QUALITY MANAGEMENT ANALYSIS

Pakistan Tobacco Company

Group Members: Hiba Mujeeb Imtisal-e-noor Arooj Fatima

In 1947 took over the business of the Imperial Tobacco Company of India and became part of the British American Tobacco Group

Remarkable supporter of social responsibility

Pakistan Tobacco Company

First multinational in Pakistan

Vital role in development and progress of the industrial and agricultural sector

Leading Tobacco Company with the highest market share and the highest tax payer

Mission Statement
Transform PTC to perform with the speed, flexibility and enterprising spirit of an innovation, consumer-focused company

Why We Chose PTC?

1st multinational company in Pakistan Tobacco industry works at a mega scale

International impact

Data availability

First choice

Transform PTC to perform with the speed, flexibility and enterprising spirit Regain volume leadership by positioning viable brands Drive W/C standards in products , Processes and services. Strive to meet stakeholder expectations

Business Principles

Mutual benefit

Responsible Product Stewardship

Good Corporate Conduct

Brands Offered

Raw Materials

Tobacco Paper

Locally grown tobacco from Akora, Nowshehra Imported tobacco from Turkey

Obtained from Packages Pakistan Limited Used for making cigarettes rods and other components

Filters
Packaging

Most expensive component of cigarette

Supplied by Packages Pakistan Limited Is done through aluminum foils, air tight plastic coating, branded cases

Factory Layout
The factory is:
A state of the art manufacturing wonder Certified by ISO-9001 Boasts the title of being the only 5-S certified company

Plant area is divided into two main parts:

Primary Manufacturing Department (PMD) Secondary Manufacturing Department (SMD)

Over All Manufacturing Process

Manufacturing process main objective:
maximum productivity maintaining quality

Each step is monitored by

computers human eye

The manufacturing process is divided into two parts, PMP and SMP.

Primary Manufacturing Process

Primary Manufacturing Process

Check Points
There are two quality check points in primary process : After conditioning tobacco where continuously monitored
Temperature Moisture level

And at the end to assure quality five samples are taken and examined in laboratory for:
Moisture Particle size

Secondary Manufacturing Process

Secondary Manufacturing Process

Check Points
Each filter rod is inspected using high speed computerized equipment called the Quality Testing Modules (QTM). The MCBs from PMD are scanned for bar-codes, if the bar code is a match with the maker machine, it means that the tobacco blend is for the same brand that is currently being made on this machine. All cigarette making machines are also equipped with QTM which visually inspects cigarettes for defects and if found any, cigarettes are discarded and sent for recycling. Packets are then monitored visually by machines and humans. Faulty packets are discarded and sent for recycling In between the PMD and SMD there is a small department called the Ripping department. Here all the discarded cigarettes are ripped using rippers and tobacco is separated from the paper and filters. Moisture and temperature of ripping department is also monitored and controlled.

QUALITY MEASURES IN PRACTICE AT PTC

Pakistan Tobacco Company Quality Policy

Following the quality standards set by British American Tobacco Group International

Zero defects resulting in zero accidents

Customer satisfaction comes first

Carefully evaluating and maintaining quality measures.

Parts Of Quality
Their policy helps them to divide their definition of quality into two parts,
product quality method and manpower quality

Product Quality The extent to which the finished product meets the expectations of customers and the specifications

Product Quality Attributes

Physical Attributes Moisture Fill Value

Visual Attributes
Brand Markings
Appearance Of Packet & Cigarette

Particle Size
Pressure Drop

Ends Fall Out

Circumference

Smoke Yield

Tip Ventilation

Monitoring Of Quality Attributes

Physical Factors
Random samples are taken to QA lab to calculate the puff numbers Random samples are checked in QA lab for average pressure drop readings

Visual factors
Spots ,filter joints, covering and brand impression are monitored through QTM modules. Randomly taken samples of cigarettes are mounted on E-44 testers X-charts are used to monitor the circumference of cigarettes and QTM is used to record circumferences.

Major Tools For Quality Checking

IMI Incoming Material Inspection Frontline quality checking measure COPS Continuous Optimization Ranking of quality parameters Of Primary Process QUIS Quality Information System EQUATA Exhibit Quality Training Aid Database of all the quality based data Identify problems with pictorial representation

QTM Quality Testing Module Measures all the quality parameters

FPI Final Product Inspection PI & T - Product Integrity And Traceability Measures quality of the finished product Deal with the problem of mixing of brands Manages and monitors the suppliers of PTC

C- Track System

Possible Defects
All possible defects are classified into three categories on the basis of their prominence
A-Rank: Obvious to all. 100% rejection of product B-Rank: Noticeable by quality conscious only. Stop production and rectify C-Rank: only experts can identify. Continue production and maintain machinery to remove fault

Internal audits

Quality circle meetings

Approach to zero defects

KAIZEN

Training and refresher courses

METHODS AND MANPOWER QUALITY TOOLS

Fsep foucused skill enhancement program

Internal Audits Of SMD And PMD Quality Circle Meetings Approach To Zero Defects
Training And Refresher Courses

An exercise is conducted once a month which is used to check the quality and effectiveness of methods

Quality circle meeting are attended by a group of Quality related personnel.

This is an approach used at PTC to achieve zero defects in terms of Machines, material, methods and manpower related defects. All the work force, including the workers, machine operators, Quality Assurance personnel etc are properly trained for their tasks. This is another step taken by PTC to make their work force able to do their task right at the first time with zero defects and being safe.

Fsep -Foucused Skill Enhancement Program

KAIZEN: Continuously Looking For Improvements

PTC has award winning quality measures but still they are not sleeping over it. They are constantly looking for improvements and new methods of increasing quality. Continuously looking for better suppliers who supply high quality raw materials.
This the reason why PTC does not make long term contracts with its suppliers.

Pareto analysis

Statistical process control charts analysis

Quality Management Analysis tools applied at PTC

Process flow chart analysis

Benching the mark

Cause and effect diagram analysis

Pareto Analysis Of PTC

One of the most effective cost-analysis tool.

Process Flow Chart Analysis

Process has been designed very carefully and is integrated with QUIS system. There are several quality check points after every main process

Quality is tested on selected parameters

Cause And Effect Diagram Analysis

The cause and effect diagram is used for tracing back problems to their causes A problem caused by the 4 Ms is detected. The 4 Ms are:
Machine Manpower Material Method

Benchmarking
The process of benchmarking in PTC is done internally. It compares the practices and performance of similar business units or business process that are already being used

Statistical Process Control

SPC Charts are used to assure that products are made according the specifications If the process goes out of the pre-defined limits, the manufacturing process is halted immediately and the problems are identified and solved

The Control Limits and the average values for making these charts were not.

Quality Function Deployment : House of quality

House of quality, These factors impacts the overall quality
Moisture Quality of tobacoo Pressure drop Particle size Fill value R & D and Manufacturing Quality Index

Certification Standards
ISO 9001 CERTIFICATION ISO 14000 CERTIFICATION 5-S HOUSE-KEEPING STANDARDS

Recommendations For PTC

Elimination of delay in unloading Increasing production of cigarette making process by enhancing reliability of the existing machines and buying new machines Establishing a systematic synchronization among the two major process in smd; the packing process and the cigarette making process

Recommendations contd
Establishing direct connection between filter making and cigarette making process Taking proactive measures for reduction of wastage

Conclusion
PTC has state of the art quality assurance and quality control measures. However there is no end to improvements in Quality the concept of kaizen which implies gradual and continuous improvement is still valid.

Disclaimer
We do not condone smoking in any way. Smoking is injurious to health

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