Professional Documents
Culture Documents
PROGRAM: BBA
SECTION: B
FINAL PROJECT
ORYZA RICE
Submitted to:
Mr. Haris Aslam
Submitted by:
Bilal Shaheen
094005027
Usman Shah
094005010
Zain ul Abidin
094005135
Uzair Nawaz
094005031
DATE: 12-01-2013
REMARKS
________________________________________________________________________
________________________________________________________________________
Acknowledgment
Without the support, help and guidance of certain individuals the successful completion of this
project would not have been possible. We take this opportunity to express our special gratitude to
them.
First of all we would like to pay special thanks to our resource person Mr. HarisAslam for
providing us the opportunity to go through such a detailed process and also for providing us the
required support and guidance. His supervision, dedication and prompt feedback really helped us
a lot in preparing a good final report. Then we would like to express our sincere gratitude to Mr.
Ahfaz Khan, GM of Oryza. Without his cooperation, commitment, support and counseling
surely the completion of this project was uncertain.
Last but not the least we would also like to pay special thanks to all staff of the Oryza, for their
kind support and cooperation.
Table of Contents
1
Purpose:......................................................................................................................................... 8
2.2
Objectives: .................................................................................................................................... 8
Methodology: ...................................................................................................................................... 11
4.1
Interview ................................................................................................................................... 11
4.2
Observation............................................................................................................................... 11
4.3
7.2
Paddy Selection:.......................................................................................................................... 14
7.3
Husking: ...................................................................................................................................... 14
7.4
Cleaning: ..................................................................................................................................... 15
7.5
7.6
Grading: ...................................................................................................................................... 15
7.7
Color Sorting:.............................................................................................................................. 15
Leadership:.................................................................................................................................. 16
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.3
8.3.1
Employees Training:-........................................................................................................... 21
8.3.2
8.3.3
Employee participation:-..................................................................................................... 22
8.3.4
8.3.5
8.4
8.4.1
Automation:- ....................................................................................................................... 23
8.4.2
Critical Processes................................................................................................................. 24
8.4.3
8.4.4
8.4.5
8.5
8.5.1
Communication:- ................................................................................................................ 26
8.5.2
Cooperation:- ...................................................................................................................... 26
8.5.3
Coordination:- ..................................................................................................................... 26
8.5.4
Integration:- ........................................................................................................................ 27
8.6
8.6.1
8.6.2
8.6.3
Reduce errors:-.................................................................................................................... 28
8.6.4
8.6.5
8.6.6
Make the process satisfying for the people doing it:- ........................................................ 29
8.7
8.7.1
8.7.2
8.7.3
Performance measurement:-.............................................................................................. 31
8.8
8.8.1
8.8.2
8.8.3
9.1
5S Model: .................................................................................................................................... 33
9.1.1
9.1.2
9.1.3
9.1.4
9.1.5
9.2 ........................................................................................................................................................... 34
10
Findings ........................................................................................................................................... 34
10.1
10.1.1
10.1.2
10.1.3
10.1.4
10.2
10.2.1
10.2.2
10.2.3
10.3
10.3.1
Biotic stresses...................................................................................................................... 37
10.3.2
10.3.3
10.3.4
Rice information.................................................................................................................. 38
10.4
10.4.1
10.4.2
Biotechnology ..................................................................................................................... 39
11
Cause and Effect Diagram for Rice Quality: Problems & Solutions ................................................ 39
12
13
13.1
Repair: ......................................................................................................................................... 42
13.2
Refine: ......................................................................................................................................... 43
5
13.3
Renovate: .................................................................................................................................... 43
13.4
Reinvent: ..................................................................................................................................... 43
14
14.1
14.2
15
Conclusion ....................................................................................................................................... 46
16
References ...................................................................................................................................... 47
1 Executive Summary
The purpose of this project is basically to select an organization and identify how Quality
Management Systems are being implemented in the real world scenario. Secondly the main
objective is to provide us an opportunity to have hands on experience regarding quality issues,
tools and implementation. The organization that we have chosen for this purpose is the Oryza
Rice. Oryza is not an ISO certified company but we saw that it is a very quality conscious
company which follows a lot of quality practices. We can get information from this report
regarding all the quality practices that Oryza has in its company and also all the result of
different quality practices and improvement strategies that Oryza might implement for better
quality.
The main implication of the findings is that with TQM implementation, manufacturing
organizations are more likely to achieve better performance in customer satisfaction, employee
relations, quality and business performance than without TQM. The study also provides an
insight for the managers to understand that medium level companies are more likely to adopt
TQM than smaller ones; hence TQM implementation level varies according to the size of the
firm and amount of resources available. This may infer that due to shortsightedness, the small
companies foresee rewards of TQM implementation earlier than large companies and hence soon
get disappointed and consequently TQM benefits as they take some time to mature; are reaped
by the established firms that never get disappointed soon. We have also discussed a few
recommendations in our report that instead of selecting from different suppliers every time
Oryza gets an order Oryza should try to select one best supplier and then they should try and
build a long-term partnership with their suppliers. This would be very beneficial for Oryza and
its products quality.
The main conclusion of this study is that TQM definitely offers a strong base for dynamic
organizations to manage the total quality culture that can promote their competency and abilities
as well as other strategic priorities to gain competitive advantage.
2.1
Purpose:
This is the class project of Total Quality Management course. The purpose of this project is
basically to select an organization and identify how Quality Management Systems are being
implemented in the real world scenario. Secondly the main objective is to provide us an
opportunity to have hands on experience regarding quality issues, tools and implementation. It is
to identify the implementation of the knowledge, philosophies and theories that we discussed in
the class room and to figure out the basic difference between the study and the real world
scenario. How quality management systems are working in the Pakistani organizations.
We also have to identify the quality principles and relate them with the practical work of the
organization. How well the organization is following all or some of those principals and which
areas require significant improvements. After identifying the principles we have to figure out the
quality tools that the organization is using. What tools are being used by the organization, how
well
they
are
utilizing
them
and
what
benefits
are
they
getting
from
them.
The major part of the project is to identify the quality problems organization is mainly facing.
Identify the root cause and the major causes which are mainly responsible for poor quality.
Provide them the appropriate solution with the help of simple statistical and non statistical
quality tools.
2.2
Objectives:
To recommend long and short term solution with the help of statistical and non
statistical quality tools
Literature Review:
Rice contains more calories per half-cup portion of white rice than brown rice. (USA Rice
Federation, 2004). The rice millers prefer varieties with high milling where as consumers
consider physicochemical characteristics (Merca and Juliano, 1981). The consumers judge the
quality of rice on the basis of size and shape of rice grain. The preference for grain size and
shape can vary from one group of consumer to another group of consumers (Khush et al., 1979).
