Production quality improvement for the soft drinks bottling industry through Six Sigma methodology

2022

IJQRM

PurposeThis research aimed at lowering the non-volatile matter (NVM) of long oil alkyd (LOA) resin to meet the resin requirements in producing Hi-gloss paints. The research also aimed to assist Hi-gloss paint manufacturers who require solid resin content below 70%.Design/methodology/approachThe research utilised both the document review and experimental methods. The experimental method, which involved the blending process, was used in lowering the NVM of LOA resin, whereby eight experiments were conducted as reputations to obtain accurate data and results. A factorial design was used in the design of the experiment (DOE), where three factors were required to be evaluated: specific gravity, viscosity and NVM and two levels were required: weight of LOA and white spirit.FindingsThe NVM of LOA resin was successfully lowered, and different shades of paint were produced for reliability testing. The quality parameters of Hi-gloss paints that used the modified LOA were all found within the company's specifications compared to those with unmodified LOA, where some parameters were either above or below the specifications. However, all samples with the NVM of LOA used below 50% were found to be poor in terms of quality during the reliability testing. So, if the company had used the modified LOA resin in the production of Hi-gloss paints, it would have potentially saved 18,925.2 kg and 9,446.4 kg, respectively, of LOA just in producing Hi-gloss black and white paints only. Moreover, the cost of 1 kg of LOA is $2.3, which is equal to Tanzanian Shillings (Tshs) 5,290. The company would have potentially saved Tshs 100.114 million Tshs and Tshs 49.97 million Tshs in producing Hi-gloss black and white paints, respectively, making a total of Tshs 150.08 million per year. This was counted as a loss during that year because they did not use LOA resin with 50% NVM in production.Research limitations/implicationsThis study focused on LOA resin used in producing Hi-gloss paints. The study also did not consider other categories of alkyd resins used in producing paints and varnishes e.g. epoxy resin and short and medium oil alkyd resins.Originality/valueThis is probably the first alkyd resin improvement study conducted using white spirit as Tanzania's main agent or material. The study utilised vegetable oils such as coconut, sunflower and tobacco seeds.

“…Quality parameters of paints and paint materials were obtained using document review and brainstorming sessions at Company X as suggested by Taifa et al. (2021) and Deshpande et al.…”

Section: Resultsmentioning

confidence: 99%

Quality improvement of long oil alkyd (LOA) resin requirements in the formulation of Hi-gloss paints

James

2022

IJQRM

“…Quality can be defined as a degree of excellence (Nzumile and Taifa, 2019, 2021), and quality improvement fosters profit increase (Taifa et al. , 2021b).…”

Section: Theoretical Backgroundmentioning

confidence: 99%

“…2.2 Quality 4.0 Quality can be defined as a degree of excellence Taifa, 2019, 2021), and quality improvement fosters profit increase (Taifa et al, 2021b). Several researchers agree that Quality 4.0 meticulously affiliates quality management with Industry 4.0 (Antony et al, 2021).…”

Section: Theoretical Background 21 the Fourth Industrial Revolutionmentioning

confidence: 99%

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Quality 4.0 transition framework for Tanzanian manufacturing industries

Maganga¹,

2022

TQM

Self Cite

PurposeThis research aimed at developing the Quality 4.0 transition framework for Tanzanian manufacturing industries.Design/methodology/approachThe survey method was used in this study to gather practitioners' perspectives. The approach included open-ended and closed-ended structured questionnaires to assess respondents' perceptions of Quality 4.0 awareness and manufacturers' readiness to transit to Quality 4.0. The study's objective was to adopt non-probability and purposive sampling strategies. The study focused on fifteen Tanzanian manufacturing industries. The data were analysed qualitatively and quantitatively using MAXQADA 2020 and Minitab 20 software packages, respectively.FindingsThe study demonstrated a high level of awareness of Quality 4.0 among Tanzanian manufacturing industries (i.e. 100% in Quality 4.0 traditional attributes and 53% in Quality 4.0 modern attributes). Individuals acquire knowledge in various ways, including through quality training, work experience, self-reading and Internet surfing. The result also revealed that most manufacturing industries in Tanzania use Quality 3.0 or a lower approach to manage quality. However, Tanzanian manufacturing industries are ready to embrace Quality 4.0 since practitioners are aware of the concepts and could see benefits such as customer satisfaction, product improvement, process and continuous improvement, waste reduction and decision support when using the Quality 4.0 approach. The challenges hindering Quality 4.0 adoption in Tanzania include reliable electricity, high-speed Internet and infrastructure inadequacy to support the adoption, skilled workforces familiar with Quality 4.0-enabled technologies and a financial set-up to support technology investment. Moreover, the study developed a transition framework for an organisation to transition from traditional quality approaches such as quality control, quality assurance and total quality management to Quality 4.0, a modern quality approach aligned with the fourth industrial revolution era.Research limitations/implicationsThe current study solely looked at manufacturing industries, leaving other medical, service, mining and construction sectors. Furthermore, no focus was laid on the study's Quality 4.0 implementation frameworks.Originality/valueThis is probably the first Quality 4.0 transition framework for Tanzanian manufacturing industries, perhaps with other developing countries.

“…Of course, the majority are in line with Industry 4.0 frameworks, including the studies by Taifa et al. (2020, 2021a, b). Q4.0 studies per se which were executed include the following.…”

Section: Theoretical Orientationmentioning

confidence: 99%

The readiness of manufacturing industries to transit to Quality 4.0

Maganga¹,

2022

IJQRM

Self Cite

PurposeThis research provides the essential aspects of the transition from traditional quality methods like total quality management, quality assurance and quality control to a new quality approach linked with the Industry 4.0 era. The purpose of this paper is to address this issue.Design/methodology/approachThe study used a survey method to obtain the practitioners' perceptions of the Quality 4.0 (Q4.0) concepts. Both closed-ended and open-ended structured questionnaires assessed the perceptions of respondents regarding manufacturers' readiness and Q4.0 awareness to transition to Q4.0. Non-probability and purposive sampling tactics selected 15 Tanzanian manufacturing industries (TMIs). Garnered data were scrutinised quantitatively and qualitatively utilising Minitab® 20, SmartPLS 3.3.7 and MAXQADA 2020 software packages.FindingsThe results indicate that TMIs are equipped to deploy the Q4.0 approach because industrialists are familiar with the concept's characteristics and dimensions and the benefits of implementing Q4.0. Most TMIs utilise a Q3.0 method for managing quality, while some manufacturing industries have begun to apply Q4.0 leveraging technologies. The study revealed several factors influencing Q4.0 readiness in TMIs, including leveraged technology adoption, training, Q4.0 skills, infrastructures, the government set-up, top management support, Q4.0 strategy and vision, collaboration, awareness, knowledge of Q4.0, customer and supplier centeredness and organisational culture.Research limitations/implicationsThe implication of this study is on Q4.0 awareness creation so that industries can grab the advantages of Q4.0 leveraged technologies. Another implication is that organisational readiness factors identified in this study are critical for the effective adoption of Q4.0. The highlighted influences may be utilised as indications to determine an organisation's readiness to transition to the Q4.0 approach. This research was limited to TMIs, excluding service firms, mining, and the building and construction industry due to differences in their mode of operation.Originality/valueDetermining readiness factors and awareness for the Q4.0 study is probably the first amongst the seven East African countries, including Tanzania. This study thus bridges a huge gap in fulfilling the need of this research type.