DESIGN AND IMPLEMENTATION OF A COMPUTERISED QUALITY CONTROL SYSTEM IN STOCK PRODUCT (A CASE STUDY OF ANAMMCO NIG. LTD EMENE ENUGU )
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DESIGN AND
IMPLEMENTATION OF A COMPUTERISED QUALITY CONTROL SYSTEM IN STOCK PRODUCT
(A CASE STUDY OF
ANAMMCO NIG. LTD EMENE ENUGU )
ABSTRACT
The purpose of the study is to
computerize quality control system in production (A case study of Anammco Nig.
Ltd Enugu) and to develop a computer packages whereby the technique observed
from the manual method can be improved on.
It is a known feet that the manual
method of quality control in production has been associated with lots of
inaccuracy in quality control and this has lead to early break down of parts
when in service.
The software when developed will
facility and enhanced the mode and methods of quality control in spare parts
production of Anamco.
TABLE OF CONTENTS
CHAPTER
ONE
1.0
Introduction
1.1
Background information on Anammco
1.2
Justification of the project
1.3
Purpose of the study
1.4
Scope of study
1.5
Aims and objectives
CHAPTER
TWO
2.1
Literature review
CHAPTER
THREE
3.1
Description and analysis of the existing system
3.2
Fact finding methods
3.3
Organisation structure
3.4
Objectives of the existing system
3.5
Justification for the new system
CHAPTER
FOUR
4.1
Design of the new system
4.2
Output specification and design
4.3
Input specification and design
4.4
File design
4.5
Procedure chart
4.6
System flowchart
4.7
System requirement
CHAPTER
FIVE
5.1
Implementation
5.2
Program design
5.3
Program flowchart
5.4
Pseudocodes
5.5
Test run
CHAPTER
SIX
6.1
Documentation
CHAPTER
SEVEN
7.1
Recommendation
References
CHAPTER ONE
INTRODUCTION
A quality control system in production
management is a qualitative technique with strong financial implications having
direct relationships with production, marketing, purchasing and financial
politics.
Also, it is a system used in the
management of stocks held by any organisation as it concern addition to,
storage and removals from the trading stock with appropriates record keeping.
ANAMMCO LTD, Enugu as an assembly plant
maintains a large amount of stock vehicles spare parts which are imported from
any of her vendors, Vce:- MBAG. Mercedes Benz AG Germany, MBBRAS.
Mercedes – Benz Brazil or MBE – Mercedes. Benz Espama for the production
line or sales to distributors or authorized agents dealers.
The stock are held for various among
which are:-
(a)
To ensure unit sufficient goods are available to meet anticipated demand.
(b)
To provide a better between production processes.
This is, applicable to work in project
stocks which effectively decouple operation.
(c)
To meet possible shortage in future
(d)
To absorb seasonal fluctuation in usage or demand.
(e)
To enable production process to flow smoothly and efficiently.
(f)
As a necessary part of the production process.
All these are logical yet, stocks
accumulate due to the Less promise worthy reasons which are:-
(a)
Obsolete items are retained in stock
(b)
Poor or non-existing inventory control resulting in over targe orders,
replacement orders being out of phase with production etc.
(c)
Inadequate or non-existing stock records
(d)
Marketing departments.
Whether as a deliberate policy or not, sticks,
represents an investment by the organization. Thus, as with any other
investment, the cost of holding stock most be related to the benefit to benefit
to be gains. To do this effectively the cost must be identified and this
can be done in the three categories:-
(a)
Cost of obtaining stock
(b)
Stock out costs.
All these spare parts which may how
similar menu by description varies greatly among themselves depending on the
type or model of vehicle using them. Thus, the management and operation
of stories function and the control of stock on only be performed in on
efficient manner when there is an appropriate means of up turning and storing
information and a facility for the analysis and use of this information.
In the light of the above, ANAMMCO Ltd
Enugu maintains a visible record system returned to as KARDEX, a manual form of
inventory control system.
As a prerequisite in any quality
control system, ANAMMCO Ltd maintains a peculiar but unique coding system such
that all the numerous spare parts are each uniquely coded and identified for
accurate and specific information on them.
The operation of the KARDX was often
prove to redundancy or duplication of items whenever there is instilling; it
requires a lot of paper work with their possible variations or discrepancies
during documentation; it involves, so many people thereby investing a lot of
man hours; increased cost of procure storage of non-moving or obsolete items
leads to customer dissatisfaction due to time wasting and unavailability of
information. Thus, the efficiency of the system is greatly dependent on
human factor and as such accuracy.
So, it is an attempt to rectify and
modify the above inadquaciets that we have decided to develop and implement on
integrated computerized stock control system so as to maximize the operation
efficiency, ensure customer satisfaction based on quick.
Services, minimize the non-hour
requirement involved, reduce the running costs, guarantee accuracy and at the
same time generate reports that assist management in her decision making as it
concerns planning, organizing and controlling.
1.2
BACKGROUND OF THE STUDY (MB-ANAMMCO LTD) ENUGU.