The classification of rice quality is based on the length of grain i.e. short, medium and long
grain. Arborio rice grains are high in width and Basmati rice grains are high in length (AduKwarteng et al., 2003). The ratio of length to width is an important aspect to determine the shape
of the variety (Normita and Cruz 2002) and grain weight gives the information about the size
and density of the grain. The density of different rice grains effect the cooking quality. So grain
weight should be uniform because it determines the quality of grain (Rice CRC, 2003). The
appearance always appeal to consumers so the size, shape and width should be the top criteria to
determine the quality of rice and breeders are also consistent to develop new varieties for
commercial point of view (Adair et al.,1966). The length to breadth ratio ranging from 2.5 to 3.0
is widely acceptable and the grain length > 6mm is preferred (Kaul, 1970). But the long grain
rice has also acquired the leading position in International market (Normita and Cruz,
2002).Hur et al. (1989) studied about the grain appearance and eating quality of some developed
rice varieties. The grain length of milled rice ranged from 4.53mm to 5.07mm and width from
2.43 to 2.62mm. The length to width ratio ranged from 1.84 to 2.09. The varietal characteristics
such as shape, size and density affect the quality of rice grain as reported by Juliano (1990).
Sagar et al. (1988) described the physical characteristics of aromatic and non-aromatic
commercial rice varieties grown in Pakistan and found the highest values for length (7.3mm)
recorded for Basmati-6129, where as in lowest value of 5.8mm for the same quality traits was
observed in JP-5 rice variety. The moisture content during storage showed changes with the
length of storage and the temperature of storage (Gooding and Davies, 1997). Rice protein is
more nutritious because of its higher lysine content than any other cereal proteins. Chemical
compositions of cereals are characterized by protein content (Lasztity, 1999).The fiber content in
different Pakistani rice varieties varied from 0.20 to 0.35% (Awan, 1996; Tufail, 1997). The
fiber content in brown rice after milling was found to be 1.90.6% (Sotelo et al., 1990). The
dominant factors which describes the consumer liking in many countries of the world are grain
9
whiteness, shape, amylose content, alkali spreading value (gelatinization temperature), aroma
and other cooking properties (Rice Quality Workshop, 2003). There are so many environmental
factors like temperature which may affect the grain during their development (Cruz et al., 1989).
Higher volume expansion of cooked rice is mostly believed as good quality rice by the medium
or lower class peoples who do not think about that the expansion is breadth wise or lengthwise.
In another view, Urban people have preference of those rice varieties which expand lengthwise
as compared to breadth wise (Choudhury, 1979). Tufail (1997) conducted studies on cooking
and eating quality of some varieties of rice. Among cooking quality, the volume expansion ratio
of Basmati-385, Basmati-370, IRRI-6 and KS-282 were found to be 3.20, 3.64, 3.08 and 2.35
respectively. The water absorption ranged from 2.29 to 2.96% among the tested rice varieties.
Several insects pests attack rice crop in Pakistan (inayatullah et al. 1986 Salim et al 2001.)
Rice is a cereal consumed by great part of the human population throughout the word in many
kinds of products, such as white rice, parboiled rice, meal rice and rice bran (FOOD 2009).
Rough rice (paddy) is composed of a white starchy rice kernel tightly covered by a coating of
bran, enclosed in a tough siliceous hull (Lakkakula et al., 2004. PARBOILING is a process
developed for improving rice quality. It consists of soaking, steaming and drying of the rough
rice. (F. E. Cherati, R. Babatabar and F. Nikzad 2012).The increase of nutrients and functional
compounds detected in parboiled rice justifies the expansion of this products market along the
past years. In spite of these beneficial effects, some changes due to the processing are
undesirable, such as the development of unpleasant taste, texture, and color in the opinion of
traditional white rice consumers (HORIGANE et al., 2006; LAMBERTS et al., 2008). Nearly
3000 years ago, parboiling method was settled in Indian subcontinent, in a very simple form for
the first time, and has improved gradually until now that; it is used in most of Southeast Asia
countries. (F. E. Cherati, R. Babatabar and F. Nikzad 2012).When husk is removed; bran layer
comes in direct contact with air, resulting in the development of off-flavor in brown rice due to
its endogenous lipase. Moreover, the appearance of brown rice is not appealing due to its color
(Saunders, 1990).Hence further processing of rice is required to remove the bran from brown
rice to produce white rice (Hu et al., 1996). It is consumed after appropriate polishing to give a
desired degree of whiteness (Juliano, 1985). Rice bran constitutes about 10% of the weight of
rough rice (Hu et al., 1996). It is comprised of pericarp, aleurone, sub-aleurone, seed coat,
nucellus 9along with the germ and a small portion of endosperm (Salunkhe et al., 1992;
10
Hargrove, 1994). The percentage and composition of rice bran vary according to the rice variety,
pretreatment before milling, type of milling system and the degree of milling (Saunders,
1990).Rice bran is light in color, sweet in taste, moderately oily and has a slightly toasted nutty
flavor (Hu et al., 1996).Texture varies from a fine, powder-like consistency to a flake, depending
on the stabilization process (Barber and Benedito de Barber, 1980). Rice bran proteins are of
high nutritional value (Kennedy and Burlingame, 2003) and hypoallergenic (Tsuji et al.,
2001).Rice bran can be used as a stool bulking agent (Tomlin and Read, 1988) and for the
enrichment of some foods (Burton, 2000).Rice bran contains 15-22% oil by weight (Orthoefer,
1996; Patel and Walker, 2004).
Methodology:
4.1
Interview
For the purpose of our project, we conducted a thorough in depth interview of GM of Oryza, Mr.
Ahfaz Khan. Complete findings of the interview are provided in the relevant sections of this report.
4.2
Observation
Other than in depth interview we used our own observation, we visited the factory twice and
observed the entire refining process our self.
4.3
Sampling Data
For the purpose of our project we also conducted informal interviews of six employees of Oryza
world.
