A STATISTICAL QUALITY CONTROL IN THE BAKER INDUSTRY

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A STATISTICAL QUALITY CONTROL IN THE BAKER INDUSTRY

ABSTRACT

A process through which a business seeks to ensure that product quality is maintained or improved and manufacturing errors are reduced or eliminated. Quality control requires the business to create an environment in which both management and employees strive for perfection. This is done by training personnel, creating benchmarks for product quality, and testing products to A major aspect of quality control is the establishment of well-defined controls. These controls help standardize both production and reactions to quality issues. Limiting room for error by specifying which production activities are to be completed by which personnel reduces the chance that employees will be involved in tasks for which they do not have adequate training. This work gives a statistical analysis of quality control in the bakers industry (A case study of Highlife bakery Emene, Enugu). A hundred and twenty questionnaires were distributed among workers, managers and people from other selected bakery firms in Port Harcourt. Interviews and surveys were also carried out. Primary and secondary data were used in the analysis. Tables and percentages were used as the instrument of analysis. Based on the statistical analysis carried out, it was observed therefore that Highlife bakery Emene, Enugu has a quality control in the bakers industry. A methodology for the closed loop control of biscuit quality during baking is proposed and was validated during several experiments. This methodology involves expert knowledge which is captured in a modular way. Three modules are involved in the control strategy of the process. The first module reproduces sensory evaluation by the operator. The second module diagnoses the state of the process with respect to quality state of biscuits. Finally, a decision module supervises the actuators of the process. Different fuzzy concepts are applied within these modules and fuzzy information is processed through the control chain. Results show that using only 11 rules, all components of quality are controlled with accuracy and robustness. This is particularly interesting in the light of the complexity of the process. Such a modular approach makes it possible to follow the evolution of quality during the process, in successive steps which are easily recorded and interpreted by experts. This approach could be envisaged as an operator decision support system. In the food industry, quality control (QA) systems are applied to ensure food safety and food quality to prevent liability claims and to build and maintain trust of consumers. Bakeries apply QA systems such as Hygiene code, HACCP (Hazard Analysis Critical Control Points), ISO (International Organization for Standardization) and BRC (British Retail Consortium), but for them to be able to decide which system suits their specific situation (i.e., context) most and how this system should be implemented, they lack the necessary insight into the interdependence of contextual factors of bakeries and the quality management level at which these bakeries operate. This article reports on these aspects. The contextual factors that were studied include QA system, size of organization, degree of automation and type of product group. The level of food quality management between groups of bakeries differing in these contextual factors was analysed. Differences between groups of bakeries were found in the level of the quality management activities, control of strategy, allocation of supplying raw materials, supply control, planning of production and control of execution of production tasks. Bakeries that applied BRC, bakeries with 150 employees or more, industrial bakeries, and confectionery and biscuit bakeries performed some of these activities at a higher quality level than the other groups of bakeries. The study shows that by using the instrument IMAQE-Food, bakeries can select suitable quality management activities and QA systems for their specific situation to achieve effective quality management. In the food industry, quality assurance (QA) systems are applied to ensure food safety and food quality to prevent liability claims and to build and maintain trust of consumers. Bakeries apply QA systems such as Hygiene code, HACCP (Hazard Analysis Critical Control Points), ISO (International Organization for Standardization) and BRC (British Retail Consortium), but for them to be able to decide which system suits their specific situation (i.e., context) most and how this system should be implemented, they lack the necessary insight into the interdependence of contextual factors of bakeries and the quality management level at which these bakeries operate. This article reports on these aspects. The contextual factors that were studied include QA system, size of organization, degree of automation and type of product group. The level of food quality management between groups of bakeries differing in these contextual factors was analysed. Differences between groups of bakeries were found in the level of the quality management activities, control of strategy, allocation of supplying raw materials, supply control, planning of production and control of execution of production tasks. Bakeries that applied BRC, bakeries with 150 employees or more, industrial bakeries, and confectionery and biscuit bakeries performed some of these activities at a higher quality level than the other groups of bakeries. The study shows that by using the instrument IMAQE-Food, bakeries can select suitable quality management activities and QA systems for their specific situation to achieve effective quality management.

