Application of Statistical Process Control in a Production Process

Abstract

This study evaluates the process of production of Champion Breweries Plc., located at Aka Offot, Uyo, Akwa Ibom State Nigeria. The information on the following measurable characteristics used during production were obtained; Brilliance (Haze), pH, Original Gravity (O.G) and Alcohol Percentage. Information on the number of defective crates recorded for the period of fifteen (15) days on Amstel Malta were also obtained from the bottling section. Mean (
) and Range (R)control charts for variable were adopted to ascertain if the process with respect to each quality characteristics is statistically in control. The result shows that, the out-of-control points for BRILLANCE (B) were four (4) and one (1) out of twenty (20) for the mean and range charts respectively. For pH: two (2) and one (1) out of control for mean and range charts respectively. For Original Gravity (O.G): five and zero were out of control for mean and range charts respectively. For Alcohol Percentage (A): twelve and zero were out-of-control for mean and range charts respectively. Since the out-of-control points for Alcohol have exceeded the average of all points, the entire process is disregarded, and hence the process has to be overhauled. Using the P-chart to examine the defects in the finished produce daily for 15 days; it was found that 11 points were out of control, also the need for overhaul of the entire production line.Given the overall findings it could be deduced that the process was largely out-of-control, hence the need for total overhaul and the revised control schemes as appropriate. Thus, revised control schemes were formulated for the different quality characteristics for the process to be in control and the following control schemes were proposed for the future upper and lower specifications: B (
: 0.6563, 0.2738; R: 0.4940, 0.00), pH (
: 3.9786, 3.7916; R; 0.2871, 0.00).