11
Oryza is a leader in the industry when it comes to rice production initiatives; it is an established
global & multidimensional company which solely focuses on its clients success and their key
business requirements. Oryza is a company that is known for its export quality rice. Oryza
exports rice to a lot of different countries around the globe including mainly Saudi Arabia and
Iran. The companys presence is strategically located in multiple hemispheres of the globe
making it truly accessible to our global audience. Oryza focuses a lot on quality and for that they
have bought a lot of expensive technology to provide its clients with the best quality rice .Oryza
is not doing any business locally instead they just export rice to other countries. They export
different classification of rice which are Super Kernel Basmati Rice,1121 ( Steamed & Parboiled
),PK - 386 long grain Basmati Rice, Basmati 385 Rice, Irri - 9 long grain rice and Irri - 6 ( KS 282 ) long grain rice. Oryza uses a complete range of rice processing machines right from
cleaning to hulling & polishing, optical sorters, control systems and accessories to meet the
needs of the rice milling industry. Oryza Rice Mills are equipped with the latest technologies and
has very hard working and committed employees. The company has partnered up with Buhler
Group which is one of the best industry standards for over 150 years. This partnership insures
Oryza to attain maximum These factors help Oryza Rice Mills to maximize yield of head rice,
minimize product breakage and deliver consistent product quality. Oryzas global leadership in
rice milling stems from intensive research and development; vast world-wide experience in the
setting up of rice mills as well as synergy with many other technologies in grain processing. The
founders of the company are extremely committed to their business and they have done an
extensive research on rice to bring their company to this position that it is in at the current time.
At the current time Pakistan is facing energy crisis and Oryza mills are characterized by efficient
power consumption hence making it a Green industry standard so this shows that they are also
playing a part in making this world a better place to live in. Oryza is not yet an ISO registered
company but it follows all the quality practices that are required for it to meet all the ISO
standards. Oryza Rice Mills export rice so its competitors are the local rice producers of the
importing country or other exporters to that country. Quality of Oryza Rice can be judged from
the fact that countries that have bought rice from Oryza once have bought it from them on
regular basis.
12
Rice Processing:
Paddy
Cleaning
Raw Paddy
Cleaned
Paddy
Yes
Paddy Husker
Filtering
Brown Rice
Yes
Whitening
No
No
Reject
ion/
Waste
No
No
White Rice
No
Rice
Without
Paddy
Paddy
Separating
Cleaned
White Rice
Yes
Stone
Filtering/ De
stoning
Yes
Cleaned
White Rice
Pre Cleaning
No
Yes
No
Rice
Without
Immature
Grains
Thickness
Grading
Reject
ion/
Waste
No
Yes
Water
Polishing
Yes
No
No
Polished
Rice
Yes
Rice Sifting
Sifted Rice
Yes
Length
Grading
Graded
Rice
Yes
Reject
ion/
Waste
Packed Rice
Packing
Machine
No
Final
Processed
Rice
Color Sorting
Yes
Processing Summary:
Oryza has a firm believe in the latest technology & new agricultural methods in order to ensure
the finest & uniform quality of the end product. The company owns a modern basmati rice
processing plant. The plant possesses several new technological advancements made in the field
13
of rice milling and processing the plant comprises state-of the art equipment. The plant has the
latest and technologically developed machines for the processing of rice from whitening to color
sorting.. The plant has a milling capacity of 50,000kg / hour. This capacity varies subject to the
variety of rice to process. The rice is fumigated before putting it in these milling processes which
can be divided in to following sections:
7.1
7.2 Paddy Selection:
Oryza ensures the production of the finest quality of Basmati paddy to guarantee the best quality
of end product. For the purchase of best quality paddy, the company pays premium price to the
suppliers. Each & every employee at Oryza tries his best to achieve the objectives of high
quality. Experienced selectors assess the quality of Basmati Paddy through sampling, analyzing
and assessing. Before the final purchase, once again the paddy grains are tested through reliable
equipments. Analytical tests are also conducted to determine moisture content, rice yield, broken
percentage, field admixture etc.
7.3 Husking:
The selected Basmati paddy is allowed to slowly reduce its moisture by natural-sun-dryingmethod, to achieve optimum moisture content for husking. Paddy is spread over large fields
during the day and left for drying in the sun. This gradual drying helps to avoid thermal cracks in
the rice Grain, which would result in broken grains at later stages, Paddy is brought in to Sheller
where brown Rice is produced after cleaning, de-husking and grading. In Brown rice, only the
outer husk is removed, leaving the germ and bran layer, and retaining most of the nutritional
value.
Bran is rich in minerals and vitamins. This minimal processing therefore produces rice that is
healthier to eat. This brown rice is then used to produce white rice.
14
7.4 Cleaning:
First stage consists of several steps for cleaning of rice to ensure hygienic end-product absolutely
free from all impurities like straw, mud balls, threads, stones, paddy etc.
It is further ensured that once cleaned rice is not contaminated during processing. The perfect &
high performance pre cleaners, paddy separators are used to obtain great accuracy in feeding
purified rice to the later processes. This process is applicable to both the white rice and brown
rice. Apart from the cleaning process itself, it is ensured that none of such impurities are added
into rice during subsequent processes.
7.6 Grading:
Rice is graded at different stages on the basis of thickness and length to remove malnourished,
shriveled and broken grains from healthy pure and full grains.
Advanced technology from Buhler in Drum Grader, Plan sifter and Indented Cylinders employed
at three different stages achieves optimum and uniform grain length.
15
In Color sorting, complicated computer controlled process technology is used for high resolution
optical inspection of each and every kernel. It removes the high concentration of predominantly
chalky and discolored kernels from healthy ones.
Oryza has new Z-series color sorter, which feature state of the art cameras that detect subtlest
colors and defects even smaller than 0.3mm; it has novel sorting algorithms that identify spot or
color defects with high efficiency and increased yield. Accuracy of this can be judged from the
fact that after this process there can be maximum only 4 discolored kernels in every 45000 good
kernels. The equipment has a product tracking and automatic calibration mechanism that ensures
consistent sorting efficiency and performance. Basmati rice sold as brown rice or cargo rice is
also properly fumigated, cleaned and graded before packing.
8
8.1
Quality Practices:
Leadership:
General Manager of Oryza emphasized a lot on Leadership and role of a Leader in implementing
rules and regulations. He said he is strongly committed to his work and his company and he
motivates others by his own example. He performs all the critical tasks himself and whenever
any new initiative is implemented, he is the first one to apply on himself then he asks others to
do accordingly. He himself goes to various cities during procurement then himself goes to
laboratories for conducting lab tests. He and the other top management shows serious concerns
about employees and provide them some incentives for implementing quality practices and doing
work up to the mark. One of the example he coded is that they provide salaries to their
employees even in the off season including all the relevant facilities such as; food, shelter and
bonuses. Quality is their main concern, top is mainly held responsible regarding all the quality
16
issues so he and his top management makes sure that no compromise is made on quality. As they
are involved in export of rice so they are allowed leverage up to certain mark, beyond this level
their rice would not be accepted in the Middle East so they have to make sure that rice meets the
specified standards. In this regard they have invested some huge funds to completely automate
their refining process, reducing human work to eliminate or at least reduce the chance of mistake
significantly. They follow certain standards during their hiring process, only those candidates are
hired who completely fulfill those standards, so they make sure right from the beginning that
negligible hiring is avoided to improve quality performance. Top management is open to new
ideas all the time, regardless of which areas and departments they come from. He said we always
encourage employees working on the floor to come up with their ideas and suggestions in order
to improve our performance. This way it gives employees a sort of freedom and sense of
ownership,
which
ultimately
enhance
their
level
of
trust
on
top
management.
