THE IMPACT OF PLANT MAINTENANCE ON QUALITY PRODUCTIVITY IN NIGERIAN BREWERIES, KADUNA

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THE IMPACT OF PLANT MAINTENANCE ON QUALITY PRODUCTIVITY IN NIGERIAN BREWERIES, KADUNA

ABSTRACT

This study examines the impact of plant and equipment maintenance on quality Productivity in Nigeria Breweries. The research questions that guided the study were: How does plant and equipment maintenance affect the standard of production in Nigeria Breweries Kaduna? How does plant and equipment maintenance affect efficiency and speed of production in Nigeria Breweries? What is the effect of plant and equipment maintenance on quality production in Nigeria Breweries Kaduna, and what are the problems militating against plant and equipment maintenance in Nigeria Breweries Kaduna? A survey method was used for this study. The population consists of all the staff in the Production department of Nigeria Breweries Kaduna. Out of the population 120 people, so was selected using the simple random sampling technique? A questionnaire developed by the researcher based on the five liker scale format must used as the sole instrument of data collection. Mean scores was used to analyze the data obtained from the field. Research result indicates that plants and equipment maintenance effect efficiency and productions speed by safe guiding plant and equipments against breakdown which could cause error in production and consequently affect quality. This enhances the quality and as well as productivity in production due to uninterrupted production. In spite of this plant and equipment maintenance is confronted with constraint arising from the used of substandard spare part due to improper inspection of such part by procurement officers constant power out age and regular use of generator which affect the health of plant and equipment.

TABLE OF CONTENTS

Title Page – – – – – – – – – – i

Declaration – – – – – – – – – ii

Approval Page – – – – – – – – – iii

Dedication – – – – – – – – – – iv

Acknowledgement – – – – – – – – v

Abstract – – – – – – – – – – vi

Table of Contents – – – – – – – – vii

CHAPTER ONE

1.1 Background of the study- – – – – – – 1

1.2 Statement of the problem- – – – – – – 3

1.3 Objectives of the study- – – – – – – 3

1.4 Significance of the study- – – – – – – 4

1.5 Research Questions- – – – – – – – 5

1.6 Scope of the study- – – – – – – – 5

1.7 Limitation of the study – – – – – – 6

CHAPTER TWO – LITERATURE REVIEW

2.1 Introduction – – – – – – – 8

2.2 The concept of maintenance of plant and equipment in factory 10

2.3 The concept of quality production – – – – – 11

2.4 Fundamental requirement of plant and equipment maintenance 13

2.5 The technique used in plant maintenance – – – 16

2.6 The relationship between quality and production – – 20

2.7 The impact of plant and equipment maintenance on quality production – – – – – – – – – 22

2.8 The constraint of plant and equipment maintenance – 23

2.9 Summary of findings – – – – – – –

CHAPTER THREE: METHODOLOGY

3.1 Introduction – – – – – – – 26

3.2 Research design – – – – – – – – 26

3.3 Area of the study – – – – – – – 26

3.4 Population of the study – – – – – – 27

3.5 Sampling size and sampling technique – – – – 27

3.6 Instrument of data collection – – – – – 27

3.7 Validation of instrument – – – – – – 28

3.8 Reliability of instrument – – – – – – 29

3.9 Method of data collection – – – – – – 29

3.10 Method of data analysis – – – – – – 30

CHAPTER FOUR

4.1 Introduction – – – – – – – – 31

4.2 Characteristic of respondents – – – – – 31

4.3 Data Analysis- – – – – – – – – 34

4.4 Summary of findings – – – – – – – 42

4.5 Discussion of Findings – – – – – – 43

CHAPTER FIVE

SUMMARY CONCLUTION AND RECOMMENDATIONS

5.1 Introduction – – – – – – – – 46

5.2 Summary – – – – – – – – – 46

5.3 Conclusion – – – – – – – – – 48

5.4 Recommendation – – – – – – – 48

5.5 Suggestions for Further Study – – – – – 49

Bibliography – – – – – – – – 51

CHAPTER ONE

INTRODUCTION

1.1 Background of the Study

Plant maintenance is the comprehensive management of machineries and fool in a factory. This could take the form of preventing of breakdown through extensive lubrication of machine, detection of fault carryout minor repairs and replacement of obsolete spare parts at interval to enhance efficient production and consequently enhance quality and productivity (Edward, 2007).

