Trang 1 MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATIONCAPSTONE PROJECTMAJOR: INDUSTRIAL MANAGEMENT ANALYSIS OF QUALITY CONTROL IN PRINTINGAND
Research objective and research scope of the topic
Analyze and evaluate the current situation of quality control, thereby proposing some solutions to improve quality control at ANSELL Vietnam Co., Ltd (printing and packing department).
On the basis of studying the development of the domestic economy, the situation of the protective gloves manufacturing industry in general, and the production and business activities of ANSELL Vietnam Co., Ltd in the period of 2019–2022, analyze the current situation, identify strengths and weaknesses, find out the causes, and then propose solutions to improve quality control at ANSELL Vietnam Co., Ltd.
Qualitative methods: expert interview, Delphi method
Chapter III: Analyze Quality Control in Printing and Packaging at Ansell Vina Co., Ltd.
Chapter IV: Propose Solutions in Printing and Packaging
INTRODUCE OF ANSELL VINA CO., LTD
General Introduction
Ansell is a leader in the design, development, and manufacture of a wide range of solutions for protection to meet the changing needs of the market With a vision, everyone in the world is optimally protected against the risks they face many offices and manufacturing plants in 55 countries In 1893, Dunlop UK established a bicycle tire factory in Melbourne, Australia In 1905, Eric Norman Ansell purchased condom machinery from Dunlop and founded the Ansell Rubber Company In 1946, the first automatic glove dipping machine was developed; in 1965, disposable surgical gloves were sterilized with Gammex technology; and in 1969, Dunlop Australia Limited acquired Ansell Rubber Company From 1970 to 1989, Ansell acquired industrial glove companies and expanded production in Malaysia and the USA In 1989, Ansell acquired Edmont Industrial Gloves in the United States From 1990 to 2002, Ansell became the world's largest supplier of medical gloves, household gloves, and industrial gloves. Moved its headquarters to the United States in 1998 In 1995, Ansell purchased American Perry surgical gloves 1998: Ansell launches the Hyflex brand with the first 11-800 ultra- flexible multi-purpose gloves 2002: Pacific Dunlop split and changed the company name to Ansell Limited In 2007, Ansell acquired three companies from China, Poland, and Brazil to focus on the sexual health business 2010: new strategy and strengthening of human protection industry development Ansell acquired Sandel of the United States in
2011 In 2012, Ansell acquired Trelleborg of Sweden and Comasec of France In 2013, Ansell bought Midas from South Korea and Hércules from Brazil established a 1,486- square-meter modern R&D center in Sri Lanka Ansell acquired BarrierSafe Solutions International for a record $600 million and Hands International in Sri Lanka In 2015, Ansell acquired Microgard of the UK and GammaSupplies of the US In 2017, it retracted
$600 million of investment in the sexual health business and transformed it into a company focused on protecting people Ansell acquires the UK's Nitritex In 2018, Ansell celebrated its 125th anniversary, following the acquisition of Digitcare Corporation, a leading supplier of medical and specialty gloves, and the launch of a $100 transformation program million dollars to reduce costs with huge investments in Vietnam, Sri Lanka, and Malaysia In 2019, Ansell acquired Ringers Gloves from the United States to expand its product portfolio During the period from December 27, 2021, to March 4, 2022, he participated in an internship at Ansell Vietnam Co., Ltd., address number 7, Long Thanh Industrial Park, Long Thanh District, Dong Nai Province The company specializes in manufacturing and exporting specialized industrial gloves Ansell is not simply about safety; its products and services help people everywhere become more confident and enable businesses and workers to work more efficiently With a mission to deliver secure, innovative solutions in a trusted way, creating a 'Protected by Ansell' world The company's major customers are mainly products that produce industrial protective sleeves for heavy and light industries Helps protect materials or chemicals such as anti-cut sleeves, anti-chemical sleeves.
Figure 1.1: ANSELL VINA CO., LTD
Ansell's main products include such as industrial safety gloves, medical gloves, life science/cleanroom gloves Industrial safety gloves will be produced at ansell vina including types such as anti-liquid and chemicals, mechanical gloves, disposable gloves, these are the main types of gloves directly produced here Next are medical gloves, with types such as medical examination gloves and surgical gloves Finally, cleanroom gloves include laboratory & research, rabs and isolation cabinets.
Our vision is of a world where everyone enjoys optimal protection against the risks they face Whether at work or outside of work, everyone needs the right protection for the right situation After all, what better guarantee is there for increased safety, security and productivity than adequate protection.
Innovators strive to create innovative solutions and technologies that solve workers' problems, creating a safer and more protected world
Factory Scale
Ansell Vietnam Co., Ltd started with 7095 m2 of production area, 300 employees,seven chemical dipping lines, and 234 flat knitting machines By 2021, the company will have increased the production area to 24231 m2 with 1315 workers, 15 chemical dipping lines, and 1916 flat knitting machines (an increase of 8.2 times compared to 2015).
Departments and functions
Figure 1.3: Management Chart Of Ansell Vina Co., Ltd
+ Set out policies, goals, and targets appropriate to the company's goals to make the company operate effectively.
+ Identify the responsibilities and authorities of the parts of the company's organizational structure and the relationships between its parts.
+ Supplement and train human resources capable of meeting the workload.
Directly direct the departments in the company.
+ When the director is away, the director authorizes department heads to handle the company's activities.
