Q overview
Why is Quality so important at PG?
Delight consumer & customer, sales go up, increase revenue, OTSR improvement
Who is responsible for entering quality alert
Everyone
All transporting of food and/or drink within the plant, either from outside to an eating area or between eating areas, will be in closed containers in designated walk ways only. T/F
True
Definition of Loss?
a loss is everything that does not add value to the consumer.
Quality is free when built into the process, Quality is a loss when inspected
True or False
True
• QUALITY IS EVERYONE’S RESPONSIBILITY
• QUALITY CAN AND WILL BE MANAGED
• A ZERO LOSS QUALITY CULTURE IS ACHIEVABLE
• EVERY QUALITY FAILURE AND DEFECT COULD HAVE AND SHOULD HAVE BEEN PREVENTED
• ALL PRODUCTS CAN BE MADE AT THE QUALITY EXPECTED BY THE CUSTOMER AND THE CONSUMER
what is the primary benefit of entering QA?
reduce the likelihood of them turning into a much more serious opportunity (i.e., repeated QI, SQI)
DOUBLE JEOPARDY !!!!
GMP stands for ___________ and its purpose is to safeguard against product _______ at any point in the manufacturing process
Good Manufacturing Practices, contamination
DOUBLE JEOPARDY !!!
The Quality risk enables us to be alerted of the systems or special situations. The tool “_____” is intended to raise QUALITY awareness and be proactive to develop the solid countermeasure
Quality Trigger List
The top causes of Quality Incidents for the site is Mis-Labeling /Mis-Packing, Changeovers and not following Standards.
True or False
True
Explain the color code principles in Quality triangle
Blue
Green
Yellow
Red
Blue: execution of I quality program, solid foundation
Green: Good quality behaviors to comply with QA system
Yellow: quality near miss or wake up call, QA and QI
Red: scrapping products, SQI, product recall
DOUBLE JEOPARDY !!!
Name few examples of QA
Raw material defects found during RM verification
During change over, the records are incomplete
Find insects or pest control issue
Missed quality checks
Quality checks performed incorrectly
Equipment calibration not performed
GMP issue
Line clearance not done properly
DOUBLE JEOPARDY !!!
Share your specific action plans to comply with GMP
Wash your hands, no drinking other than water on floor, good practice of QA entry, close door, windows, and other openings to the outside environment, all food and drink garbage is to be disposed of in designated areas, good house keeping, following the basic QA system
DOUBLE JEOPARDY!!!
Name 3 QRLs in PG system
Consumer complaints
Finished Product Hold for Quality Defects
Material/Supplier Quality Issues
Lost Sales due to Quality Defects
Quality Incidents
Rework and Reprocessing
Scrap - Broke
DOUBLE JEOPARDY !!!
The 4 classifications of Quality Incidents are _____, Inappropriate Release, Inadvertent Shipment and Damage/Degradation after shipment.
Contamination
DOUBLE JEOPARDY !!!
Tell me examples of good quality behaviors
QA check per test method at right frequency
Line clearance
change over execution- follow the standard
process order(PO)/BOM verification
Definition of QI? examples of QI ( 4 Category)
Quality Incident is defined as a quality system failure that risks compromising the quality and integrity of P&G’s Products, or P&G’s reputation.
contamination, inappropriate release, inadvertent shipment, damage/degradation after shipment
Procter and Gamble’s manufacturing guidelines make sure that everything we make is
Pure, ____, Effective
Safe
_______ are the proven settings to run our equipment to optimize the process and its end products. It is part of RTT
Centerlines
DOUBLE JEOPARDY !!!
Our Foundational Beliefs
• QUALITY IS EVERYONE’S ________
• QUALITY CAN AND WILL BE_______
• A ZERO LOSS QUALITY CULTURE IS ______
• EVERY QUALITY FAILURE AND DEFECT COULD HAVE AND SHOULD HAVE BEEN _______
• ALL PRODUCTS CAN BE MADE AT THE QUALITY EXPECTED BY THE C_____ and C______
Responsibility
Managed
Achievable
Prevented
Customer and consumer
All Quality Incidents can be prevented by following? explain examples of following
Building operation capability, system execution, learning from quality near miss
Perf (preventive maintenance, 1hr quality check, CL/CPE, qualified operator performing check, rigor on hold process)
Contamination (OHBD, line clearance, RLS, CIL)
What GMP written procedures do we use?
•Changeover CBA’s
•Line Clearance / Line Supply
•Housekeeping Procedures
Product Hold CBA
DOUBLE JEOPARDY !!!
Specific action plans you have to reduce T&W cost?
Centerline(RTT), RLS, CIL, PM. equipment at base condition, compliant with QA system (line clearance, raw material verification, hourly QA checks)
DOUBLE JEOPARDY !
what are the benefits of good process control ?
deliver consistent quality result by minimizing quality risks and/or variations
deliver stable and predictable process- better PR, better quality
Facilitate problem solving