This document outlines a conceptual framework for a total quality management plan for producing high quality yam flour. It discusses key quality management concepts like customer-defined quality, cost of quality statements, and knowledge required for financial and production planning. It then provides details on the proposed production process, quality assurance and control measures, necessary equipment, and plant layout for instant yam flour manufacturing. The goal is to establish a quality management system to consistently deliver a high quality product that meets customer requirements.

1. CONCEPTUAL FRAMEWORK OF TOTAL QUALITY
MANAGEMENT PLAN FOR HIGH QUALITY YAM
FLOUR
BY
EMEKA, NNAEMEZIE
172488
DEPARTMENT OF FOOD TECHNOLOGY
FACULTY OF TECHNOLOGY
UNIVERSITY OF IBADAN
COURSE CODE: TFT 708
COURSE TITLE: QUALITY CONTROL AND PLANT
SANITTION
LECTURER-IN-CHARGE: Dr. ARUEYA, GIBSON

2. MARCH, 2013.
TABLE OF CONTENT
Title page
Table of content……………………………………………………………………II-V
Abstract…………………………………………………………………………….01
CHAPTER ONE
1.0 INTRODUCTION………………………………………………………...02
1.1 TOTAL QUALITY MANAGEMENT………………………………02
1.2 Customer-defined Quality………………………………………………...02
1.2.1 Performance to specifications…………………………………………….03
1.2.2 Fitness for use……………………………………………………………...03
1.2.3 Value for price……………………………………………………………..03
1.2.4 Support services……………………………………………………………03
1.2.5 Psychological criteria………………………………………………………03
1.3 Cost of Quality Statements……………………………………04
1.3.1 Prevention………………………………………………………………….04
1.3.2 Appraisal costs……………………………………………………………..04
1.3.3 Internal failure……………………………………………………………..04
1.3.4 External failure costs………………………………………………………04
1.4 KNOWLEDGE REQUIRED FOR THE FINANCIAL PLAN………………...05
1.4.1 THE FINANCIAL PLAN………………………………………………………...05-06
CHAPTER TWO
2.0 KNOWLEDGE REQUIRED FOR THE PRODUCTION
PLAN OF YAM FLOUR [INSTANT YAM FLOUR] USING TOTAL QUALITY
MANAGEMENT CONCEPT……………………………………………………...07
2.1 MANAGEMENT POLICY STATEMENT……………………………….07
2.1.1 OUR VISION……………………………………………………………………….07
2.1.2 MISSION STATEMENT…………………………………………………………..07
2.1.3 OUR CORE VALUES……………………………………………………………....07
2.1.4 QUALITY POLICY………………………………………………………………...08
2.1.5 COMPANY ORGANOGRAM……………………………………………………..08
2.2 MANAGEMENT RESPOSIBILITY………………………………………………09
CHAPTER THREE
3.0 PLANT DESIGN AND EQUIPMENT PLANNING……………………….10
3.1 FACTOR CONSIDERED DURING DESIGN AND
II

3. EQUIPMET PLANNING………………………………………………….....10
3.1.1 Technical factors………………………………………………………………10
3.1.2 Economic factors……………………………………………………………....10
3.1.3 Human reactions……………………………………………………………….10
3.2 COMPANY’S TARGET FOCUS AND ACHIVEMENT METHODS…….10
3.2.1 Focus on Costumer ……………………………………………………………10
3.2.2 Continous Inprovement………………………………………………………..11
3.2.4 Benchmarking System…………………………………………………………11
3.2.5 Employee Empowerment……………………………………………………...11
3.2.6 Team Approach………………………………………………………………..12
3.2.7 Use of Quality Tools……………………………………………………………12
3.2.7.1 Cause-and-Effect Diagrams…………………………………………………...12
3.2.7.2 Flowcharts……………………………………………………………………...12
3.2.7.3 Checklists……………………………………………………………………….13
3.2.7.4 Control Charts…………………………………………………………………13
3.2.7.5 Scatter Diagrams………………………………………………………………13
3.2.7.6 Pareto Analysis………………………………………………………………...13
3.2.7.7 Histograms……………………………………………………………………..14
3.2.8 QUALITY FUNCTION DEPLOYMENT…………………………………..14
3.2.8.1 Customer Requirements……………………………………………………..14
3.2.8.2 Competitive Evaluation……………………………………………………...15
3.2.8.3 Product Characteristics……………………………………………………..15
3.2.8.4 The Relationship Matrix……………………………………………………15
3.2.8.5 The Trade-off Matrix……………………………………………………….15
3.2.8.6 Setting Targets………………………………………………………………15
III