Having the role of recruiting, training, and developing human resources to ensure the business operation is continuous and effective Ensure the number of personnel necessary for the operation of the business and the quality of the staff Capture information and regulations on personnel in the company and promptly transmit such information to all employees in the company At the same time, he is also in charge of taking care of the lives of all employees in the company, organizing short-term training programs for employees to improve their professional skills and the necessary skills for the job.
On the basis of the defined plan within the allowable range, depending on the nature of the work, appropriate capital should be mobilized to ensure the production activities of the company are carried out with high economic efficiency Prepare a financial draft, agree with the company's production plan, and pay in full, on time, and in accordance with the payment regime Pay necessary amounts to customers and employees and recover capital from customers with outstanding debts, if any Set up and use funds in accordance with policies, regimes, and purposes.
1.3.4 Health, safety and environment department
Formulate internal rules, regulations, processes, and measures to ensure occupational safety and health and to prevent and fight fire and explosions in labor establishments.Develop an annual occupational safety and health plan, urge and supervise the implementation of the plan, assess risks, and develop an emergency response plan.
Organizing the implementation of propaganda activities and disseminating regulations on occupational safety and hygiene of the state and of labor establishments within the labor establishment Organize training on occupational safety and health for employees. Checking on occupational safety and hygiene on a weekly basis in the working areas of employees and offering remedial and improvement measures Inspect the working environment and food safety, monitor the situation of injuries and illnesses arising from the occupation, and propose to the employer measures to manage and take care of labor health.
Research and design new products Estimating the necessary materials and making technological processes and plans for the production departments to implement.
Strictly supervise the stages from production to supply to ensure the quality of products and services when they reach consumers Strictly inspecting product quality and measuring production equipment in spinning, weaving, coating, and printing processes. Issue regulations and continuously update guidelines to ensure quality Deal with customer feedback Standard EN388 (the European standard used to assess mechanical risks for protective gloves) Currently, Ansell Vietnam Co., Ltd has the ISO 9001:2015 standard.
Regularly check the production process and machinery and equipment; if there are any mistakes, promptly fix them Make a plan to repair and maintain equipment and machinery, and check and repair infrastructure, houses, electricity, and water in the company.
Directly involved in the production of goods The head of the production department is the production manager; other members of this department include technicians, engineers, machine operators, etc Carrying out the production, preservation, and transportation of goods in the factory Conduct research activities to improve the quality and output of the factory's products by changing or innovating parts or all of them. Manage production costs and ensure product production at the lowest cost to maximize profits.
The workshop area consists of two floors: the first and second floors The office is on the first floor and manages all activities of the workshop There is a shift leader area to control the production of each room, a medical room to manage health and first aid, essential drugs, and emergency situations arising from occupational accidents On the first floor, there are a raw material storage area, two 13G loom rooms, one 18G loom room, a chemical coating area, an overturning area, a printing area, a packing area, a finished product storage area, and other facilities QA (quality assurance), QC (quality control), and training departments
On the 2nd floor, there are two spinning and weaving rooms, two 15-G weaving rooms, and one 10-G weaving room.
Company Rules
Working days: from Monday to Friday or Saturday, the nature of work and agreement in the labor contract.
Break time between shifts: 30 minutes from 11:30 to 12:00 (not included in working hours).
Working days: from Monday to Saturday
Break time between shifts: 60 minutes (not included in working hours).
By shift: from Monday to Saturday
Shift 1: 6:00–14:00 A 30-minute break counts in working hours.
Shift 2: 14:00–22:00 A 30-minute break counts in working hours.
Shift 3: 22:00–6:00 A 45-minute break counts in working hours.
In the case of working 3 shifts or 4 shifts (24/7), weekly rest days will be arranged alternately during the week.
Each employee has a responsibility to the company, its stakeholders and to colleagues to protect company assets as carefully as their own personal property.
1.4.2.1 Intellectual property and corporate security
Ansell uses a variety of intellectual property ("IP") protections, including copyrights,patents, trademarks, and trade secrets If you create any IP, whether at work or after hours,you agree to assign to Ansell all of your rights in such intellectual property, subject to applicable law and any other agreements any agreement between you and Ansell.
Confidential information is generally any information that is not available to the public. You may only share confidential information with colleagues who are authorized to hold that information for legitimate business purposes Confidential information may include unissued financial results, valuations, development activities, trade secrets and other sensitive technical information, and potential acquisitions or divestments Protect Ansell's confidential information by: Do not discuss confidential information that you may overhear; do not leave private information in places where unauthorized people can see it; store information securely; express any concern about abuse or theft by others; before disclosing confidential information to third parties or sharing company property, employees should ask for authorization and ensure that appropriate contract terms are in place.
Ansell respects and protects the personal data of employees, customers, and other third parties, and Ansell is committed to handling such personal data responsibly Each employee should ensure: Only personal data is collected for legitimate business or legal reasons The protection of personal data is entrusted to us Use the data for the purpose for which it was collected.
In order to ensure the safety of the body of employees, not to have occupational accidents, to limit occupational diseases Reduce health consumption, improve working days and hours, maintain and maintain long-term health, work with high labor productivity.
All managers must minimize hazards and prevent any injury at the core of their responsibilities and operational goals at any Ansell plant, office, warehouse or R&D center.
+ Employees must wear labor protection and use protective equipment, safety equipment as required by the Company Any violation of this will be considered a disciplinary violation.
+ Employees do not listen to headphones, use phones for personal work, listen to music while working.
+ Do not come to work in a drunken state due to the use of alcohol, stimulants and drugs.
+ Employees must strictly comply with the Company's regulations, processes and procedures on occupational safety and must immediately report to the Management when an occupational accident occurs at the workplace.
