DESIGN AND IMPLEMENTATION OF AN EXPERT SYSTEM APPLICATION IN QUALITY CONTROL AND MONITORING

1.1 Introduction

An expert system is a software system that attempts to reproduce the performance of one or more human experts, most commonly in a specific problem domain, and is a traditional application and/or subfield of artificial intelligence. Expert system play an indomitable role in various disciplines and the assistance it renders to man cannot be overemphasized. The development of experts system that capture skills and expertise of a human expert has not been easy and date back to the Second World War, where experts of computer tried relentlessly to develop technique or systems that would allow act more intelligently than human. A computer is digital electronic machine capable of accepting input data, processing and producing an output. The computer is an important tool that plays a good role in the analysis of any subject that is to be programmed. A quality control and monitoring system in production management is a qualitative technique with strong financial implications having direct relationships with production, marketing and purchasing.

As a prelude to other parts of this study, this chapter will discuss the background upon which this study was initiated, the statement of problems that led to this study, the Aim and Objectives of the study. Others are Significance of the study, Scope of work, Limitation of the study and Definition of technical terms.

1.2 Background of Study

Since the advent of computer, effort has been to fashion the tool that could able to solve most of the intriguing problems that comfort man. In the early days, researchers in the field of Artificial intelligence (AI) were using mere illustrations that shown ideas. As time passed by different experimental systems were developed many of which hypothesized answers to truly handle problems that defy superficial speculations.

Presently, systems exist which can handle most of the problems considered impossible by early researchers. Such intriguing task as playing chess with computer can now be programmed with relative ease. Other expert systems have also been developed in areas such as medicine, finance and education. However, one problem area yet to be properly addressed and for which this project is concerned is in manufacturing as regards to quality control and monitoring. Thus, the application of expert system in quality control and monitoring in a manufacturing industry is the focus of this research work.

Technology has had a tremendous impact on the society from the changes instituted during the industrial revolution to today's information age, new technology has been adopted to solve a problem or speed a process. In business, technology includes the skills, procedures, equipment and systems used to perform the work. As manufacturing companies strive to improve, they seek the most appropriate technology to accomplish the work.

Thus the increasing persuasive domination of computer system which is gradually phasing off the manual process will unequivocally bring the world and its problems to the grass-root solution. Recently there have been advance technology like the expert system and it is interesting to know that the expert system can be used to solve problems in every field and discipline, and can assist in all stages of the problem-solving process.

Hence, the expert system in quality control and monitoring has made it possible to effectively combine the software and hardware in quality control department to measure the quality of products. The quality control and monitoring knowledge base and the software requires quality controllers to input the results from various tests carried out .the data is analyzed to identify opportunities for improvements. This advancement in technology has helped quality controllers and manufactures to locate problems in manufacturing stages, increase the quality of the products and dominate problems in the productions process. The pay off of this system can be a reduction in cost a boost in production and sales.

1.3 Statement of Problem

Investigation revealed the loopholes in quality control and monitoring of raw materials, unfinished products are quite obvious. Hence, the problems often encountered in this system include:

1. Delay in report dispatch to different production sections
2. The hampering of production efficiency in the absence of quality control manger and supervisor.
3. Inconsistent and delayed decision making as a result of human deficiency.
4. Difficulty in accessing results and reports from log books and files.
5. High cost and unreliability in paper work.

More so, if there is a very high demand for quality products, is it imperative for an efficient and effective system of quality control and monitoring to be incorporated? This impact in production can be consolidated through this expert system.

1.4 Aim and Objectives of the Study

The aim of the study is to develop and implement an Expert System Application in Quality Control and Monitoring using PZ Company, Aba as a case study. In achieving this aim, the following specific objectives were laid out as follows to design and develop an application software that will:

1. Create easy communication channels for all the managers as the quality control reports are made to reach them on time;
2. Provide quality control personnel with vital tools for fast decision making;
3. Reduce stock redundancy or inherent in the manual system of quality control and monitoring system in production;
4. Trace error in overall production stages and reduce paper work; and
5. Duplicate the knowledge of a domain (quality control manger) in order to ascertain efficiency and effectiveness of the system production.

1.5 Significance of Study

The significance of this research will assure a hitch free and successful completion of this research, very important significance has been made:

1. The application of expert system in quality control and monitoring will immensely boost production.
2. Real-time explanation and interrogation of the system may not be required.
3. The system development process is in chronological sequence.
4. The feasibility study has been completed and final assignment being issued meaning that the system has been certified worthy and cost effective.

This study will be of immense benefit to other researchers who intend to know more on this study and can also be used by non-researchers to build more on their research work. This study contributes to knowledge and could serve as a guide for other study.

1.6 Scope of Study

The scope of this research is focused on the Design and Implementation of an Expert System Application in Quality Control and Monitoring using PZ Company, Aba as a case study.

This research is concerned with a soap manufacturing firm, it would be applied to other manufacturing companies but the scope is on detergent as it covers the following:

• Quality specification
• Problems in production process
• Decision — making and possible solutions.

1.7 Limitations of the Study

During the course of this study, many things militated against its completion, some of which are:

1. Time Constraint: The time frame given to accomplish this project was very short due to school academic calendar and it was carried out under pressure which made the researcher not to implement some necessary features.
2. Establishment Policies: Establishment policies posed a serious limitation as most staffs are not ready to release information needed for this project work. There were lots of information needed from the staffs of this institution to enhance the study which took them time to release or they did not release at all for security purposes, hence the scope was reduced.
3. Research material: availability of research material is a major setback to the scope of the study.
4. Frequent power failure: This made the researcher append more money on fuel to ensure sustainable power.
5. Financial Constraint: Insufficient fund tends to impede the efficiency of the researcher in sourcing for the relevant materials, literature or information and in the process of data collection (internet).

1.8 Definition of Terms

It is ideal to identify and define some terms, which may look awkward and confusing to the reader for easy understand of the work.

Expert System: This consists of hardware and software that stores knowledge and make inferences, similar to a human expert.

Domain Expert: The individual or group who has the expertise or knowledge one is trying to capture in the expert system.

Knowledge Base: The component of an expert system that store all relevant information, data, rules cases and relationship used by the expert system.

Inference Engine: This is a component of expert system that seeks information and relationships from the knowledge base on and provides answers and suggestions.

User Interfaces: The user interface is the surface portion of a program with which a user interacts. It displays system through which a program “talks” to its and also receives the users' response.