After the recommendation of the fourth
(4th) National Development plan in 1975 to increase the number of
automobile plants in Nigeria in order to address the problem of transportation,
a Mercedes Benz Plant was chosen. Other reasons for establishing the
plant being to:
(a)
Diversification and Rapid industrialization of the Nigeria Economy
(b)
Modernization of industrial workers
(c)
Indigenous man-power training
(d)
Technology transfer and
(e)
Manufacture and Assembly of Mercedes Benz commenced vehicles and trucks in
Nigeria.
MB-ANAMMCO LTD, as it is famious by
known and called means Mercedes-Benz Anambra motor manufacturing company
limited Enugu. This company is strategically located along IBB A port
link Road Enugu Industrial Layout Enugu.
The plant is a joint owned by the
Government and people of the federal Republic of Nigeria and Daimier-Benz AG of
Germany. Their share equity is in the ratio 60% to Nigeria and 40% to
Daimier, Benz AG Germany.
Therefore Mercedes-Benz ANAMMCO LTD,
Enugu was Licensed to manufacture Mercedes Benz commercial vehicles in Nigeria.
The company was incorporated in Nigeria
as a private limited liability company on the 17th the day of
January 1977. On the 12th day of May 1978, it’s foundation
store was laid by colonel John Atom Kpera the then military Governor of ANAMBRA
States (Now, ENUGU and ANAMBRA STATE). Later on the 8th day of
June 1980, Mercedes-Benz ANAMMCO LTD, was commissioned by Alhaji Shehu Usman
Aliyu Shagard, the them president Head of state and commander in client of the
Nigeria Armed forces; ANAMMCO LTD, commenced production officially on January
1981. Ever since them her services network is speed throughout
Nigeria. The company uses foreign and local contents in the manufacture
of the Mercedes Benz commercial vehicles.
1.3
STATEMENT OF THE PROBLEM
It is a common knowledge that decision
makers in any organization require information to perform the great functions
of planning, producing and controlling. Therefore, it is necessary to
discover and adequate means of making the information available to every on
concerned. This is because, for decisions to be made correctly, the
information must be consistent, accurate, timely and reliable.
Thus, this work is aimed at developing
and implementing an integrated computerized quality control system in
production of an automobile firm (case study ANAMMCO LTD ENUGU NIGERIA).
1.4
PROBLEMS OF THE STUDY
1.
The encountered when carrying out this study are that obtaining necessary
information from staff of Anammco was not easy because some of their
information are regarded as company secret.
2.
Production of spare parts on manual approaches has been very difficult.
3.
There may be inadequate or non-existent stock records.
4.
Obsolete items are retained in stock, which makes it difficult for one to know
the overall items in stock.
5.
Finally, problem of fund, the economy is bed, so to get money now is difficult.
1.5
THE PURPOSE OF THE STUDY
The objectives of this work inadequate
the following:
1.
To ensure appropriate stock quality control coding with a view to minimizing
stock redundancy or duplication inherent in the manual system of quality
control system in production.
2.
To ensure operational efficiency thereby maximizing the customer services level
with in level with I menaced accuracy.
3.
To generate consistent, accurate timely and reliable reports that assist the
management in her decisions as it affects the stock and the organization for
effective pleasing, organizing and controlling.
1.6
SCOPE OF THE STUDY
Even though that Mercedes-Benz Anammco
Ltd, is the case study with her divers inventories, this work is only continued
to the administration of spare parts (finished good type of inventory) as it
concerns ordering, Receipts, soles and Reports.
Therefore it excludes the W-I-P
work-in- progress) and other forms of quality stock control. It also
excludes other automobiles firms.
1.7
AIMS AND OBJECTIVES
The aims and objective of this work is
that when, the system becomes operational it will.
1.
Permit on-line-time data storage and information retrieval
2.
Save the production time per section and as such ensure customer
satisfaction
3.
Increase the operational efficiency and accuracy
4.
Reduce stock redundancy or inherent in the manual system.
5.
Generate consistent, Accurate, timely, and effective stock control towards
profit making and
6.
Reduce the operational costs
1.8
DEFINITION OF TERMS
1.
Lead or procurement time: This is the period of time expressed in days,
week’s months etc. between ordering and replenishment ie leathern goods are
available for use.
2.
Demand: This is the amount or quantity required by sales, production etc.
per week, month or year etc.
3.
Economic ordering quantity (EOQ): This is the calculates ordering
quantity which minimize the balance of costs between inventory holding cost and
recorder costs.
4.
Physical stock: This is the number of items physically in stock at a
given time.
5.
Minimum or safety stock: This is a stock allowance to cover errors in re
casting the lead time or demand during the lead-time.
6.
Maximum stock level: This is the stock level selected as maximum
desirable which is used as an indicator to show that stock have risen too high.
7.
Recorder level: This is the level of stock of which further replenishment
order should be proud. It dependent upon the lead-time and the demand
during the lead-time.
8.
Recorder quantity: This is the quantity of the replenishment order. In
some types of inventory control system it is the EOQ.
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