Though the company does not contain any specific quality manuals but pay a significant
importance and apply some major quality practices.
8.1.1 Quality Manuals:As its mentioned earlier that Oryza is mainly concerned with the exporting of their product so
they have a deep concern with their quality maintenance and they are doing so as per the global
standards regarding rice production and size of rice by getting the best raw form of rice. They get
their cross breed rice for the ideal quality and to get the desirable traits of different varieties.
Oryza is not certified with the ISO but their quality standards are up to mark and has deep
concern in it. The objective of this rice to contribute to improve the capacity to produce quality
rice which meets the global standards. The manual is a quick reference material for the rice
refining companies in this sector who are already involved in refining processes or are planning
to produce certified quality of rice. Seed quality is one of the major concern of getting the final
product of good quality .Normally, cultural operations for conventional crop production are
similar to those for seed production but additional operations, such as isolation, rouging to ensure
the quality of seeds make a great difference. Such seed quality control operations are conducted
to make the seed true to type and to sustain the genetic potential of the intended variety.
17
8.1.2 Quality Goals:Meeting the quality goals is every companys main aim and to achieve that aim company uses
various resources to achieve that goal because considering quality is the major concern of final
consumers especially in eatable industries in the same way Oryza is also using most of their
resources in assurement of quality as their business requirement. All product variables are preset
at fixed benchmark levels in oryza. They offer the customers info on complete product
specifications which they guarantee to met to their spirit in each of their processed batch. For
more than a decade, their superior and consistent quality performance has been winning the
confidence of business partners across international markets.
Planning is the initial stage of any type of project, without the best plan no proceedings can be
done effectively and the maximum output cannot be achievable. The top management of Oryza
are very much concern with their planning process before any addition to the processes they go
through the planning process, watch out the forecasted outcome through their planning then they
take the final decision so the brainstorming phenomenon is very much considered in their plans.
Things include during research are as follows: Replacement of hexane by a bio renewable solvent.
Extraction of rice bran oil using ethanol.
Effects of the extraction conditions on the yield and extractability of minor compounds.
Oryzanol and tocols behave in different ways during extraction process.
on the quality principles and for maintaining quality, resources are required. These resources
have to be allocated to get maximum results at the end. Oryza's management also uses systematic
processes and different formulae to allocate the funds, so this company's financial area is also
quite appreciable.
8.1.5 Role of Top Management:The top management team of a company controls decision making that affects everyone from
the president down to entry-level employees. Those decisions, along with the way the
management members treat the staff, affect the success of the company. Understanding those
effects helps the management team make changes as necessary to improve the achievement of
the company. Oryza's top management keeps on looking all the processes with deep concern
efficiently at the same time effective as well. They regularly communicate with their staff
members and involve them to some extinct in decision process and try to take their opinions,
hear their problems while performing the processes then brainstorm the problems and try to
make countermeasures in short period of time.
8.2
Customer Focus:
At the center of Oryzas business lies the Customer Satisfaction. GM of Oryza said all the
purpose of our business is to satisfy our internal and external customers. We cannot compete in
the intense industry without the consent of our customers. So we pay great attention to customer
needs and try our level best to fulfill those needs better than our competitors. They have
developed strong mechanisms to make sure that customer receives the right thing. What they do
is before delivering the final output to their client they conduct laboratory tests in their internal
laboratories even after that customer can conduct external tests as well to fully satisfy
themselves. There are certain standards in the industry which every exporter has to fulfill like,
standard length of the rice is 7mm and an error of only 4% is accepted. So he said all the
companies have to follow these terms but we are using some heavy machinery to make sure we
perform better than other players in the industry. They have constant checks on the broken
percentage that out of the total material how much is wasted as broken rice using their inspection
machines then take appropriate measures to reduce that percentage. He said they always
welcome the customer feedback and also open to criticism because customer has the right to
criticize when the product does not meet the standards. So, he said they receive feedback through
19
emails and letters from the customers and immediately respond to their queries. Simultaneously
they make their employees aware that such mistakes should not happen in the future. Regarding
the competitive edge he said we have a sort of natural competitive advantage against our
competitors because high quality Basmati rice is only available in subcontinent so it gives them
an extra edge in the world market, which ultimately improves their name and prestige in the eyes
of the customer. Through constant feedback and marketing channels they come to know the
changing demands of the customers, they immediately take appropriate actions and train their
employees accordingly to make sure that quality is not compromised and customers needs are
accurately fulfilled.
8.2.1
As its discussed earlier Oryza is exporting the rice mainly in Middle East region like Saudia
Arabia, Syria etc so their customers are mostly of abroad not from this region. Its pretty difficult
to understand the psychic of customers of different regions because every region's people have
different mindset, their perceptions are different so the top management of Oryza is carrying out
various researches to understand the mindset of customers and then try to improve the product
according to them.
8.2.2
Customers are most important for every business because the businesses very much rely on
them. Profitability and the declining of businesses are very much dependent on the customers.
This phenomenon plays a central role in maintaining the relation with the customers, like other
departments this company's CRM department
because according to them customers can guide in best way in order to reform their processes,
this department is also very much efficient as they keep on taking the feedback of their
customers and after that do a deep research to solve the queries but as quality practices are
strongly followed by this company, their queries ratio is not that much.
8.2.3
Customer Feedback:-
Customer's feedback helps a lot in product development process and fixing the problems which
keep on occurring. Oryza is using Post-Transaction Surveys method for collecting the feedback.
Post-transaction surveys are conducted immediately after a customer service interaction, and
usually provide feedback directly on that interaction. They are particularly useful for establishing
customer service performance goals or benchmarks, and setting standards around service
20
delivery.
8.2.4
Customer Satisfaction:-
Customer satisfaction, a term frequently used in businesses, its a measure of how products and
services supplied by a company meet or surpass customer expectation. The number of customers
or percentage of total customers, whose reported experience with a firm, its products, or its
services exceeds specified satisfaction goals also come in this phenomenon. After interviewing
the owner of Oryza regarding various areas we also discussed this thing with him in return he
replied that as our processes are mostly systematic and we have far and on check on the product
which we are producing so customers are mostly satisfied with their product and at present they
are pretty strong refined rice producer in market. The popularity of the company in market is
very much related to Customer satisfaction.
