Cover
Preface
1 Quality Management in the Food Industry
1. 1.1 Introduction
2. 1.2 Definition of Quality Control
3. 1.3 Quality Control in the Food Industry
4. 1.4 Quality Assurance
5. 1.5 Quality Management System in the Food Industry
6. 1.6 Statistical Thinking
7. 1.7 Summary
2 Food Industry and its Contribution to the Global Economy
1. 2.1 Introduction
2. 2.2 What Is the Role of Food Industry in the Global Context?
3. 2.3 Several Classifications of Food Industry from Several Sources
4. 2.4 How is the Food Industry Different from Other Industries?
5. 2.5 Customers and Consumers
6. 2.6 Government Plan
7. 2.7 Summary
3 Quality and Safety in the Food Industry
1. 3.1 Introduction
2. 3.2 Food Quality
3. 3.3 Food Safety
4. 3.4 Hazard Analysis and Critical Control Point (HACCP)
5. 3.5 Good Manufacturing Practice
6. 3.6 Food and Drug Administration (FDA)
7. 3.7 Summary
4 An Introduction of SPC in the Food Industry: Past, Present and Future
1. 4.1 Statistical Process Control: A Brief Overview
2. 4.2 Quality Control in the Food Industry: Before SPC
3. 4.3 The Evolution of SPC in the Food Industry
4. 4.4 The Principle of Current Quality Control
5. 4.5 Future of SPC: Organisational Learning Through Statistical Methods Application
6. 4.6 Summary
5 Tools in SPC
1. 5.1 Basic Quality Tools
2. 5.2 SPC Tools
3. 5.3 Cause‐and‐Effect Analysis
4. 5.4 Pareto Diagram
5. 5.5 Process Flowchart
6. 5.6 Histogram
7. 5.7 Scatter Diagram
8. 5.8 Control Chart
9. 5.9 Common Mistakes
10. 5.10 Summary
6 Team Formation, Team Dynamics and Training
1. 6.1 The Team
2. 6.2 Team Dynamics
3. 6.3 Training
4. 6.4 Consultant
5. 6.5 Follow‐Up in‐House Training
6. 6.6 Measuring Training Effectiveness
7. 6.7 Summary
7 SPC Readiness Self‐Assessment Tool
1. 7.1 Ready….?
2. 7.2 Concept of Readiness
3. 7.3 History of the Readiness Concept
4. 7.4 An Approach to Assessing SPC Readiness in the Organisations
5. 7.5 Key Components of SPC Readiness
6. 7.6 Top Management Support
7. 7.7 Identifying the Readiness Level
8. 7.8 Summary
8 Critical Aspects in SPC Implementation Process
1. 8.1 Introduction
2. 8.2 Key Findings from an Empirical Study in the UK Food Manufacturing Industry
3. 8.3 CSF of SPC Implementation
4. 8.4 Gap Between the Importance of SPC and the Frequency of Actual Practice
5. 8.5 Common Barriers to SPC Implementation
6. 8.6 Process Performance Measurement
7. 8.7 Summary
9 Roadmap for the Deployment of SPC
1. 9.1 A Cookbook Approach
2. 9.2 Phase Awareness: Sell the Program
3. 9.3 Phase Preparation
4. 9.4 Phase Initiation
5. 9.5 Phase Institution: Company‐Wide Implementation
6. 9.6 Phase Sustainability
7. 9.7 Summary
10 Case Studies
1. 10.1 Application of the Control Charts in the Industries
2. 10.2 Case Study 1 Monitoring Fish Product Packaging (Grigg, Daly, and Stewart, 1998)
3. 10.3 Case Study 2 Monitoring the Sausage Production
4. 10.4 Case Study 3 Controlling Microbiological Hazards on the Food Products
References
Index
End User License Agreement

List of Tables

Chapter 2
1. Table 2.1 Comparisons on the classifications and contributions of the food indus...
Chapter 5
1. Table 5.1 The common symbols used in the flowchart.
2. Table 5.2 Rules for interpreting a control chart.
Chapter 6
1. Table 6.1 Team effectiveness criteria.
2. Table 6.2 SPC training programme.
Chapter 7
1. Table 7.1 SPC readiness self‐assessment tool.
2. Table 7.2 The SPC readiness score threshold.
Chapter 8
1. Table 8.1 The rank of CSFs according to its importance and frequency in practice...
2. Table 8.2 Barriers towards the SPC implementation.
3. Table 8.3 Process performance.
Chapter 10
1. Table 10.1 Net weight data set (gram).
2. Table 10.2 Data defectives sausages from the inspection.
3. Table 10.3 Raw data and transformed data.
4. Table 10.4 The data distribution for net weight fish packaging.