+ Do not wear sleeveless t-shirts Do not wear ripped jeans and shorts 10cm above the ankle Do not wear shorts For women: Short skirts no more than 10cm above the knee.
Do not wear high heels, do not wear shoes higher than 5cm.
+ Employees are not allowed to operate any machinery or equipment without being instructed to operate and process If the Employee does not know how to work safely, the Employee must ask the Manager.
+ Employees are only allowed to operate machinery and equipment when they have complied with safety regulations.
+ Employees are not allowed to use machines and equipment to work outside the scope of work.
+ Do not put hands or feet into moving equipment such as belts, chains, motors or rollers in motion Must follow the correct process of locking the card machine when it needs to be manipulated.
+ Employees must immediately report damage to machinery, equipment and unsafe behaviors to the Management Employees must comply with the Company's regulations, processes and procedures on machine safety.
+ Employees are not allowed to repair, adjust or connect to any other electrical equipment without the approval of the Management.
+ Must check the electrical safety of the device before use.
+ Before leaving, Employees must check and strictly implement safety measures on electricity, turn off electricity and water at work Employees working with electricity must use appropriate labor protection such as: determined.
+ Do not enter prohibited areas such as power stations and electrical cabinets.
+ Do not arbitrarily connect to the power source, absolutely do not use the bare wire to plug directly into the electrical outlet.
+ Do not arbitrarily open and close switches and circuit breakers at control cabinets inside electrical cabinets.
+ Employees must comply with the Company's regulations, processes and procedures on electrical equipment safety.
+ The Company is equipped with instruction boards, fire extinguishers and full fire fighting tools where necessary.
+ The Company periodically organizes fire prevention and fighting drills to ensure that Employees master the operations to be performed in case of fire.
+ The Company applies necessary measures to prevent, install and maintain all fire protection equipment in accordance with technical standards.
+ Employees must strictly comply with the "No Smoking" regulation at the prescribed places.
+ Employees must not obstruct or obstruct stairs, aisles or emergency exits.
+ Do not arbitrarily cook or light a fire within the Company.
+ When detecting a fire or a risk of flow, it must promptly handle fire prevention and fighting rules and give an alarm so that everyone can fight the fire together and immediately notify the responsible Employee.
+ Employees must comply with the Company's regulations, processes and procedures on fire safety.
Environmental Regulations And Waste Treatment Processes
Do not litter indiscriminately; dispose of garbage in designated places.
Drain only the amount of water used; do not waste water.
Do not discharge contaminant substances such as oil, grease, or chemical rags into the environment.
It is strictly forbidden to dump solid waste, lubricants, and chemicals down the sewage system.
Garbage must be divided by type and disposed of in the correct bin or lot of waste.
Do not mix chemically contaminated garbage (such as chemical rags) with household waste.
1.5.2 Waste treatment process at Ansell
1.5.2.1 Source of wastewater generation at the factory
During the production process at the factory, wastewater is mainly generated from the
PU coating and NBR coating stages.
Figure 1.4: Nbr Wastewater Storage System
For the NBR coating line, wastewater is mainly generated during the processes of dipping, washing, and washing gloves Wastewater generated from this process contains mostly hazardous chemicals.
Similar to NBR, wastewater from the PU process is generated during solidification and glove washing However, unlike NBR, PU wastewater will be treated outside instead of at ETP Because the wastewater generated from the PU process can be recovered asDMF for reuse, it is not possible to recover the internal DMF at Ansell.
Figure 1.5: Wastewater Storage System Dmf
Domestic wastewater arising from the process of operation and the need for water use by employees is not large, but it is still capable of causing environmental pollution if not treated Domestic wastewater will be transferred to the septic tank before entering the wastewater treatment system.
In addition, the factory also has wastewater from the canteen due to daily food supply activities for the whole company Wastewater from the canteen will have to be de-oiled before entering the wastewater treatment system.
1.5.2.2 The company's wastewater treatment process
Wastewater from the factory's production process is collected by a collection tank with a capacity of 300 m3/day This wastewater will be transferred to the rubber separation tank by the pump to remove the rubber in the wastewater before flowing into the wastewater system Rubber wastewater is transferred to a rubber separation tank to remove rubber by chemical means In this tank, H2SO4 will be added to reduce the pH to about 4 for the coagulation process, and the blower provides air for mixing, avoiding odors The dust basket is located at the inlet point The rubber separator is responsible for separating any large objects and preventing them from entering the system Regularly clean the comb basket to avoid clogging the pump and other equipment After leaving the rubber separation tank, the wastewater will flow to the neutralization tank for the purpose of neutralizing the pH of the wastewater with NaOH Then the water will go to the conditioning tank, where 50 air blowers will provide air for the mixing process to regulate the wastewater composition and avoid the generation of odors This tank also has the function of storing and regulating wastewater when the system needs to be stopped for maintenance or repair Next, the water will be led to the flocculation tank, where alum is continuously added for the purpose of forming small flocs, and then NaOH is added to adjust the pH to suit the flocculation process In addition, in the flocculation tank, a stirrer is arranged to evenly mix NaOH and wastewater during the reaction After flocculation, the wastewater will move to the flocculation tank to stick together to form a larger floc, which is easy to separate from the wastewater in the flocculation tank The flotation tank has the function of separating the flocs formed in the flocculation tank by air bubbles; the flocs floating on the water surface are collected by the rake wings and sent to the sludge collection trough Part of the wastewater from the flotation will overflow into the intermediate tank.