4. 3.2.9 RELIABILITY ………………………………………………………………15
3.3 PROCESS MANAGEMENT………………………………………………..16
3.4 MANAGING SUPPLIER QUALITY………………………………………16
3.5 COSTUMER AND MARKET FOCUS…………………………………….16
3.6 THE DEMING PRIZE………………………………………………………17
3.7 ISO 9000 STANDARDS……………………………………………………..17
3.8 ISO 14000 STANDARDS……………………………………………………18
CHAPTER FOUR
4.0 MARKETING AND FINANCIAL PLANNING………………………….19
4.1 MARKETING …………………………………………………………..19
4.2 FINANCE………………………………………………………………..19
4.3 OM ACROSS THE ORGANIZATION………………………………..19
4.4 WHY TQM EFFORTS FAIL…………………………………………..20
4.5 SET UP COSTING……………………………………………………...20
4.6 INFORMATION SYSTEM [IS]………………………………………..20-21
CHAPTER FIVE
5.0 OUR PRODUCTION PLAN………………………………………………..22
5.1.1 RAW MATERIALS…………………………………………………….22
5.1.2 THE PROCESS…………………………………………………………23-24
5.1.3 QUALITY ASSURANCE AND CONTROL STATEMENT………...25
5.1.3.1 Quality…………………………………………………………………..25
5.1.3.2 Quality Control/Quality Assurance……………………………………25
5.1.3.3 Quality Control Analyses……………………………………………...26
5.1.3.4 Technical Testing………………………………………………………26
5.1.3.5 Shelf life Testing………………………………………………………...27
5.1.3.6 Sensory Evaluation…………………………………………………….27
5.2 PROCESING/MANUFACTURING AND EQUIPTMENTS………….28
IV

5. 5.2.1 INTRODUCTION………………………………………………………..28
5.2.2 INSTANT POUNDED YAM FLOUR
PRODUCTION TECHNOLOGY………………………………………29
5.2.3 Production Process of Yam Flour [home bases]……………..30
5.2.3.1 Yam Selection And Weighing…………………………………………...30
5.2.3.2 Washing…………………………………………………………………..30
5.2.3.3 Peeling And Slicing………………………………………………………30
5.2.3.4 Parboiling…………………………………………………………………..30
5.2.3.5 Drying………………………………………………………………………30
5.2.3.6 Milling………………………………………………………………………30
5.2.3.7 Packaging…………………………………………………………………...30
5.2.4 Machinery and Equipment…………………………………………..32
5.2.5 Space Requirement…………………………………………………...32
5.2.6 Our Proposed Instant Yam Flour…………………………………………..33
5.2.7 Uniqueness of Our Yam Flour………………………………………………33
5.2.8 Uses Of Instant Poundo Yam Flour ………………………………………..33
5.2.7 Our Proposed Plant Layout………………………………………………….34-35
CHAPTER SIX
6.0 CONCLUSION AND REFERENCES………………………………………….36
6.1 CONCLUSION…………………………………………………………………...36
REFERENCE……………………………………………………………………..37-38
V

6. 5.2.1 INTRODUCTION………………………………………………………..28
5.2.2 INSTANT POUNDED YAM FLOUR
PRODUCTION TECHNOLOGY………………………………………29
5.2.3 Production Process of Yam Flour [home bases]……………..30
5.2.3.1 Yam Selection And Weighing…………………………………………...30
5.2.3.2 Washing…………………………………………………………………..30
5.2.3.3 Peeling And Slicing………………………………………………………30
5.2.3.4 Parboiling…………………………………………………………………..30
5.2.3.5 Drying………………………………………………………………………30
5.2.3.6 Milling………………………………………………………………………30
5.2.3.7 Packaging…………………………………………………………………...30
5.2.4 Machinery and Equipment…………………………………………..32
5.2.5 Space Requirement…………………………………………………...32
5.2.6 Our Proposed Instant Yam Flour…………………………………………..33
5.2.7 Uniqueness of Our Yam Flour………………………………………………33
5.2.8 Uses Of Instant Poundo Yam Flour ………………………………………..33
5.2.7 Our Proposed Plant Layout………………………………………………….34-35
CHAPTER SIX
6.0 CONCLUSION AND REFERENCES………………………………………….36
6.1 CONCLUSION…………………………………………………………………...36
REFERENCE……………………………………………………………………..37-38
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