2. Introduction
• Statistical process control (SPC) is the application of statistical
methods to the monitoring and control of a process to ensure
that it operates at its full potential to produce conforming
product.
• SPC process behaves predictably to produce as much
conforming product as possible with the least possible waste.
• SPC has been applied most frequently to controlling
manufacturing lines, it applies equally well to any process
with a measurable output.
• In addition to reducing waste, SPC can lead to a reduction in
the time required to produce the product or service from end
to end.
3. • Statistical Process Control
– Statistical we collect large amounts of data about
our memory products from experiments.
– Study that data to learn how our actions affect the
performance of our products.
– Process is the method of doing something.
– Control we use the data to adjust the process to
achieve the desired results.
– results are dependent on customer requirements,
efficiency, quality, and reliability.
4. • How to Use SPC:
– Statistical Process Control may be broadly broken down
into three sets of activities:
• understanding the process,
• understanding the causes of variation,
• and elimination of the sources of special cause variation.
– In understanding a process, the process is typically mapped out
and the process is monitored using control charts.
– When excessive variation is identified by the control chart
detection rules, or the process capability is found lacking,
additional effort is exerted to determine causes of that variance.
– Once the causes of variation have been quantified, effort is
spent in eliminating those causes that are both statistically and
practically significant.
5. Pakistan Tobacco Company
• Pakistan Tobacco Company Limited was incorporated in 1947
immediately after partition, they took over the business of
the Imperial Tobacco Company of India which had been
operational in the subcontinent since 1905.
• First multi-national company to begin its operations in
Pakistan.
• From being just a single factory operation to a company which
is involved in every aspect of cigarette production, from crop
to consumer, they have evolved into one of the leading
corporations in Pakistan.
6. • Our Vision
“First choice for everyone.”
• Our Mission
“Transform PTC to perform responsibly with the speed,
flexibility and enterprising spirit of an innovative,
consumer focused company.”
• Our Strategic Objectives
“Our strategy reflects our vision of being the
champions of Growth, Productivity, Responsibility
and Winning Organization.”
7. SWOT Analysis
• Strength • Opportunities
– Continuous learning and – PTC has the potential to further
improvement. improve the cost reduction method.
– Diversified workforce and – Export of premium brands
environment.
– Technologically advanced machinery • Threats
and equipments. – Some of its competitors are also
– Training and development of its producing high quality brands.
employees. – Limitation of their product,
• Weakness – Decline in tobacco growth
– Technological advancement would
decrease the workforce and
unemployment will increase.
– Workers are always under threat
because of downsizing.
– Improper distribution of work
8. Implementation
• This research intends to combine the Hourly Data System (HDS) and
Statistical Process Control (SPC) practices to improve manufacturing
performances in manufacturing companies.
• The focus of this work is to find out the frequencies and time duration of
machine breakdowns as well as the major causes of breakdowns affecting
productivity.
• Total quality management (TQM) was introduced to improve continually
the products or services to increase the customer satisfaction level.
• TQM is a people focused management system that aim at continual
improvement in customer satisfaction. It helps to monitor process
continuously.
9. Methodology
• The volume of cigarette packing department (CPD) has been taken for
analyzing the performance of the machines.
• The major difference between brands lies in tobacco mixture and they
have same packing and making process.
• These data are then plotted in Minitab, which is a Statistical Software
for production trend analysis.
• Root causes of failure for production data which is out of control limit
are then looked for from HDS, Maintenance Schedule, Communication
Log Book, and Electrical Log Book and then the findings have been
analyzed.
10. • LOSS TIME DATA ANALYSIS
– Pareto Chart for Break-Down Time
• According to the rules of SPC chart, all the out of specification
points have been detected.
• Each point on the control chart represents the total production
volume of a particular day.
• The defects responsible for each individual out of spec data have
been traced from HDS and the root causes of those defects are
then analyzed.
– Alert Signal Before Major Breakdowns
• The best approach to address any breakdown is the preventive
measure.
• Preventive maintenance is a scheduled maintenance program that
prevents the machineries and equipments from unwanted
breakdown in between production process.
11. • Economic Analysis
– Loss Incurred From Machine Break Down
– Loss Incurred from Non-Conforming Products
• Conclusion
– Detailed analysis has been done to find out the
frequencies and time duration of cigarette making
machine breakdowns as well as the major causes of those
breakdowns.
– The obtained result shows that any breakdown can cause a
huge cost and the best approach to address any
breakdown is the preventive measure.
– The economic analysis has clearly affirmed the fact that
any preventive measure assuming the breakdown patterns
can help a lot in terms of revenue generation.