In the intermediate tank, part of the wastewater is used for flotation by the DAF pump;the rest continues to the denitrification tank No 1 The denitrification process is the first treatment step that will make full use of the source carbon in the input BOD Organic nitrogen and ammonium will be converted to nitrate by nitrification A second denitrification process then decomposes the nitrate into nitrogen gas and total nitrogen.Then continue to the nitrification tank to convert organic nitrogen and ammonium remaining in the wastewater to nitrite and nitrite to nitrate by Nitrosomonas and Nitrobacter bacteria The wastewater will then continue to denitrify to convert all the nitrates into nitrogen gas.
The post-biological water will flow into the deaeration tank to push nitrogen out of the wastewater by aeration, and the treated water from the deaeration tank will be transferred to the settling tank to separate the sludge and water.
LITERATURE REVIEW
Quality Definition
According to Ta et al (1998), here are some definitions of product quality: the manufacturer, quality is the product or service that must meet the set technical standards. The seller, quality is a sold-out product; there are regular customers Consumers, quality is conformity to their desires Product or service quality must show the following aspects: Show off its technical features or usefulness Express with cost associated with specific consumption conditions.
According to Luu (2003), quality is the ability to satisfy the needs of the market at the lowest cost According to Nguyen (2003), the quality of a product is its ability to satisfy the needs of the user According to Ta et al (1998), according to Philip B Crosby in the book "Quality is Something for Free," "quality is conformity to requirements" Producers, sellers, customers, managers—depending on different perspectives, there are different interpretations or conceptions of quality However, as a basis for quality management, it is necessary to provide a correct, accurate, and consistent conception of quality.
The characteristics of the product are usually determined by the criteria; the economic, technical, and aesthetic parameters can be weighed, measured, calculated, and evaluated. The quality of the product is a measure of its use value; the same use value of the product can have different levels of usefulness and different levels of quality.
According to Nguyen (2003), the concept of quality as above is highly general; this concept has dominated and fundamentally changed the theories of quality management It also completely changes the way people perceive the process of creating quality and the position of consumers in quality relations.
Quality Management Definition
According to Pho et al (2002), quality doesn't come naturally, and it is not a random result; this is the result of the impact of a series of closely related factors To achieve the desired quality, it is necessary to manage these factors properly Management activities in the field of quality are called quality management It is necessary to have the right understanding and experience in quality management to solve the quality problem well.
Quality management is the responsibility of every member of the enterprise, but first of all, it must be fully recognized by the top management and implemented synchronously. The head of the unit needs to organize and check the technical, administrative, and human factors regularly and closely so that the product is really high quality at a low cost.
According to Philip (1984), he got involved in the soy sauce business in 1952, at the end of his military service years in Korea During the nearly five decades of that collection, he became known in the business world as a boxer in the field of quality management He emphasized the importance of getting it right from the start, diagramming, and quality control in his 34-step approach, and since then, we have built the Four Basics of Quality in But among the achievements, Coty is most famous for lowering my standards and testicular tissue into "Zero Defect" (ZD).
According to Philip (1984), quality is a free thing It's not a gift, but it's free Things that cost money without quality are all related to not doing the right job in the first place.
Why waste time figuring out, fixing, and arguing when you can prevent trouble in the first place? It's not about what you find; it's about what you do with what you find. Quality management is necessary because nothing is simple; if it is, it is already simple.
"Good things happen only when there is a plan; bad things come from it" "Customers deserve to get exactly what we promised: a clean room, a mug of coffee, non-porous lips and school, a trip to the face avoided by thin wings like silk."
According to Deming (2000), Deming was a pioneer in quality management He introduced a theoretical system of quality control using statistical methods, thereby forming a new philosophy of work management He developed statistical sampling techniques that are still used today by the US Census Bureau and the US Bureau of Labor Statistics He applied the method of statistical process control developed by Walter A. Shewhart to calculate and manage the work process He developed what he called the Shewhart Cycle into the PDSA (Plan-Do-Study-Act, i.e., Plan-Do-Research-Improvement) or PDCA (Plan-Do-Check) Cycle In order to revive the Japanese economy after World War II, the Association of Engineers and Scientists of Japan invited Deming to Tokyo to lecture on Quality Control by Statistics (Statistical Product Quality Management). According to Deming (1950), the application of Deming's theory by Japanese leaders and managers to post-war economic recovery is credited with being the source of Japan's postwar economic miracle In just over a decade, from the ashes of war, Japan grew to become the second most powerful economy in the world by the 1960s.
According to Armand (1991), Armand developed this concept using a systematic approach in which all stakeholders influence the outcome Viewed from an industry perspective, Armand proposes that the final quality level of a product is not the sole responsibility of the production department responsible for its creation but that other components are integrated into the process.
With this proposal, Feigenbaum (1991) aspires to meaningful and effective integration of all levels of organizations to improve quality and service, always aiming for excellence and end-consumer satisfaction For Feigenbaum, total quality control is an
"effective system that integrates development, maintenance, and quality improvement efforts across different groups of an organization to enable manufacturing and service at lower economic levels and allow for complete user satisfaction".
Quality Control Definition
According to Mitra et al (2016), a method for maintaining a desired quality level through feedback on product or service characteristics and remedial action when these qualities deviate from established criteria is known as quality control.
The ISO 9001:2015 version also defines quality control as a part of quality management focusing on fulfilling quality requirements To prevent the manufacture of defective products, it is vital to manage all aspects that directly affect the quality process.
