DESIGN AND IMPLEMENTATION OF A WEB BASED QUALITY CONTROL SYSTEM

1.1 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 organization as it concern addition to, storage and removals from the trading stock with appropriates record keeping. 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.

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, Limitations of the Study and Definition of technical terms.

1.2 Background of Study

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 and Benz Espama for the production line or sales to distributors or authorized agents dealers.

The stocks are held for various among which are to ensure unit sufficient goods are available to meet anticipated demand, and provide a better between production processes. This is, applicable to work in project stocks which effectively decouple operation, meet possible shortage in future, absorb seasonal fluctuation in usage or demand, enable production process to flow smoothly and efficiently and as a necessary part of the production process.

All these are logical yet, stocks accumulate due to the Less promise worthy reasons which are obsolete items are retained in stock, poor or non-existing inventory control resulting in over target orders, replacement orders being out of phase with production etc., inadequate or non-existing stock records and 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: Cost of obtaining stock, and 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 inadequacies that we have decided to develop and implement on integrated Web Based 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.

Brief Background of MBAnammco 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: Diversification and Rapid industrialization of the Nigeria Economy, modernization of industrial workers, Indigenous man-power training, technology transfer and 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 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, 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 Problem

Investigation revealed the challenges of the existing system which is stated as follows:

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.

1.4 Aim and Objectives of the Study

The aim of the study is to develop and implement a web based quality control system in production of an automobile firm using ANAMMCO LTD Enugu Nigeria 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. 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 of quality control system in production.
5. Generate consistent, Accurate, timely, and effective stock control towards profit making and reduce the operational costs

1.5 Significance of Study

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 study focuses on the Design and Implementation of a Web Based Quality Control System using ANAMMCO LTD Enugu Nigeria as a case 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 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

Lead or procurement time: This is the period of time expressed in days, week’s months etc. between ordering and replenishment i.e leathern goods are available for use.

Demand: This is the amount or quantity required by sales, production etc. per week, month or year etc.

Economic ordering quantity (EOQ): This is the calculates ordering quantity which minimize the balance of costs between inventory holding cost and recorder costs.

Physical stock: This is the number of items physically in stock at a given time.

Minimum or safety stock: This is a stock allowance to cover errors in re casting the lead time or demand during the lead-time.