CHAPTER ONE

1.0 INTRODUCTION

1.1 BACKGROUND OF THE STUDY

Linde delivers value when solving the processing and handling needs of a diverse bakery industry. From artisan breads to breadsticks, from cakes and cookies to pastries and pasta, the dry foods and bakery sector covers a diverse set of flour-based products. Increasingly, it includes bakery mixes and frozen dough products, which are growing in popularity to accommodate the expanding convenience and thaw & serve markets, while also meeting the need to further automate baking processes. Just as diverse as the bakery products themselves are the processing needs and shelf-life requirements from one category to another.

Temperature control is essential, for instance, to ensure that dry ingredients (such as flour, sweetener, shortening and yeast/leavening) are delivered to the mixer at a consistent temperature in order to improve quality and efficiency. Before being packaged, baked goods are cooled to about room temperature. Without proper cooling, the product can be too tender, overly moist and prone to breakage. In the next step, processes such as slicing, bagging and wrapping call for careful handling due to the sensitive nature of the foodstuffs. Before slicing portionable products, for example, it is often helpful to freeze the crust to maintain rigidity and shape for subsequent freezing. The Quality control of food has a significant role in assuming a high quality, safe and nutritious food supply for the public, for their good health and for the economic benefits derived from trade of safe and high quality food. Quality control is applicable throughout the entire food system. The three basic characteristics of a food quality control infrastructure include-

· Food Law and accompanying regulations:

o Quality control in food cannot operate without adequate food law

o The law should define the role and responsibility of the private sector and other institutions such as industry, academic institutes, scientific committees and consumers in relation to food quality and safety.

· A Food Inspectorate, Analytical Services, and Compliance Unit.

o Role of the inspectorate is to inspect food manufacturing, processing and handling facilities, import/export foods.

o The inspectors should be trained in the latest investigative techniques and fully educated in the latest food safety and Q.A methods.

o The laboratory function is critical to Q.C in food.

o Use of latest analytical instruments and sophisticated methods of analysis.

o A compliance unit ensures that the recommendations for legal action are appropriately supported by sufficient and supportable evidence.

o It would be responsible for those actions that are considered regulatory in nature such as court actions.

· Supporting services i.e. education, information, training and advisory support, industry, consumers.

o Science and Technology services provide backup in research planning and support or for review of the latest technologies in food control or food processing.

o Food Industry shares responsibility with the governmental agencies in achieving quality control strategies such as Good Agricultural Practices (primary production) and Good Manufacturing Practices (secondary production).

o Consumer organizations can play an important role in representing the consumer in the development of a Q.C strategy and bringing the concerns of consumers to the attention of the policy makers and the industry. The main reason for having quality control is to ensure that the products are made as per the standards demanded by the management. It ensures that raw materials meet set standards; processing methods perform as designed; finished products meet company standards and consumer confidence in the company remains high.

Quality control in a typical food processing system begins right from the stage of production of food and runs till the stage of its sale and distribution. Some of the common quality control measures at each stage of a processed food are highlighted below:

PRODUCTION

Control on the use of pesticides, veterinary drugs, and fertilizers.

Quality control at the time of harvesting.

Post harvest handling particularly during storage (temperature, humidity and time control)

PROCESSING

Use of Good Manufacturing Practices (GMPs). Application of Hazard Analysis of Critical Control Points (HACCP) approach to achieve optimum results with regard to the quality and safety of the product. The application of ISO 9000 series of standards to establish Q.C regimes.

DISTRIBUTION AND SALE

The ambient conditions under which food is stored or transported. For ex. Time, temperature, humidity.

Application of ‘first-in, first-out’ principle to see that food is not held beyond its shelf life.

1.2 STATEMENT OF THE PROBLEM

Asika (1999/2000) posited that a problem is recognized when a doubt is raised, difficulty is created or dissatisfaction occurs and a solution is needed on this note, the foundation upon which any research work is based is the probing question initiated by the numerous problems which this research undertaking is set to address. Some of them are mentioned below:

– The idea of Quality control (QC) in the existing baking sector of Nigerian .