8.3
Employee Involvement:
As discussed earlier, Oryza is fully committed to satisfy its internal as well as external
customers. For this they make sure that they retain their employees, by building strong trusting
relationship with them. He said we pay a lot more attention to our employees because ultimately
its employees who have to perform the final task. So right from the beginning we make sure that
right candidate is selected which meets all the specified criteria. Then gradually we train our
employees according to the needs and situation. Importance of quality is told to employees and
the same message is reinforced over a period of time. Whenever a company applies a new
initiative they make sure that their employees are ready to accept it and then train them
accordingly. Company is open to new ideas from employees of all level; however their culture is
quite centralized where all the major decisions are made by the top management and then
cascade them to the lower level employees. Employees are not autonomous in this regard where
they can take their own decisions they have to first ask the top management.
8.3.1
Employees Training:-
Oryza's concern in every field is very much appreciable, their training of employees takes place
after orientation takes place. Its necessary to enhance their skills, capabilities and knowledge of
employees for doing their respective job. According to them it moulds the thinking of employees
and leads to quality performance. It is continuous and they perform this task after regular
intervals to make employees stick to the main agenda, it also increases job satisfaction and
21
8.3.2
Suggestions of employees:-
They take the suggestions from employees but dont take it very much serious because their
processes dont need so much suggestions as most of the work done by machines not
manually, on manual work people usually have more suggestions. The owner of Oryza take
suggestions then think about it if the suggestion has really a strength then he does work on
that suggestion.
8.3.3
Employee participation:-
Oryza provides bonuses to their employees when they achieve the desired goals, other
benefits includes facilitating the employees in health issues, education of their children give
shelter to their employees, they also have small colony.
8.3.5
the performance of their competitors and also communicate this thing with his employees in
order to make them more and more effective, to increase the spirit of competitiveness in
order to get maximum results. According to him if we keep on telling them about the
competitors performance they try to work more better and better.
8.4
Process Approach:
Oryza has deployed some huge machinery to automate its refining process in order to minimize
human work and make the process error free/fail safe. Yet at times the machine neglects some
major errors but due to continuous inspection those errors are identified and eliminated. So he
said we have to make continuous tuning of our machines in order to eliminate the chance of
incurring poor quality. The standards of the product are quite clear, which customer
communicates to them then they communicate these standards to their employees. Finally using
their machines they fulfill those standards. They follow some statistical tools in their laboratories
during inspection and try to reduce the wastage up to maximum level.
For continuous
improvement of their product and processes they conduct annually and at times semi annually
external audits from MGI, which helps them, a lot to improve their processes and eliminate
waste. The long term objectives of the company clearly demonstrate that they are too much
involved in Rand D and promote culture of innovation and continuous improvement.
8.4.1
Automation:-
Automation is the use of machines, control systems and information technologies to optimize
productivity in the production of goods and delivery of services. The correct incentive for
applying automation is to increase productivity. In the scope of industrialization, automation is a
step beyond mechanization. Whereas mechanization provides human operators with machinery
to assist them with the muscular requirements of work, automation greatly decreases the need for
human sensory and mental requirement. According to the processes of Oryza they are related to
mechanization not automation because in automation human requirement is almost negligible but
here human labor is there and they are very much committed in handling the process although
most of the refining work is done by containers by putting the raw rice from one end and refined
rice from other end after passing through several containers.
23
8.4.2
Critical Processes
There are three basic processes, which create ultimately all the value and which are mainly
responsible for all the value creation and success of the Oryzas business. First process is the
process of recruitment, which starts with the search of the appropriate supplier after they receive
customer order. The GM told us that he himself travel to different regions in search of a good
reliable supplier. He collects different samples and bring them to their laboratory, where they test
each sample and on the basis of the results they prepare certain reports. After comparing several
reports they ultimately select one supplier which is most reliable in terms of quality and material
such as which causes them minimal waste.
The next process is the process of refining, as refining is their main business they take raw
material such as paddy and convert it into its most purified form which can be exported to
different countries. All the refining process is automated and finally there is a checking with the
help of sovter machine which is their quality inspection machine. The refining process is
described in detail in the appropriate section congaing process mapping.
The final process is the delivery process; they do packing according to the customer demand and
send it to their agencies which are responsible for exporting. Client if feel necessary he conducts
laboratory tests and once he is satisfied he finally takes the material.
The important thing in this industry is that there is no wastage; everything they produce or refine
can be sold in different markets at different rates.
8.4.3
CRM process:-
Management review is often misunderstood and underutilized, but it is the process that
supports continuous improvement and emphasizes its importance in the drive for success. A
management review produces output that ultimately positively impacts the customer. Oryza's
management uses this process by organizing weekly production planning meetings, schedule
review meetings. The inputs of this process are as follows:
Customer feedback.
After analyzing the inputs they start to work for the betterment in the output review
process, the outputs are as follows:
Resource needs.
Company's management also communicate with the employees after the amendments
which they want to apply on the processes for getting the maximum results.
8.4.5
Value Creation:-
The most successful organizations understand that the purpose of any business is to create value
for customers, employees, and investors, and that the interests of these three groups are
inextricably linked. Therefore, sustainable value cannot be created for one group unless it is
created for all of them. The first focus should be on creating value for the customer, but this
cannot be achieved unless the right employees are selected, developed, and rewarded, and unless
investors receive consistently attractive returns. In today's economy, such value creation is based
typically on product and process innovation and on understanding unique customer needs with
ever-increasing speed and precision Oryza focuses a lot in these areas and they are so much
stick, understand how to make their business successful. Owner keeps an eye on the modern
techniques. He and his management works a lot in order to maintain their value in eyes of the
people related to their business whether they are customers, suppliers, stakeholders etc.
8.5
Oryza uses system approach to align all their processes, tasks, activities performed in all
departments. They consistently get feedback from their clients regarding their changing
demands; also they emphasize a lot on Rand D internal and external. They get information from
external companies based on their research work so they work accordingly on these parameters
to improve rice engineering and introduce new verities in rice. They area where they are lacking
is their complete supply chain, they have many number of suppliers and none of them is their
25
permanent supplier. This increases the cost and increases the verity of raw material. However
they need to emphasize on less number of suppliers and make their internal partners, help them
grow and provide them the required raw material within time. So it will significantly improve
their time cost as well as it will further reduce the wastage which was solely because of the poor
raw material.
8.5.1
Communication:-
The success depends on how clear and powerful the vision is and how well you communicate it.
Businesses need to create the systems and products to back up the promise you make to your
customers. The principal areas where communication is essential include:
Client meetings.
Customer service.
Face-to-face networking.
