Total Quality Management

and Quality Assurance

in
Salt Production and Processing

Presentation by
Lorenzo Locatelli-Rossi
INTERNAL AND EXTERNAL QA
 Internal QC- are the procedures used by the
producer/processor to ensure that their
product consistently meet internal
requirements and government and industry
standards.
 External QC- periodic inspection by
government regulatory body that confirm that
products and procedures meets standards
 DEFENTION OF QUALITY
ASSURANCE
 QA is a wide-ranging concept which covers
all matters which individually or collectively
influence the quality of a product.
 It applies to equipment, product design,
supplies and logistics, management and
human resources development.
 All elements designed to ensure that
products are of the quality required for their
intended use.
TOTAL QUALITY MANAGMENT
 TQM is a management strategy to “”embed
awareness” of quality in all organizational
processes (quality thinking).
 QA through “statistical methods” is a key
component.
 Overall quality management influences
company profitability.
 PROFITABLE BUSINESS
 No business can succeed if the product has
no quality and guaranteed consistency.
 Consistent quality guarantee is closely linked
to affordability.
 No one can afford inconsistent, bad quality
and no guarantee. It is too expensive!
W. Edwards Deming (1900-1993)
 STANDARDS
 In order to have quality we need Standards
Standards are:
 An accepted or approved example of something
against which others are judged or measured.
 Guideline
 Point of Reference
 Ensures Consistency in the Product
 Guarantee of Quality
 TQM- AREAS OF INTEREST
1- Prime Requirements
2- Processing Technology
3- Production: TQM and QA
6- Packing Iodized Salt
7- Warehousing and Dispatching
8- Marketing and The Consumer
 1- PRIME REQUIRMENTS
1a- People
1b- Factory
1c- Technology
1d- Salt (Raw Material)
1e- Iodate
1f- Spare Parts
1g- Packing Material
1h- Auxiliary Supplies
 1a- PEOPLE
Every person:
 Is an important investment
 Must know why their job is important
 Knowledgeable about the and product
 Given an opportunity to suggest ideas
 Ownership of his/her place of work
 Importance of participation
 1b- FACTORY
 Designed to be practical and economical
 Must be people friendly
 Allocate clearly defined spaces
 Proper place for resting/eating and lockers
 First Aid kit and person trained
 Emergency and fire points
 Kept clean all places at all times
 1c- TECHNOLOGY
Appropriate Technology
 Vacuum process
 Washing/Refining process
 Rock Crushing process
 Re-Packing process
1- Investment Costs
2- Running Costs
3- Maintenance Costs
Final Product Costs
 Technology………continue
Each process has a different:
1- Investment Costs
2- Running Costs
3- Maintenance Costs
These costs influence the
Final Product Costs
 SALT 1d-
The salt must:

 Meet the Standards

 Stored in an appropriate place

All the above factors have a cost implication.

 1e- IODATE
 Meets standards
 Stored in appropriate place
 Control of issuance of the product
 Always in stock sufficient quantities
 Avoid over supply (frozen capital)
 1f- SPARE PARTS
Properly Stored
Catalogued
Control over issuance
Know your supplier
Replace immediately
Spares cost money; as a part and as in
production
 1g- PACKING MATERIAL
 Supplied with bag/packs as per order
Quantity
Printing Quality
Quality plastic/carton
Proper size
 Tapes and glues
 Proper issuance procedure
 Hold appropriate quantity in stock
 Supplier keeps stock?
 1h- AUXILIRY SUPPLY
 Proper maintenance of all electrical
equipment and cables
 Caution against danger
 Proper electrical links
 Stand-by generator (if appropriate)
 Appropriate stock of extra fuel
 Water Leakages
What about the Prime Materials
 They all carry an investment cost

 Some are short term other long term

investments

 They are all equally important and any

“additional” cost must be avoided.
 How to Control costs/quality

TQM applies principles of controlling the quality

of machine-based factories operations to
controlling the quality of people-based
management operations
2- PROCESSING TECHNOLOGY
 What ever the process, daily production data
must be recorded. Data must include:
- Time of start/stop and eventual breakdowns
- Specific reason/s for breakdowns and
solutions adopted.
- Maintenance daily report list of areas
requiring work.
Processing Technology…………
 Plan for weekly, monthly and yearly
maintenance program.
 TQM aims to do things right the first time
rather than need to fix problems after they
emerge and cause more problems.
 A bad or non existent maintenance plan is a
costly business. There is no savings!
Processing Technology…………
 Tally daily production with number of
packs/bags issued.
 Tally the end of the month consumption of
iodate and iodized salt production.
 Calculate plant capacity efficiency by
comparing hours over tons of iodized salt
 PRODUCTION: TQM and QA
We focus on Iodized Salt:

1- The processing equipment:

 Tanks, pipes, pumps and nozzle or dozers; daily check-up to
ensure that are they clean and in good working order.
 Monitor even during production.
 If dry mix or a solution; is the mix well prepared?
2- Iodization:
 At the start, titration must be done continuously until standard
has been achieved.
 After which, minimum once every hour.
PRODUCTION: TQM & QA ………….
 Keep an hourly record every day
 Base your findings on titration not on the
rapid test kit
 Chart the results
 Share the Results
 Make a monthly report
 Follow-up on issues that have been raised
Charting Daily Iodizing Progress
 Packing Iodized Salt
 Guaranteed production of iodized salt needs
to be packed and sealed in order to retain its
guaranteed quality.
 Ensure that seams and seals can withhold
transport/handling.
 Maybe a small pin-prick hole avoids
problems
 Bag the packed salt in an orderly fashion
 WAREHOUSING AND
DISPATCHING
 Goods to be protected from water, dust and
other pollutants.
 Goods to be placed off the floor (on pallets)
and away from the wall.
 Practice the First In Last Out (FILO).
 Ensure that trucks carrying the product have
clean trailers and goods are covered
MARKETING AND THE CONSUMER

 Iodized Salt pack/bag must have full details of the production

company.
 It must indicate a “Customer Care” contact incase of product
dissatisfaction.
 Prepare a “complaints handling procedure”.
 Product must state type and quantity of iodine.
 Interact with wholesaler/retailers if and when possible
 The customer is always right!
 Customer confidence builds business
 SUMMARY OF TQM / QA
PRINCIPLES
 Set quality standards
 Monitor and record plant efficiency
 Plan for good maintenance program
 Involve/interact with workforce
 Measure iodization output against standards
 Define corrective action for non-compliance
 Focus on quality - TQM
INCREASING AVAILABILITY OF
IODIZED SALT
 Consumer education / awareness
 Prohibit the production, import and sale of
non-iodized salt.
 Production facilities should interact with MoH
 Zero rated import duties on iodate
 Some form of tax rebate for producers as
iodized salt is of national importance.