– The monitory of total quality control techniques in setting standards in organization.

– Continuous improvement in total quality control objectives, policies and strategies in baking sector.

– Commitment to total quality control training and management.

– The implementation of strategies embracing the process of Quality control (QC) .

– Measurement of performance and management horizons to sustain improvement on potential problems.

– The management, priorities and coordination of problem solving activities.

1.3 OBJECTIVE OF THE STUDY

1.To understand the concept of quality control and its application in bakery industry.

2. To assess the contribution of quality control to food safety and hygienic.

3. To evaluate the challenges of bakery industry in the application of quality control techniques in food processing.

4. To make suggestion to solve the possible challenges based on research findings.

1.4 RESEARCH QUESTION

1.How one understand the concept of quality control and its application in bakery industry?

2. Are there any contributions of quality control to food safety and hygienic?

3. What are the challenges of bakery industry in the application of quality control techniques in food processing?

4. Are there plausible suggestion to solve the possible challenges based on research findings?

1.5 RESEARCH HYPOTHESIS

H0: One cannot understand the concept of quality control and its application in bakery industry.

H1: One can understand the concept of quality control and its application in bakery industry.

H0: There is no significant relationship between quality control and food safety and hygienic.

H1: There is a significant relationship between quality control and food safety and hygienic.

H0: There are no challenges of bakery industry in the application of quality control techniques in food processing.

H1: There are challenges of bakery industry in the application of quality control techniques in food processing.

SIGNIFICANCE OF THE STUDY

This research work which is on the study of quality control in the bakers industry using Highlife bakery Emene, Enugu is an important and interesting topic which will contribute immensely to the body of knowledge to students of food science, hotel and cartring management, house hood management and as well as entire public.

SCOPE OF THE STUDY

This study is centered onthe study of quality control in the bakers industry using Highlife bakery Emene, Enugu as a case study.

1.8 LIMITATION OF STUDY

Despite the limited scope of this study certain constraints were encountered during the research of this project. Some of the constraints experienced by the researcher were given below:

i. TIME: This was a major constraint on the researcher during the period of the work. Considering the limited time given for this study, there was not much time to give this research the needed attention.

ii. FINANCE: Owing to the financial difficulty prevalent in the country and it’s resultant prices of commodities, transportation fares, research materials etc. The researcher did not find it easy meeting all his financial obligations.

iii. INFORMATION CONSTRAINTS: Nigerian researchers have never had it easy when it comes to obtaining necessary information relevant to their area of study from private business organization and even government agencies. The staff of Highlife bakery Emene, Enugu find it difficult to reveal their internal operations. The primary information was collected through face-to-face interview getting the published materials on this topic meant going from one library to other which was not easy.

Although these problems placed limitations on the study, but it did not prevent the researcher from carrying out a detailed and comprehensive research work on the subject matter.

1.9 DEFINITION OF TERMS

Quality control is the more traditional way that businesses have used to manage quality. Quality control, or QC for short, is a process by which entities review the quality of all factors involved in production. This approach places an emphasis on three aspects:[citation needed]

Under traditional quality control, inspection of products and services (checking to make sure that what’s being produced is meeting the required standard) takes place during and at the end of the operations process. Quality control is the more traditional way that businesses have used to manage quality. Quality control is concerned with checking and reviewing work that has been done. But is this the best way for a business to manage quality. Under traditional quality control, inspection of products and services (checking to make sure that what’s being produced is meeting the required standard) takes place during and at the end of the operations process.

Water: Water is the major contributor to the eating and keeping qualities and structure of baked products. Its management and control during preparation, processing, baking, cooling and storage is essential for the optimisation of product quality. This successful and highly practical volume describes in detail the role and control of water in the formation of cake batters, bread, pastry and biscuit doughs, their subsequent processing and the baked product.

TABLE OF CONTENT:

CHAPTER ONE

INTRODUCTION

1.1 Background of the Study

1.2 Statement of the Research Problem

1.3 Objectives of the Study

1.4 Significance of the Study

1.5 Research Questions

1.6 Research Hypothesis

1.7 Conceptual and Operational Definition

1.8 Assumptions

1.9 Limitations of the Study