The communication process of Oryza with respect to people who are related with their business
is quite appreciable, one thing which we pickled out the interview is that they dont very much
communicate with the employees in order to make decisions but their communication regarding
the ease of employees is really good, they keep on listen the queries of their employees and try to
fix as early as possible. As their clients are mainly from Middle East so they take help from the
internet and telephone in order to communicate with them, as procedure applied by them for
vendors as well.
8.5.2
Cooperation:-
Cooperation factor plays an important role in businesses and today its increasing very much, it
has positive impact on achieving the goals more effectively, business activities enable
cooperation include international trade fairs, matchmaking and networking, doing things at right
time can only be done with good cooperation of management and the labor.
8.5.3
Coordination:-
Integration:-
Businesses that connect the design of information and business process with technology.
Business process integration is the platform that will quickly and reliably integrate your data and
technologies, automating and optimizing business processes both within the organization and
across customers, partners etc. Oryza is integrated with the technology their whole refining
process is mechanical consists of several refining containers to get the purest form of rice in ideal
size and shape.
8.6
Continual Improvement:
Oryza is an emerging company in the industry; they emphasize a lot on growth and learning.
They perform the following major tasks to ensure continual improvement;
They use benchmarking to evaluate themselves against their sister companies working in
KSA
8.6.1
As Oryza exports the rice, they have to maintain the quality standards to maintain their position
in eyes of their clients, after visiting the company and interviewing the CEO of company we can
27
say that they are performing their jobs up to the mark by assuring the quality of rice. Their
refining process is completely rely on the machines consist of several containers from starting
point to ending point and every container has link with other one to refine the rice continuously
to ensure the quality of rice so we can say that their machines are strictly following the quality
control phenomenon. The continual improvement in refining the product is carried by these
machines. According to Oryzas management they keep on clean the cylinders after 8 to 10 times
processing by using different cleaning chemicals and leave them to 5 to 6 hours for dryness.
8.6.2
Oryza also perform the laboratory tests by taking the sample from the refined rice to check
whether the rice meets the quality standards or not, in this process the main things which they
consider are size, shape, color, preserved nutrients and many other components. Sometimes these
tests also perform before the refining process if they change one of their suppliers. After tests
they make reports and if they pickle out some problems then they stop the delivery process of the
respective baggages of rice.
8.6.3
Reduce errors:-
After the laboratory tests and reports formulation they try to reduce the errors occur during the
process. Research and development department brainstorm the reasons of the errors i-e how they
occur and what remedy measures they can apply to remove those errors.
8.6.4
Oryza is meeting the customers perception about their product but to exceed their
expectation they are considering the continual improvement phenomenon, Owner said they try
their best to provide highest quality level to their customers. 'Value Creation through Innovation'
strategy is very much considered by their management. According to them their customers have
come to expect reliability in everything we do for them, from product performance through the
order process to our final delivery. They also said that we are committed to continuous
improvement in our performance and we seek smart and simple solutions to fulfill our
customers needs.
28
8.6.5
None of their job is done manually like cutting or using sharp edges instruments, steel pots with
sharp ends for removal of waste etc so their whole process is safe for their employees.
8.6.6
After so much discussion on processes this heading is self explanatory, Oryzas people are pretty
satisfied while performing their duties.
8.7
The company intensively relies on facts and figures regarding decision making. Right from the
beginning they conduct laboratory tests during procurement process; they take samples from
different vendors and assess them in their internal labs. Then they formulate certain reports on
the basis of their results. Then analyze which sample they should take to minimize cost and
reduce the wastage. Similarly during the process they use Soveten Machine for inspection
purpose. They analyze the percentage of broken and other parts which cannot be uses. On the
basis of which they further take preventive actions. Finally during their delivery process again
they use the laboratory test, they take several samples and tests them in the labs, send the reports
to client and fully satisfy their customers.
8.7.1
The research and development refers to a specific group of activities within a business. The
activities that are classified as R&D differ from company to company, but there are two primary
models. In one model, the primary function of an R&D group is to develop new products in the
other model, the primary function of an R&D group is to discover and create new knowledge.
Oryza is currently working on second type of model they keep on studying the new trends and
behavior of market, processes they are performing and try their best to solve the queries of
customers or the deficiency in quality measures of the refined rice.
8.7.2
Oryza is very much focused in quality terms, that is why they have spent huge amount of money
in quality of conformance, which is to prevent and avoid quality problems.
Quality costs are the costs associated with preventing, finding, and correcting defective work.
Many of these costs can be significantly reduced or completely avoided. Oryza has 2 Quality
29
Engineers who work on the reduction of the total cost of quality associated with a product. They
considers following type of costs:Prevention Costs: - Costs of activities that are specifically designed to prevent poor quality.
complaints.
Internal Failure Costs: Failure costs that arise before your company supplies its product to the
customer
Waste doing unnecessary work or holding stocks as a result of errors, poor organization
or
communication
Scrap defective product or material that cannot be repaired, used or sold
Rework or rectification the correction of defective material or errors
Failure analysis activity required to establish the causes of internal product or service
failure
30
8.7.3
Performance measurement:-
Are explicitly defined in terms of owner, unit of measure, collection frequency, data
quality, expected and thresholds
8.8
A mutually beneficial relationship with supplier enhances the ability and competitiveness of both
the organizations. It allows both of the companies to cooperate, learn from each other and enjoy
each other success. This is probably the main area where company is lacking and incurring lot of
cost in terms of inventory, time, money, and at times quality too. What Oryza needs to do they
need to identify some of the key suppliers and establish long term successful relationship with
them. They need to communicate the benefits of collaboration and help them grow and meet the
appropriate standards. Both the supplier and the company should have open and frequent
communication with each other to enhance each other effectiveness. They should jointly
establish and understand what do customers really need and develop future plans accordingly.
Finally company needs to involve them in their success, reward them, praise them and recognize
31
their achievements. Show them that they are part of their success story and build long term
successful relationship with their suppliers.
8.8.1
Oryza does not have a fixed supplier for their business. Before every order they consider a lot of
suppliers and then perform sample test. After the tests they select the best supplier on the basis of
the test result. What Oryza needs to do is that they should keep one fix supplier for each type of
rice they refine. Reducing number of suppliers will help Oryza to be more efficient and effective.
They should select one supplier which they think would always provide them with paddy rice of
their requirement. This would help them lessen inconsistency in the supplying process and a
supplier will always be available to Oryza when they need it. This would also help Oryza
smoothen its business process if they have an organized supply chain with no variability in the
supplying company.