The process of quality control requires a company to come up with a way to guarantee that product quality is either enhanced or maintained To do that, the business must foster an atmosphere that values quality assurance among management and staff. Additionally, quality control makes sure that the manufactured item complies with all requirements and specifications The ultimate goal is to spot mistakes and act quickly to fix them so that organizations can better serve customers and consumers.
Step 2: Determine the quality control point or stage.
Step 3: Set up the test method.
Step 5: Record and analyze the data.
According to Hart (2002), 5W1H is a model that helps you define specific goals, plans, and steps for each campaign, project, or idea The 5W1H method is commonly used in marketing, helping businesses quickly "plan" to implement and achieve their goals. 5W1H is also a very useful formula for the marketing or SEO marketing activities of a business Specifically, the ingredients in this formula have the following meanings:
What is something that needs to be specifically described as the product, problem, or purpose of the project?
When is the right time for you to implement your plan? For example, when to launch a product, when should a marketing campaign be launched, for how long, and how often?The timeline needs to be specific, precise, and possible.
Where is the location where the project or campaign will take place, or simply where your target customers live? This is the market that the business targets for the product. The location here could also be where the problem arises.
Why explains the cause of the problem or the motive behind the execution of a plan or the introduction of a product to the market.
This is a factor in determining the goals and objectives of the plan and objectively assessing whether it should be implemented.
Who are all the people involved in and affected by the project, plan, or product? It can be an implementer, an investor, or a user (customer).
This component of the 5W1H model helps you determine the number of people involved in a project as well as easily divide and manage each person's work.
How determines the method or manner of implementing the project or campaign? In this step, you need to define specific methods and steps throughout the life of the project.
5 Whys is an iterative questioning technique used to uncover the cause-and-effect relationship underlying a particular problem The main goal of this technique is to identify the root cause of the defect or problem by repeating the question, "Why? Each answer forms the basis for the next question The "5" in the name derives from an observational outcome of the number of iterations required to solve the problem.
According to Taiichi (1988), Sakichi Toyoda, one of the fathers of the Japanese industrial revolution, developed this technique in the 1930s He was an industrialist,inventor, and founder of Toyota Industries His method became popular in the 1970s, andToyota still uses it to solve problems today Toyota has a "go and see" philosophy This means making decisions based on a deep understanding of what is actually happening rather than what someone in the room thinks might happen.
Fishbone Diagram
Ishikawa, Kaoru (1990), the Ishikawa diagram, or fishbone diagram, or cause-and- effect diagram, is a method to identify problems and provide solutions in management and leadership The fishbone diagram was developed by Japanese scientist Kaoru Ishikawa While working at Kawasaki Heavy Industries, he discovered that a wide range of factors can affect a workflow To get insight into these factors, he designed a simple graphics engine In it, potential root causes are described in an orderly manner Because this model is shaped like a fish skeleton Therefore, the Ishikawa diagram is also known as the fishbone diagram In fact, the Ishikawa chart has only ever been used for production processes and associated quality management activities But now, this chart is also used in other fields.
Ishikawa, Kaoru's (1990) fishbone chart consists of six main components:
Human Resources: the operational and/or functional labor of those involved in product design and delivery This is considered a rather rare "cause" of a given problem.
Typically, if human resources are identified as the cause of an undesirable effect, it is usually a factor of 6.
Method: a production process and its contributing service delivery processes Often, processes are found to have too many steps, approvals, and other activities that don't contribute or create much value When not streamlined, simplified, and standardized, processes can be confusing and difficult to follow.
Machines: systems, tools, facilities, and equipment used for production Often, machines, tools, and facilities with their basic support systems are poorly managed or incapable of delivering the desired results due to technical or maintenance problems.
Raw materials, components, and consumables are needed to create the desired end product Materials are often mismanaged due to mislabeling, improper storage, expiration dates, and other factors.
Environment: unpredictable and uncontrollable environmental factors such as weather, floods, earthquakes, fires, etc Although many environmental factors are predictable and can be considered controllable, there are a number that cannot be avoided.
Measurement: manual or automatic testing and physical measurements (distance, volume, temperature, pressure, etc.) Sometimes, measurements can be inconsistent, making it difficult to use the data to draw reproducible conclusions that help find a consistent cause.
Steps to create a fishbone diagram:
Step 1: Identify the problem: record the exact problem in detail (apply 5W: what, who, when, where, how).
Step 2: Determine the influencing factors: For each factor, draw a branch rib."
Step 3: Find the possible causes belonging to each factor (found in step 2), and for each cause, draw a "sub-branch" If your cause is too complex, it can be broken down into several levels.
Step 4: Analyze the diagram: The built-in diagram is a complete list of possible causes, which you can check, survey, measure, etc to determine what they are the main causes, and then have specific plans to correct them.
Check Sheet
Ishikawa, Kaoru(1986), a quality control sheet is a form of form used to collect and record quality data in certain ways in order to assess the quality situation and make appropriate treatment decisions.
During the quality management process, the quality check sheet can be used to:
To check the shape of the probability distribution of a process
To quantify errors by type
Quantify failures by cause (machines, workers).
To track the completion of steps in a multi-step process
Pareto Chart
According to Magar and Shinde (2014), Vilfredo Pareto states that about 20% of the causes account for around 80% of the outcomes Pareto's law, or the 80/20 rule, refers to this.
Joseph M Juran (1940) then applied the 80/20 rule to quality Mr Joseph emphasized that only 20% of factors account for 80% of quality losses The numbers 80 and 20 do not fully convey what Juran means when he says that it is crucial to focus on the vital few" (between 20%) in order to take action to eliminate errors and address the most pressing problems.
