Statistical quality control for the food industry 3rd ed

Contents Preface to the Third Edition ............................................. ix Preface to the Second Edition ......................................... xi Preface to the First Edition .............................................. xiii Acknowledgments ........................................................... xv 1. Introduction ............................................................. 1 Variability .............................................................................. 2 Quality Control Programs .................................................... 3 Problems with Tool Selection .............................................. 8 Quality Control Tools ........................................................... 8 2. Food Quality System .............................................. 15 The Formalized Quality System .......................................... 15 Quality System Guidelines .................................................. 16 Malcolm Baldridge National Quality Award ......................... 27 Total Quality Management .................................................. 28 Team Quality Systems ........................................................ 30 Computer Network Quality Systems ................................... 30 Summary .............................................................................. 30 3. Control Charts ......................................................... 49 The Importance of Charting ................................................. 49 vi Contents This page has been reformatted by Knovel to provide easier navigation. Procedure for Constructing X-Bar and R Charts ................. 53 Procedures for Constructing Attribute Charts ..................... 57 4. Fundamentals .......................................................... 71 Analysis of Data ................................................................... 71 Probability ............................................................................ 76 Binomial Distribution ............................................................ 78 The Normal Distribution ....................................................... 82 Distribution of Sample Means ............................................. 84 Normal Approximation to the Binomial Distribution ............ 90 t-Distribution ......................................................................... 92 Confidence Limits for the Population Mean ........................ 93 Statistical Hypotheses – Testing Hypotheses ..................... 95 Distribution of the Difference between Means .................... 100 Paired Observations ............................................................ 103 F-Distribution ........................................................................ 104 Analysis of Variance ............................................................ 105 Two Criteria of Classification ............................................... 111 5. Sampling .................................................................. 115 Sampling Plans .................................................................... 115 Why Sample? ...................................................................... 116 Samples from Different Distributions ................................... 117 Sample Size ......................................................................... 118 How to Take Samples ......................................................... 123 Types of Samples ................................................................ 128 Sampling Plans .................................................................... 131 Types of Inspection .............................................................. 131 Classes of Defects ............................................................... 132 Sampling Risks .................................................................... 135 Selection of Population to be Sampled ............................... 136 Contents vii This page has been reformatted by Knovel to provide easier navigation. Selection of Sample Frequency and Location .................... 137 Hazard Analysis Critical Control Point ................................. 138 Attribute Sampling Plans ..................................................... 149 6. Test Methods ........................................................... 151 General Analysis .................................................................. 153 Special Instrumentation ....................................................... 153 Microbiology ......................................................................... 153 Sensory ................................................................................ 153 7. Product Specifications ........................................... 157 8. Process Capability .................................................. 163 Capability Index ................................................................... 170 Benchmarking ...................................................................... 173 9. Process Control ...................................................... 177 Chart Patterns ...................................................................... 179 Using the Control Chart as a Quality Management Tool ........................................................................... 184 10. Sensory Testing ...................................................... 187 The Senses .......................................................................... 188 Sensory Testing Methods .................................................... 189 Types of Panels ................................................................... 194 Selection and Training ......................................................... 197 11. Net Content Control ................................................ 201 Evaluation of Net Content Performance .............................. 205 Interpreting Net Content Control ......................................... 205 Procedures for Setting Fill Targets ...................................... 213 viii Contents This page has been reformatted by Knovel to provide easier navigation. 12. Design of Experiments ........................................... 219 Introduction .......................................................................... 219 Elimination of Extraneous Variables ................................... 222 Handling many Factors Simultaneously .............................. 226 Full Factorial Designs .......................................................... 227 Fractional Factorial Designs ................................................ 232 Response Surface Designs ................................................. 236 Mixture Designs ................................................................... 239 Experimental Design Analysis by Control Chart ................. 248 13. Vendor Quality Assurance ..................................... 253 Vendor-Vendee Relations ................................................... 255 Specifications for Raw Materials, Ingredients, Supplies ..... 257 Quality Assurance of Purchased Goods ............................. 259 Selecting and Nurturing a Supplier ...................................... 263 Packaging Supplier Quality Assurance ............................... 266 Supplier Certification Programs ........................................... 271 14. Implementing a Quality Control Program ............. 275 Management Commitment .................................................. 275 Getting Started ..................................................................... 276 An In-House Program .......................................................... 277 Team Quality Systems ........................................................ 279 Stepwise Procedures for Team Problem Solving ............... 282 Programs without Management Support ............................ 284 Training Quality Control Technicians .................................. 287 Summary .............................................................................. 288 15. The Computer and Process Control ...................... 289 Computer Integrated Management ..................................... 289 Artificial Intelligence and Expert Systems ........................... 291 Contents ix This page has been reformatted by Knovel to provide easier navigation. Computer-Controlled Processing ........................................ 294 Summary .............................................................................. 307 16. Six-Sigma ................................................................. 309 Summary .............................................................................. 313 Appendix ........................................................................ 315 References ..................................................................... 335 Index ............................................................................... 339