Cost of poor quality
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Transcript of Cost of poor quality
Project Name Cost Of Quality
Innovation Team
TEAM MEMBERSAbdullah HassanReagan MamdouhAhmed ZakiHany AllamaAhmed AllamaMohammed EldamlegySayed AbdurhmanMostafa Bastawy
What is the problem ?Increase Internal failure cost and external failure cost for
2013Where is the problem occur ?The internal failure cost occur in 3 factories but external failure
cost occur just in Sadat factoryWho gets the problem with him?Quality and production departmentWhen The problem occur ?Cost of poor quality is always occur in all factories but we can
decrease the percentage and take it target every year Which trend ?The problem repeated every year but with deferent percentageWhat is the size of the problem?The Cost o quality for 2013 about 2 million
Problem Core : Increase costs of poor
quality Research shows that
cost of poor quality can range from 15 to
40 percent of business costs
Cost of quality
Internal cost
Scrap
Rework
Waste
External cost
Customer
Complain
CustomerReturn
Appraisal cost
Test & analysis
cost
External
Internal
calibration
Prevention cost
Training
External
audit
&certification
Cost Of Quality Definitions Internal Failure Cost : Costs associated with defects found before the customer receive
the productRework - Scrap – Wastes
External Failure cost :Costs associated with defects found after the customer receive
the product Customer compliant – Returned Goods – Equipment test &
calibration
Appraisal cost : inspection / test of purshaesd material
Checking in-process and final product – callebration – measuring and testing equipment
Preventive cost : training – External audit and certification
1- Define
Problem statement : Increase total cost of quality in
2013 specially in internal cost and external cost it’s equal about 2 million
Project objective : Decrease 50% of total cost of quality
in the end of this year
Revenue expected of the project : Up to 900,000 EGP
2-Measure
Internal Cost
1- Rework
54SadatNatrun -
50,000.00
100,000.00
150,000.00
200,000.00
250,000.00 212,246.00
20,245.00 37,098.00
cost
إرتجاع التريللة – إعادة تصنيع براميل – إعادة تصنيع جرادل – إعادة تصنيع الزيت والخل
لم يتم حساب إعادة تصنيع بالسادات لعدم وجود بيانات موثقه بها
2 -Waste
54SadatNatrun -
20,000.00
40,000.00
60,000.00
80,000.00
100,000.00
120,000.00
140,000.00
160,000.00
147,375.00
39,628.00
94,000.00
cost المعامل العجيزي في والتنفيخ الفواصل ونطرون – 54نسبة - والبذر الفرزات حساب يتم لم وخام وتغليف تعبئة مواد هالك
كهالك
3- Scrap
54SadatNatrun -
50,000.00
100,000.00
150,000.00
200,000.00
250,000.00
300,000.00
-
299,331.00
-
Costإعدامات مواد تعبئة وتغليف – إعدامات مواد تعبئة وتغليف وصلصة – إعدامات خام زيتون وفول منقوع
External Cost
Customer number Customer Name Total Cost
22438 ايزى مؤسسة 25225 امبورت فود 25208 جورمنت ويسترن 25239 BGI-INTERNATIONAL ,LLC 79,53425249 nazeer abdel sady 170,33823027 Golden Sea 25208 جورمنت ويسترن 3,48123027 Golden Sea 198,397
Dollar Tree 91,000موارد 35,000
Total 574,650
1- Customer complaint cost
54SadatNatrun -
100,000.00
200,000.00
300,000.00
400,000.00
500,000.00
600,000.00
-
574,650.00
-
Cost
1- Customer complaint cost
2-Return Cost
54SadatNatrun -
20,000.00
40,000.00
60,000.00
80,000.00
100,000.00
120,000.00
112,340.0
0
10,302.00 -
Cost
Appraisal Cost
External analysis cost
&Calibration cost
Laboratories costs
50231.5 49,424
99655.5 Total Appraisal cost
Prevention Cost
Get Certificate/Ex.Audit/Renew Cost Column1 Company
LE العملة
GMP & HACCP training لتدريب - شهادة
بالمنافذ العاملين 16,650.00 DEB شهادة عقد لمصنع BRCتجديد54الكيلو 12,000.00 SGS
شهادة على - BRCمراجعةالسادات 3,000.00 SGS
شهادة على الحصول قيمةمن حتى 1/10/2013الكوشر
السادات - 30/9/2014 30,030.00 $
4,200.00ORTHODOX
UNIONجودة شهادة واصدار المراجعة
المصدرة فوود وادي لشحنةتري دوالر شركة امريكا الى 2,788.50 $390.00 Bureau Veritas
شهادة على للحصولاالورجانيك 17,384.00
€2,050.00 CERES Egypt
شهادات على - BRCالمراجعةISO22000 - ISO 9001 -
OHSAS18001 36,000.00 SGS
Total cost 117852
1-External audit and certification Cost
الشركة اسمالمدربة التدريب نوع الموقع القيمة
ZYMAG CCI Consulting cci 54ك 3,981.25
ZYMAG CCI Consulting cci النطرون- السادات 27,868.76Smith Management Consulting HACCP Round2 54ك 11,100.00Smith Management Consulting HACCP Round3 54ك 11,100.00Smith Management Consulting
GOOD MANUFACTURING PRACTICES - R3 54ك 5,550.00
ZYMAG CCI Consulting cci 54ك 5,958.45
ZYMAG CCI Consulting cci السادات 5,958.31
ZYMAG CCI Consulting cci النطرون- السادات 5,958.31Smith Management Consulting االغذية سالمة على تدريب 54ك 5,550.00
Smith Management Consulting
Warehouse Management-المخازن ادارة تدريب 54ك 3,700.00
Smith Management Consulting
Warehouse Management-المخازن ادارة تدريب النطرون- السادات 5,550.00
Smith Management Consulting
Warehouse Management-المخازن ادارة تدريب السادات 7,400.00
ZYMAG CCI Consulting cci 54ك 6,066.80
ZYMAG CCI Consulting cci السادات 6,066.64
ZYMAG CCI Consulting cci النطرون- السادات 6,066.64
القابضة من محملSTATISTICAL PROCESS
CONTROL 54ك 1,665.00
القابضة من محملSTATISTICAL PROCESS
CONTROL السادات 3,330.00Smith Management Consulting الصيانة لقسم تدريب السادات 16,650.00Smith Management Consulting HACCP1 السادات 11,100.00
2- Training cost
2 -Training Cost
54SadatNatrun0
10000
20000
30000
40000
50000
60000
70000
80000
90000
54670
89354
45446
Series1
Total Quality Cost
التكلفة الداخلية
التكلفة الخارجية
التكلفة الوقائية
تكلفة الفحص
0100000200000300000400000500000600000700000800000900000
849923
697292
307322
99655.5
Series1
80%
3-Analysis