The goal is to identify the critical variables influencing process outcomes (Wilkinson,
2006), shorten problem-solving times, conserve resources, and raise the caliber of process outputs and services (Nicolae, Nedelcu, and Dumitrascu, 2015) The chart also displays the outcomes of quality improvement activities following the implementation.
Step 1: Determine how to categorize and collect data.
Step 2: Collect and synthesize data
Step 3: Sort the data in order from largest to smallest.
Step 4: Calculate the cumulative percentage.
Step 6: Analyze the Pareto chart with the 80/20 rule.
ANALYZE QUALITY CONTROL IN
The Production Process Of Ansell Vina Co., Ltd
At the company, the production process is very important, from the selection of raw materials to the finished product All processes are agreed by Quality Control to avoid defective products to customers This is The production process of Ansell Vina Co., Ltd.
Due to the different nature of work and working environments, protective gloves are made from a variety of materials to meet requirements such as flexible grip, chemical
Material Winding Covering Knitting Turning
OvercastingCompoundingDippingPrintingPackingGlove resistance, or cut resistance Based on the combination of materials, the factory can make lighter and more comfortable gloves with better protective performance Recently, glove manufacturers have been constantly looking for new and ingenious combinations of materials to achieve these two criteria in seamless knitted gloves.
At Ansell Vietnam, the company specializes in manufacturing industrial protective gloves from available fiber materials such as HPPE, fiberglass, kevlar, nylon, spandex, etc.
Creating yarn tubes of large volume, shape, and size suitable for the next technological process is the spinning process In addition, when polishing, it also helps to remove dirt, foreign fibers, and defects (thick or thin) At the factory, there are two types of yarn tubes used: paper tubes and steel tubes, with steel tubes being the product of the winding process and paper tubes being the product of the spinning process.
Figure 3.2: Paper Fiber Tube Figure 3.3: Steel Fiber Pipe
Enhances the force-related properties of the yarn (strength, elongation, and modulus of elongation) and evenness Reduces the tendency of textured yarns to rotate around the yarn's axis and form loops, improving the yarn's resistance to friction and abrasion. Changes in structural properties affect yarn tactile properties and fiber appearance (crepe effect, resilience, gloss) In addition, spinning aims to combine many types of fibers with different uses and properties to create a protective glove that ensures many different properties, such as cut resistance and abrasion resistance, but still ensures soft breathability.
The typical glove consists of eight basic knitted components that form the finished glove These eight components include one component for each of the four fingers and thumb, two components for the palm, including one upper and one lower, and finally one component for the wrist area.
Conventional knitting processes use a flat knitting machine to knit each of these areas in a specific sequence The sequence of knitting the components follows one finger at a time, starting with the little finger and continuing with the ring and middle fingers to the index finger After each finger has been knitted with the selected range of needles on the needle bed, knitting for each finger is stopped, and the yarn is looped against the last row of fingers to create a tie point, keeping the yarn tight The finger or finished knitted component is held in place by sinkers and finger stops The next finger is then knitted sequentially, one by one, using another needle span on the needle bed When all four fingers are knitted this way, the knitting machine then knits the upper part of the palm, selecting loops from each previously knitted finger After knitting an appropriate length of the upper palm, the thumb section is then started Next, the bottom of the palm is knitted using all the needles on the needle bed Finally, the knitting machine knits the wrist part to the desired length The number of knitted loops for each component is controlled by a computer program in the knitting machine, where the number of loops can be changed to match the required lengths of the components.
Figure 3.4: Order of weaving the glove sections on a flat knitting machine
- Standard inspection after the weaving process
This is an indispensable process in the production process If the size of the glove after the weaving process does not meet the standards, it will be considered defective and will not be transferred to the next stage.
There are two types of size checking: manual measurement and automatic dimensioning During the weaving process, the machine operator will check the width and length of the gloves regularly the available standard table.
After each shift, the staff will check the glove size on the machine The inspection on the machine will be more synchronized, knowing the exact parameters of each part on the glove, and the accuracy rate will be higher At the same time, all the parameters for the size will be saved by the machine.
The thickness of the glove determines the quality and production cost of the finished glove The thickness of gloves will be checked by quality control staff at the beginning of each shift.
Similar to the size and thickness, the weight of the glove is also checked periodically every shift the standard.
Bring the right side of the glove to the outside and hide the excess thread at the places where the glove parts are connected during the weaving process to have a beautiful and comfortable glove for the user.
At this stage, gloves are selected manually or automatically, depending on the product code For products with low weaving density, thin, low-strength yarns will be manually flipped in order to keep the original style and size, and at the same time, automatic flipping with moderate speed will keep the product from tearing or puncturing.
After turning, gloves will be squeezed out for the purpose of fixing the wrist part more firmly At the Ansell factory, gloves are squeezed out by mechanical or automatic
53 machines For product codes that need to be labeled, a mechanical machine will be used On the contrary, with unlabeled product codes, they will be squeezed out at the automatic extractor.
In order to ensure the raw materials for the coating process, the PU and NBR chemical solutions need to have the appropriate viscosity and chemical ratio For the PU mixing process, depending on the customer's requirements, there are ingredients in the mix silicone or not.
After the edging process, the gloves are dipped into the surface to increase their adhesion and have both puncture resistance and effective abrasion resistance At the same time, the left and right gloves are also classified at this stage At Ansell, gloves are covered with PU or NBR.
