Development and implementation of computerized quality control system for commercial beverage production

Quality means continuous reduction of the product variation and bringing it closest to the target, i.e. it is a process of constantly striving for excellence. Formally it was foolish to continue to attempt to control the quality after the product had been manufactured, later it was realized that prevention of defects rather than detection was more cost effective and more efficient. Getting quality control means getting the quality tight, first time, every time and on the line and it is better to use the latest tools like computer to efficiently control quality. For the perfection of quality beverage, the study was launched at an internationally recognized beverage plant. The first and the foremost requirement were to provide the beverage in crystal clear hygienic bottles. Caustic concentration of 3% at 70 degree C was given in bottles. Laboratory microbiological analysis showed a range of 19 to 43 total viable counts that were less than the USL of 50 colonies per container. This indicated that the process was capable and acceptable. From a continuous beverage filling line systematic sampling after every 15 minutes in 12-hour duration collected 48 samples. Parameters of Brix, pH and Acidity were considered. Capability index was greater than 1.33 and machine capability index was greater than 1 in both Brix and pH meaning thereby that the process was very well capable of meeting the desired specifications. Whereas, it was 1.08 and 0.728 in case of acidity which may be due to variation in mango varieties used in pulp making. Quality index in fill height was 85.42% capability index was 0.4744, which was less than 1.33 showing thereby that the process was erratic and not capable. This indicated that the filling machine needs proper maintenance and troubleshooting. Control limits for each of the parameters have been provided that may serve as a guideline for the future work in quality control operations in beverages. If a single value falls outside the control limits, action Rule 1 comes in stop the process and locate the fault. Adjust the process if 8 consecutive observations fall between target and the control limits (action Rule 3). Closely monitor the process if the pattern is cycling or trending (Action Rule 4 and 5). Keeping in view a wide range of influence and participation of computer in daily activities of our life, Computerized Quality Control System for Commercial Beverage Production' has been developed. The system was developed in systematic way having suitable benefits over existing system like data entry, data updating, data editing and data computing. This system helps the users in making decision effecting present as well future events by keeping in view the structures of the system. There are three basic conversion methods, which are employed to implement new system. They are: (i) Direct implementation (ii) Parallel implementation (iii) Pilot implementation. Out of these three, parallel conversion is more suitable for the said system because the system data is very critical for the quality control and the system will gradually be modified for the direct implementation.