addition
Modification of data
Enquiry
Deletion
Print
In case of addition of data record a check
for duplication is made after accepting the record key later after the user
confirms the entry, the record gets added. For modification of data after
accepting the record key the number of records is displayed for the record key.
The record number is entered; only after the confirmation is made modification
procedures are carried out. Once again the user’s confirmation is sought before
rewriting the same record. For enquiry and deletion of data the record key
accepted from the user and the data are searched and it is displayed. In case
of deletion the user’s confirmation is sought before the record is deleted. For
printing, the required record key is accepted. After the user’s confirmation
the record gets printed. An exit option is available in case of the user wishes
to exit out of the program.
Graphical Representation of Flow of Data: -
Building of information system helps the
quality control department atomisation of documentation,
investigation of faulty material history, data analysis, reporting test results
and report generation.
RESULTS:
ANALYSIS # 1 EFFECTIVENESS OF
BUILDING AN INFORMATION SYSTEM MADE BY THE COMPUTERS - EMPLOYEES STANCE
The data was obtained from quality
control senior staff, auditors and data analyst about the effectiveness of
information system developed by the use of computers in quality control system.
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.
100.00
% respondents of quality control
department were said that the building an information system made by the
computers is effective.
2.
0.00 %
respondents of quality control department were said that the building an
information system made by the computers is effective.
From
the observations 1 to 2, it was interpreted that development of management
information system made by the computers in quality control system is
effective. This has helped the quality control employees in decision-making.
They can now analyse more data for the
interpretations,
ANALYSIS # 2 EFFECTIVENESS OF
BUILDING AN INFORMATION SYSTEM MADE BY THE COMPUTERS - MANAGER / DEPUTY MANAGER
OF QUALITY CONTROL DEPARTMENT STANCE
The data was
obtained from quality control manager and deputy manager about the
effectiveness of information system developed by the use of computers in
quality control system. 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
–
Manager and deputy manager of quality
control department confirms the effectiveness of building an information system
made by the computers. From the observation it was interpreted that building an
information system made by the computers in quality control system was
effective. From the analysis # 1 and analysis # 2 it was concluded that
development of management information system made by the computers in quality
control system is effective. This has helped the manager and deputy manager of
quality control department in day to day work. They can now analyse
more data for the interpretations,
DISCUSSION:
The analysis was done on the basis of fact
and figures. The structured method of collecting the data and storing the data
was essential in order to get the desired results. Prior computerization the
data in the form of reports were on the registers. The testing results were
sent in the memo. These memos were kept together in a file. Searching a report
was a time consuming job. Management
information system has been developed by using the software. This has benefited
for reporting of test results, analysis of data, defective report generation. Quality Documents, Statistical Data Analysis,
as they were stored in Main Computer for the future references. At any time
Works Director through Quality Control Manager, could obtain any information
from this main computer. Changes were made for Quality Specification / Contract
review / Procedure reviews by suppliers by E-mail services rapidly. From the main computer, data’s were stored in
Compact Disk. This was also helpful for security, in case main computer failed.
Thus, with the advent of computers the specified information management
system has been developed to improve quality and services in a fabric industry.
REFERENCE:
1.
Management Information and Control Systems, Taxmann Allied Services Pvt. Ltd., New Delhi By Dr. Sushila Madan
2.
The Essence of Total Quality Management, Prentice -
Hall of India Publication, New Delhi By John Bank
3.
Systems Analysis and Design , Prentice – Hall, A
Division of Simon and Schuster, Inc. Englewood Cliffs, New Jersey By Robert E.
Leslie
4.
The Essence of Information Systems , Prentice - Hall
of India Publication, New Delhi By Adrian Buckley / Chris Edwards / John Ward
5.
Raymond Limited (Textile Division- Chhindwara) Quality Control MIS
Received on 23.05.2011 Accepted on 12.08.2011
©A&V Publications
all right reserved
Asian J. Management 2(3): July-Sept., 2011 page
115-118