Introduction Of D365 Software
In Ansell software to manage quantity or materials will be used through D365 software.
Figure 3.7: Dynamics 365 Of Ansell Vietnam
Every time they start to print, the shift leaders will use D365 software to order liner from WIP Zone In the D365 software, it helps the shift leader view goods at the pre- production stages and check inventory and materials for product packing.
Currently, the company has ERP staff to be able to control the quantity of goods to avoid losses to the company D365 software also helps quality control control the number of rows to rework and reject for charting analysis So we can check the whole production process.
Common Errors In Printing And Packing
These are some typical and basic errors in the printing and packaging area, the author has collected Figures when interning at the company.
Figure 3.8: Some Errors In Printing And Packaging
Above are some of the most common errors in printing and packaging, such as lumps,wrong positions, and burn printing Thereby, we can see that in this area, there are many difficulties in solving problems related to the quality of output products These defects are very common, and there have been many cases of defective products being shipped to customers.
Evaluation Of Quality Control Activities At Ansell Vina Company
In order to ensure that the products produced at the ANSELL company facility are of the highest quality and match the expectations of the clients, there are numerous processes and stages of quality control across each step and department.
In terms of human resources, employees who are directly involved in the production process and quality control personnel always adhere to and have a strong sense of compliance with laws governing occupational safety and hygiene High levels of professionalism, specialized problem-solving abilities, and prompt departmental collaboration are required to resolve any scenario successfully.
Incoming materials, including different components of the protective glove, such as thread, chemicals, ink, packaging, etc., are inspected as part of the quality control process. Each component is examined to make sure it complies with the requirements set by the manufacturer Any part that does not adhere to these specifications will be rejected right away by the supplier or discarded in a special department.
Each pair of gloves is checked multiple times before being sold or supplied to consumers, which helps to assure the product's quality and prevent the sale of defective or subpar items to clients The process of evaluating the quality of finished products is rigorous, synchronous, and thorough.
Besides the advantages, the quality control process at the Ansell Vina factory still has some limitations, specifically as follows:
In the process of printing and packaging products, the author noticed some limitations, as follows:
Limitation 1: Check the quality control process in the printing and packaging areas. There are many limitations to finding defective products before they reach the customer. Specifically, in the printing and packaging area, QC has not assigned necessary tasks to employees; for example, at the stage of checking finished products, there are too many
QC staff, but there are still too many defective products This is both a waste of human resources and time when managing human resources.
Limitation 2: The product defect rate is high, but the company does not have the tools to control the quality in the printing and packaging areas, so the author has used the tools to check and find solutions to limit defective products Here are two charts created by the author, showing the number and percentage of defective products at the company.
Figure 3.9: Number Of Defective Product
Defect rate of each product (%)
Figure 3.10: Defect Rate Of Each Product
Through this, we can also see that the product 11-800 has a very high error rate (27,84%), accounting for almost all errors affecting the quality of the product It can be said that product 11-800 is a product with a very high annual error rate because of the high number of orders, which also leads to many product errors.
The quality of the product will depend a lot on printing and packaging Since this is the final stage to reach the customer, if the product is defective in the previous stages, the quality control staff can still bring those products to the processing department, but when these damaged products pass through the packing, they will be shipped directly to the customer.
The QC (quality control) team is responsible for product quality control Since they are in charge of quality control throughout the entire plant, they can't monitor every product they produce and must instead concentrate on checking the finished item as a whole As a result, faulty goods can be disregarded.
During the whole printing and packaging process, the author noticed some remaining limitations, as follows:
At ANSELL VINA, workers also use phones while doing a lot of work; this will greatly affect the quality of the product and be distracting when working.
The testing of materials and machines in the printing department is not good, which will result in many defective products These stages are not checked thoroughly, which will lead to QC (quality control) having to check more products before they are shipped to the warehouse This will take more time and increase the cost of production.
Therefore, the author will focus on analyzing product quality control at the stage of printing and packaging, which is very important for a product when it is shipped to the customer.
PROPOSE SOLUTION IN PRINTING AND PACKAGING
Solution 1: Apply Flow Chart To Check The Quality Control Process In Printing
Figures 4.1 and 4.2 are two before and after diagrams to check the quality control process in the printing and packaging areas Prior to the quality control inspection in this area, QC staff only inspected the product before bringing the gloves back to the finished product warehouse without performing any other checks but when re-checking the quality control process, the author suggested to the experts at the company and the departments of production and quality department heads to make changes as shown in Figure 4.2 By increasing the quality control staff at the previous stages and reducing the quality control staff at the finished product stage, it will help to make the stages less prone to errors and reduce defective products.
Figure 4.1: Flow Chart Before Check The Quality Control
According to figure 4.1, the quality control staff in this area only re-checks the product when the packaging is complete On the one hand, it will be wasteful if the defective product cannot be rejected and is completely damaged On the other hand, the product can be rejected, but it will also take a lot of time and staff to reject the product.
Figure 4.2 shows the change in quality control processes in the printing and packaging areas.
Figure 4.2: Flow Chart After Check The Quality Control
The red lines are the ones to watch out for because these are reworked and rejected products If these products reach customers, it will reduce the quality of the product and the reputation of the company.
The yellow lines are to show people what to check before going to the next stage.
Each stage in the production process is checked for product quality After completing each stage, the product will be checked again before going to the next stage According to Figure 4.2, QC (quality control) will be re-checked at four stages in the production process This will avoid damaged goods as well as increase the quantity of qualified goods.