8.8.2
Just reducing the number of suppliers would not help oryza. Oryza should reduce the number of
suppliers and then they should try to build long term relations with them. A good relationship
among supplier and ordering company always helps both the company to prosper. Oryza should
order from their consistent supplier again and again and the suppliers should always try to
provide their consistent customers with the best quality products. This would be beneficial for
both the companies. Building long term relationship with their suppliers would help oryza get the
best quality product out of their suppliers and this would help increase oryzas image amongst its
own customers (importers).Oryza should always try to build good relationship with its suppliers
as it does with its customers.
8.8.3
Suppliers should not be just considered as a normal company providing you with required
materials instead they should be considered as a partner. The focus should always be on mutual
benefits. Oryza should consider its suppliers as partners and it should help them grow. If the
supplier provides Oryza with the best quality product oryza should try to give benefits to supplier
in return. Oryza should give its word to its suppliers that as long as the suppliers provide it with
quality products its position as a long term supplier would be secured. Suppliers on the other
32
hand should always try to reduce cost and improve quality for their Partnering manufacturer.
Quality Tools:
9.1
5S Model:
Oryzas workplace is very organized. Oryza process is automated so all the things required for
the machinery like lubricants and other such things that are required for machinery are kept
closer to the machines. Oryza;s workplace is cleaned at least twice a day as they are very
conscious about their cleanliness. Anything that is not needed is regarded as waste and is
discarded by Oryza workers. Oryza is a very organized company with all its material and
machinery organized very well. They have special arrangements of ventilation and fire
extinguishers are also places at appropriate places.
9.1.3 Sieso - Spic and Span
Oryza has special worker who is just hired for cleaning purposes who cleans the workplace at
least twice a day. The machinery is cleaned twice a day first before the process and then at the
33
end of the day when the operations end. Oryza has bought some very expensive machinery for
inspection and quality purposes. Oryza has bought a quality inspection machine for about Rs. 2
Crore just for ,making inspection process easier. Every worker who works at Oryza helps to keep
the place clean and helps to inspect the processes.
9.1.4 Sieketsu Standardization
Oryza may not be ISO Certified but it follows a lot of total quality management principles as it
keeps its workplace clean all the time. It has expensive technology for the inspection of quality.
It exports its rice to abroad countries where companies want quality products so even if Oryza is
not ISO certified their export quality shows that they follow standard processes. Oryza produces
and refines rice up to standard size and color.
9.1.5 Shitsuke - Self-Discipline
At Oryza workers are trained on how to perform different tasks and what to do in case of any
emergency. Oryza has a fully trained and skillful workforce. Oryzas operations start and end at
a fixed time unless there is an increased demand. The daily operations are carried out in a
disciplined time. Oryza employees are very keen in performing their tasks on time. After the task
is performed it is cross checked and inspected.,
9.2
10 Findings
10.1 Rice Quality Problems & Suggestions
Challenges for rice research and production
The extensive adoption of modern and improved production technology was accelerated through
favorable government policy, expansion of irrigated areas, accessibility to agricultural credit,
intensive extension services and the availability of agro-chemicals, especially fertilizers and
herbicides. The Green Revolution in the 70s and 80s has maintained rice production well ahead
of the population growth in many developing countries. Concern has increased about mining
the soil for plant nutrients, changes in the status of rice pests from minor to major economic
34
importance, a negative impact on the environment and losses of natural resources and
biodiversity (Shastry et al., 1996).
10.1.1 Water problems
Water is the primary factor determining the success of the rice crop. As mentioned earlier, the
Green Revolution has bypassed Sub-Saharan Africa, due to, among other factors, inadequate
irrigation and drainage development. Wetlands have been widely exploited for rice production in
many parts of the world. Many problems relating to this matter are well known: water efficiency,
water availability and water quality.
10.1.2 A. Water efficiency
Water is a critical and the most important factor in rice production. About 55 percent of the areas
cultivated to rice are under irrigation. It is known that in irrigated systems, more than 4-5,000
liters of water are used to produce 1 kg of rice in many areas. Field level assessment suggests a
water efficiency of 50 percent and it may reach 80 percent if drained water could be recycled and
used (CGIAR, 1996a).
10.1.3 B. Water availability
Although water in South-east Asia is usually considered abundant, particularly in the monsoon
rainy season, it is predicted that many Asian countries will suffer from water shortage by 2025,
as the rate of population and urbanization growth is rapidly increasing. According to Feder and
Keck (in Pingali, 1996), the per capita availability of water declined of 40-60 percent over the
period 1955-1990.
10.1.4 C. Water quality
Poor drainage is the major factor connected to water problems including waterlogging, salinity,
toxicity and water pollution. This poor drainage situation is mainly due to inappropriate
development of irrigation schemes and passive reaction of farmers to the schemes operating
organization and their economic conditions. Salinity is caused by saline water intrusion from the
sea in the coastal regions and by the upward movement of salt-water through capillary action in
soils, and salt accumulation on the soil surface due to fast evaporation. About 24 percent of the
irrigated lands have been affected by salinity problems (Postel, 1989).
35
In Asia, during the Green Revolution, the rapid expansion of modern rice varieties has exhausted
favourable lands. By 2025, 53 percent of the people in Asia will live in urban areas compared to
30 the percent in 1990 (communication with Dr. M. Hossain, IRRI, 1995).
10.2.2 B. Change in soil characteristics
Long-term soil pudding and drying lead to the formation of hard pans 5-15 cm below the surface.
The hard pan, which has a bulk soil density with less medium and large pores, reduces the soil
permeability, and the root ability to extract nutrients from subsoil, and increases the formation of
soil toxicities due to long waterlogging condition, thereby hindering the growth of dry land crops
after rice. The widespread of modern rice also encourages the increased utilization of machinery
in rice farming, particularly in rice producing developed countries, which in turn induces soil
compaction. Permanent waterlogging and rice monoculture have commonly caused
microelement deficiencies, especially zinc and sulphur, and toxicities, notably iron. Zinc
deficiency is the most widespread microelement disorder of wetland rice.
10.2.3 C. Mining effects and fertility change
Modern rice varieties exhaust soil fertility more rapidly than traditional varieties. Modern rice
crops under intensive cropping (about 6 t/ha) remove from soils 100 kgN, 50 kgP2O5, 160
kgK2O, 19 kgCa, 20 kgMg, 10 kgS, 0.6 kgFe, 0.19 kgZn, 0,64kgMn, 0.08 kgCu, 0.06 kgB, and
0.004 kgMo per hectare per growing season. Farmers usually compensate these nutritional
losses, especially macro-elements, with chemical fertilizers while neglecting some essential
micro-elements. In the long run, the micro-elements become deficient and cause an imbalance in
soil nutrition, increase demand for phosphorus and potassium and cause nitrogen inefficiency,
affecting the ultimate grain yield. Therefore, the soil nutritional status requires periodic
monitoring, particularly for intensive cropping systems (Tran and Ton That, 1994).
ground water depletion, salinity and alkalinity. Upland rice may increase deforestation and soil
erosion if the fallow period is short.