List of Illustrations

Chapter 1
1. Figure 1.1 Example of process map of bread production.
2. Figure 1.2 SPC in food certifications.
Chapter 2
1. Figure 2.1 Food as an economic opportunity.
2. Figure 2.2 The food value chain.
3. Figure 2.3 Stakeholders in the food chain.
Chapter 3
1. Figure 3.1 Food quality and food safety.
2. Figure 3.2 Steps in implementing HACCP.
3. Figure 3.3 PDCA for HACCP implementation.
4. Figure 3.4 Target of HACCP implementation.
5. Figure 3.5 Severity of hazards.
6. Figure 3.6 Example of tree diagram.
Chapter 4
1. Figure 4.1 Inspection for defects.
2. Figure 4.2 Inspection vs SPC.
3. Figure 4.3 The comparison of SPC and inspection.
4. Figure 4.4 Evolution of SPC in the food industry.
5. Figure 4.5 Learning through experience.
6. Figure 4.6 Relation of OL in process improvement.
Chapter 5
1. Figure 5.1 Steps to apply cause‐effect analysis.
2. Figure 5.2 Fishbone diagram.
3. Figure 5.3 Cause‐and‐effect analysis for variability in the height of coconut c...
4. Figure 5.4 Steps to develop Pareto diagram.
5. Figure 5.5 Steps to develop process flowchart.
6. Figure 5.6 Steps to develop histogram.
7. Figure 5.7 Steps to plot scatter diagram.
8. Figure 5.8 Steps to construct control charts.
9. Figure 5.9 Steps in developing run chart.
Chapter 6
1. Figure 6.1 Types of SPC teams, team members and their tasks.
2. Figure 6.2 SPC team members' roles.
3. Figure 6.3 SPC Team maturity.
4. Figure 6.4 The roles of a leader in a team.
5. Figure 6.5 Training evaluation criteria.
Chapter 7
1. Figure 7.1 Concept of readiness.
2. Figure 7.2 Positioning SPC readiness in SPC implementation.
3. Figure 7.3 The innovation diffusion for change process.
4. Figure 7.4 Components of SPC Readiness.
5. Figure 7.5 Overall SPC readiness score.
Chapter 8
1. Figure 8.1 Type and location of sample food companies in the UK.
2. Figure 8.2 Size of company and SPC adoption.
3. Figure 8.3 Type of commodities.
4. Figure 8.4 Pareto analysis of CSFs in SPC implementation.
5. Figure 8.5 Common SPC leader in the food companies.
Chapter 9
1. Figure 9.1 Implementation of SPC roadmap.
2. Figure 9.2 Role of SPC training.
3. Figure 9.3 SPC training holistic program.
4. Figure 9.4 Preparation phase.
5. Figure 9.5 Steps for control chart construction.
6. Figure 9.6 Out‐of‐control action‐plan.
7. Figure 9.7 Control chart selection flowchart.
Chapter 10
1. Figure 10.1 X‐bar chart.
2. Figure 10.2 Range chart.
3. Figure 10.3 Flowchart of sausage production.
4. Figure 10.4 Pareto analysis of consumer complaints.
5. Figure 10.5 p‐Chart of sausage production.
6. Figure 10.6 Anderson‐Darling Normality test.
7. Figure 10.7 Individual chart (Ln‐RLU).
8. Figure 10.8 CUSUM plot of the ATP data (Ln‐RLU).
9. Figure 10.9 CUSUM chart of the ATP data.

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This edition first published 2019

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Library of Congress Cataloging‐in‐Publication Data applied for

ISBN: 9781119151982

Cover Design: Wiley

Preface

Quality and process control are two important fields in the area of food quality management and currently the improvement of both areas being used as a strategic approach to surviving in the competitive but highly regulated industry. Food quality control is the subject of attention in the food production lines. This book refers to quality control, not in the constricted meaning of the term that is often used within the industry where there are hazards such as microbial, chemical and physical assessment of the product. The authors offer the readers the opportunity to view quality control as the reactive activity that involves controllable factors, which affect the quality of the finished product. The most reliable and renowned technique to address process control in the realm of quality management is one based on the statistical method. Unlike other statistical quality control manuals, this book does not cover the heavy topic of the manual calculation on developing control charts. Instead, it covers the process in implementing SPC such as readiness, planning, and managing the SPC implementation. In adopting the technique, it is critical for the managers to understand ‘what, where, who, when and how’. It was therefore deemed preferable to include discussion on the related issues on SPC implementation in the industry, such as challenges, advantageous of the implementation and the relation of SPC application towards process performance. Another critical area that is often being missed in the industry is the preparedness of business to deploy SPC implementation. A self‐assessment tool is provided for the managers to assess their business preparedness level before investing in the SPC application. The book also covers another significant phase of SPC implementation, which is the ‘implementation phase’. Managers and practitioners can benefit from a step‐by‐step cookbook approach on the SPC implementation provided in this book.

This book is divided into 10 chapters. Part 1 covers the philosophy and fundamentals of quality control in the food industry. Chapter 1: Introduction to the food quality management, the role of SPC in quality management, the importance of SPC in the food industry. Chapter 2 briefs the readers on the food industry chain. Chapter 3 introduces the readers the nomenclature of quality and the interlink of quality and food safety. Chapter 4 introduces the application of SPC and its role in the food industry. Chapter 5 covers the basic tools of SPC and how these tools work in the food manufacturing context. Part 2 covers the stages involve in implementing SPC in the food businesses. Chapter 6 illustrates the importance of team formation for implementing and sustaining an SPC initiative in the organisational setting, the roles and responsibilities of team members will be clearly addressed. Chapter 7 elucidates the readiness factors and a self‐assessment tool for the implementation of SPC in the food industry. Chapter 8 presents the critical element in implementing SPC such as critical success factors, challenges, benefits and process performance measurement. Chapter 9 provides a systematic and disciplined set of guidelines showing how to get started with an SPC initiative as well as how to deploy it companywide. Chapter 10 presents case studies of SPC application in the food industry on both the quality and safety aspect. This book may serve as a cookbook for the managers in the food industry to assess their readiness to adopt SPC in the company and initiating the SPC application in their respective companies.

Statistical Process Control for the Food Industry

A Guide for Practitioners and Managers

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Preface