The first stage of QC (quality control) will randomly check 32 lines at the WIP of the previous stage After checking the 32 or 64 pieces in the box, if there is damage or error, it will be returned to the previous stage This will reduce labor costs as well as poor- quality products.
The next stage of QC (quality control) is to check the machines before printing and packing QC (quality control) staff will check by testing the product on 2 to 3 pairs of gloves (they will use damaged gloves from previous products) if the products are up to standard as well as in the correct position and size, then they will run the machine If the machine has a problem, the maintenance staff will ask the maintenance staff to check the machine to see if it is damaged, and if the problems are related to the product, QC (quality control) will check again.
The next step is to check materials such as nylon, product paper, cartons, etc There will be some employees who get the wrong information about the products For example, glove product 11-800, but retrieve product information 11-801 This will affect the controller if they do not check carefully The cartons will also be carefully checked before being given to the operator; there will be errors such as holes in the box, etc.
The final inspection stage is also the most important in the product inspection process because this product, if passed, will go directly to the customer Therefore, this inspection step is very important and requires staff with inspection experience Here, QC (quality control) will check all parameters on the product and on the package QC (quality control) staff will randomly remove 2 to 3 boxes of goods to check the products inside; this will also inevitably lead to mistakes in the checking stage, such as missing defective products. But if you find 1 or 2 defective products, immediately check the whole product, and there will be a way to fix it later, such as rejecting it or reworking it This helps the finished product achieve the highest quality for the customer.
This is the diagram that the author has consulted with specialized engineers at the company and approved.
Solution 2: Apply SPC Tools To Reduce Defective Products In The Printing And
Step 1: Collect data in the printing and packaging areas.
Step 2: Using Delphi to find defective products
Step 3: Using the Fishbone Diagram, 5whys, and 5W1H to fix the wrong position in the printing and packaging area
Step 4: Provide solutions to limit defective products in the printing and packaging areas.
4.2.1 Collect data in printing and packaging area
In quality control, samples will be randomly drawn to check for errors During error checking, the following common errors are encountered:
Packing printing area from July 19 to July 25, 2023
Figure 4.3: Number Of Name Defective Products
Through the pareto chart, we can see that the error of the wrong position is very high, affecting the quality of the production process in the printing and packing area and the quality of the product In just 1 week, the error of wrong positioning up to 335 pieces accounts for a high percentage of the problem-solving process.
ERROR CODE PRINTED IN THE WRONG POSITION
Figure 4.4: Defective Code Products Printed In The Wrong Position.
Here we can also see that the product that needs improvement and quality control is product 11-800, which is in the wrong position This is also a problem that the company has been facing for many years The fact that orders are placed in large and urgent quantities also affects the failure of products 11–800.
During the internship at ANSELL, the author participated and learned at all stages of quality control, from input to the finished product of work gloves Some parts affect product quality The company has many lines, but in this report, the author only focuses on errors that often occur in the printing and packaging departments Next, the author will use the Delphi method and the expert interview method to identify factors that cause misplaced printing errors as well as many other errors, then use the fishbone diagram, 5W1H, and 5Whys methods to evaluate the most influential factors that created the above error.
Here, the author will carry out the Delphi technique in a three-step process.
The Delphi rectification method will be used by the author to check the documents before beginning the survey because this is a problem that has occurred in the ANSELL VINA company.
Step 1: Build a set of indicators.
This stage involves the author reviewing papers that are connected to the previously mentioned problem; she then identifies four influential elements and conducts interviews with subject-matter experts using the Likert scale The author chose and asked a number of experts to participate in the survey because the method's dependability and accuracy mostly depend on the expert answering the question, including two quality engineers, two
QA staff, and two staff with five years of experience in the assembly department The Delphi method ensures accuracy and impartiality in its aspects by allowing experts who will take part in closed interviews to respond independently based on their expertise and experience without being influenced by a third party.
Question: Here are some thoughts on what causes many printing and packaging defects Please mark (X) the answer that you think is the most correct.
The survey will have five different levels, ranging from 1 (strongly disagree) to 5 (strongly agree) After conducting the survey, the author collected the following answers:
1 Employees are not aware of the importance of quality X
2 At the end of the working day, employees do not clean the workplace X
3 The hot working environment makes employees unfocused and tired X
5 Do not check position light when using X
6 Objects are not properly placed when finished using X
7 The screw in the bracket is not installed correctly X
8 Do not check the parameters on the instruction sheet X
9 “Staff are not properly trained in knowledge and skills” X
10 There is no instruction manual at the place of assembly X
Figure 4.5: Questionnaire To Survey Experts' Opinions
Step 2: Calculate the average value and Content validity ratio (CVR) for each factor:
Wong et al., 2020 calculate the content validity ratio (CVR) as (ne − N/2) / (N/2). ne = number of SME panelists indicating "essential"
N = total number of SME panelists
Lawshe (1975) assumes that each item has three options: necessary, important but unneeded, and unnecessary The author of this study employs a five-point Likert scale, so the two scales must fit together At a score of 1, 2, it is rated as unimportant, at level 3 as important but not necessary, and at a level of 4, 5 as important.
After conducting the first round of the survey, the author obtained the following data table:
Figure 4.6: First-round Delphi According to Min (2015) and Nguyen et al (2022), the mean value of the scale is:
If the average value of the scale is > 4, then the variable is successful.
The average value of the scale is 3.50–3.99, then conduct a round 2 survey.
The mean value of the scale is 3.50; the variable does not pass.
So, in this round of interviews, the author interviewed six experts, and with a CVR