Maintenance of plant and equipment use in production lead to the production of high quality product, increase speed of production and enhance the overall plant performance. The maximum utilization of maintenance resources enhance cost reduction or controls a substantial part of the total operating budget in most plants as well as reduction in total labour cost through increase speed of production and efficiency. The impact of maintenance of plant cannot be overemphasized sequel to it importance in enhancing the quality of production.

In recent years, a firm has given more attention to the quality of the product or services they produce. The act of monitoring and improving the quality of product and services produce is commonly referred to as total quality management. Which gives emphasis on production efficiency the ability to produce products at a low cost? This will consequently give a firm competitive advantage.

It is against this that most firms embark on plant maintenance in order manufacture high quality product efficiently to reduce cost and make high sales.

However, most firms use the wrong technique of maintenance sequel to cost reduction but incur such cost when breakdown interacts with production leading great loss.

It is against this background that the researcher sees the subject matter, the impact of plant and equipment maintenance on quality production as an issue worthy of being investigated. Putting a searchlight on Nigeria breweries Kaduna plant.

1.2 Statement of the Problems

The inability of an organization to effectively maintain its plant and equipment result in poor product quality, reduction in production speed, or affect other factors that limit overall plant performance. This subsequently leads to production failure in the market and could lead the collapse of an organization. It is against this, that researcher sees the subject matter, the impact of plant and equipment on quality production as an empirical problem worthy of investigation. Hence the researcher intends to study plant and equipment maintenance and their impact on quality production in Nigeria breweries P.L.C with search light on Kaduna plant and in particular their maintenance Department.

1.3 Objectives of the Study

The broad objective of the study is to examine the impact of maintenance of plant and equipment on quality production in Nigeria breweries Kaduna. The specific objective is to:

Examine how maintenance of plant and equipment affect standard of production in Nigeria Breweries Kaduna.
Find out how maintenance of plant and equipment affect efficiency and speed of production in Nigeria Breweries Kaduna.
Identify the effect of plant and equipment maintenance on quality production in Nigeria Breweries Kaduna.
Identify the problems militating against effective plant and equipment maintenance in Nigeria Breweries Kaduna.
Proper possible solutions to the identified problems.

1.4 Significance of the Study

This study will contribute to policy formulation as regard plant and equipment in organization. As such Nigeria Breweries Kaduna will find the result of the research useful especially as they utilize the finding to enhance the maintenance of their plant and equipment.

The study will also contribute to existing body of knowledge on the subject matter.

It is worthy to know that the research will be a good reference material to incoming students who may wish to use the research as reference material or a springboard for further research.

1.5 Research Questions

1. How does plant equipment maintenance affect the standard of production in Nigeria Breweries Kaduna?

2. How does plant and equipment maintenance affect efficiency and speed of production in Nigeria Breweries Kaduna?

3. What is the effect of plant and equipment on quality production in Nigeria Breweries Kaduna?

4. What are the problems militating against plant and equipment maintenance in Nigeria Breweries Kaduna?

1.6 Scope of the Study

This study covers the empirical examination of the impact of maintenance on quality control to this end; empirical data will be collected from Nigeria breweries Kaduna. The study will equally cover an evaluation of how plant and equipment maintenance affect standard of production as well as well as its effect on efficiency and speed of production. The study equally identifies the problems militating against Nigeria breweries plc Kaduna. Data and information will be for a period of 5 years that is 2006-2010.

1.7 Definition of Terms

Plant: A factory where production process falls place (ponal, 2003).

Maintenance: The act of keeping plant machineries and equipment in good condition by checking or repairing it regularly (Paula, 2006).

Quality production: The degree to which production meet a require specification or standard (obodoeeh, 2006).

Quality control: This is a process determining whether the quality of a product or service meets the desire quality level (Lawal, 2003).

TQM: Acronym for total quality management (Eghe, 2006).

TPM: Acronym for total productive maintenance (okoh, 2003).

Productivity: The rate at which a firm produces good and the amount produced compare to how much time, labour and capital used in producing them (Donald, 2003).

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