10.3.1 Biotic stresses
In the humid tropics, the introduction of semi dwarf-stature varieties and the large use of
nitrogen fertilizers and insecticides have changed the status of pests from low to high related to
the economic importance in rice production. It was reported the serious incidence of some
insects such as brown plant hoppers, stem borers, leaf folders, etc., and diseases such as blast,
bacterial blight, and sheath rot. The short growth duration of modern rice varieties has modified
existing cropping patterns and increased farming intensity from single crop to double or triple
crops, thereby inducing a favorable environment for insect pests and pathogen multiplication.
10.3.2 Improvement of rice yield
Productivity of rice does not only vary between one country and another, but also within the
same country based on the different agro-ecological zones and production systems used. The gap
between the farmers yields and those obtained by research stations is still large, even though
some reduction has been reported recently. This Indicates the various limiting factors affecting
rice productivity and production, ranging from land development, production and marketing.
The Rice check concept consists of seven points relating to yield:
1) Develop a good field layout,
2) Use the recommended sowing dates,
3) Obtain good and economic weed control,
4) Establish a seedling population of 150-300 plants/m2,
5) Achieve 500-1100 tillers/m2 at panicle initiation and NIR tissue nitrogen content of 1.2-2.2
percent.
6) Top-dress nitrogen based on tiller counts and NIR tissue analysis using the PI Nitrogen Test,
and
7) Achieve, at an early pollen microspore, a water depth of 20-25 cm, depending on variety.
37
Water control was the main factor necessary to increase the rice production and productivity in
Asia during the Green Revolution, but a decline in investment for the development of irrigation
infrastructures in many developing countries has taken place, thereby affecting the growth of rice
production as well as productivity. In Asia, the irrigation investment has declined by about 60
percent since the 1960s (Pingali, 1996). The amount loaned for irrigation development decreased
from $630 million in 1977-79 to $202 million in 1986-87 (Rosegrant and Pingali, 1993).
Likewise, the growth rate in research expenditure in Asia declined from 7.4 percent in 1961 to
about 4.6 percent during the 1980s (Rosegrant and Pingali, 1993).
10.3.4 Rice information
One of the most effective means to promote the flow of agricultural information over the world
is the modern computerized communication facilities, which allow to gather, disseminate, and
facilitate interaction and exchange of such information among a large number of people and
institutions working in the same field. Obviously, but in Pakistan it still needs to have initiatives,
coordination and leadership in this regard.
In Pakistan there is no special interest for new rice varieties, but recently, hybrid rice is the only
emergent technology available for raising the ceiling of rice yield potential by 15-20 percent.
Hybrid rice, which is grown on 17 million ha and accounts for more than 50 percent of the total
rice area in China, has helped this country to produce additional 300 million tonnes of rice since
1976 and has saved more than 2 million ha for agricultural diversification. This was achieved
due to the fact that the yield of hybrid rice is more than 20 per cent (or 1 to 2 tons/ha) higher than
that of conventional varieties (Yuan and Fu, 1995). This technology is very essential for highly
populated areas, where arable lands are limited.
In Pakistan typically, the variety IRRI 6 & IRRI 9 still has the highest yield potential (10-11
T/ha) against the other improved varieties, recently introduced to farmers. Rice researchers have
been working towards raising the present yield level to 15 t/ha or more by making carbohydrate
partitioning more efficient for increasing grain yield (sink size) or harvest index. The work on
38
super rice initiated in 1988 by IRRI, with studies on improvement of physiological aspects of
modern rice for increasing yield potential.
10.4.2 Biotechnology
In Pakistan considerable progress has been made toward this new frontier upstream rice research
programme, particularly on the genetic engineering of rice for resistance to brown plant hoppers,
yellow stem borers, tungro virus, rice ragged stunt virus, bacterial leaf blight, and sheath blight.
IRRI has worked on Bt toxin gene and coat protein gene for ragged stunt virus, gene for
submergence tolerance, gene for controlling CMS lines and nitrogen-fixing genes for rice plants.
However, techniques and approaches to molecular breeding still need to be perfected to make
them more efficient, accurate and less costly practices. Researchers have made great
contributions towards the development of innovative technologies of rice.
11 Cause and Effect Diagram for Rice Quality: Problems & Solutions
Resources
Water Shortage
Processes
Automation
Land
Constraints
Soil Characteristics
Inflation Raising
costs
Fertility Change
Decline Investments
Hybrid Seed
New
Technologies
New Rice
Types
Bio Technology
Super Rice
Nutrition Value
Quality of Rice
Methane
Production
Ground Water
Depletion
Water Logging
Imbalanced
Soil Nutrition
Farmer Skills
Information
Labor
Expertise
Training
Environment
Rice Yield
People
39
Member
Member
Member
Member
Total
#1
#2
#3
#4
#5
Actionable/ Feasibility
0.3
0.35
0.25
0.2
0.3
1.4
Acceptance by Users
0.2
0.15
0.3
0.2
0.25
1.1
Cost
0.35
0.4
0.3
0.4
0.35
1.8
Technology
0.15
0.1
0.15
0.2
0.1
0.7
40
Processes
Resources
People
Environment
Nutritional Value
Automation
New Technologies
Hybrid seed
New Rice Types
Super Rice
Bio Technology Issues
Water Shortage
Soil Characteristics
Fertility Change
Declined Investments
Land Constraints
Inflation raising Costs
Farmer Skills
Labor Expertise
Rice Yield
Information Lag
Training
Methane Production
Water Logging
Salinity & Alkalinity
Ground Water Depletion
Imbalanced Soil Nutrition
Biotic Pressure
9
7
7
8
8
9
8
8
7
7
8
7
7
9
8
7
9
8
7
7
8
6
8
7
10
8
7
7
8
8
7
10
9
9
8
8
7
8
9
7
8
8
6
7
7
10
9
7
7
6
7
8
7
7
7
7
6
6
8
5
7
7
6
6
7
7
6
6
6
5
6
6
og
y
Te
ch
no
l
by
Co
st
Ac
t io
na
bl
e/
Strategies
Ac
ce
pt
an
ce
Fe
as
ib
ilit
Us
er
s
Prioritization Matrix: Improving Rice Quality Using the Consensus Criteria Method
8
10
9
9
9
8
9
8
8
7
9
8
8
8
9
8
9
9
6
8
8
8
9
8
Now computed the option importance score under each criterion by multiplying the rank by the
criterion weight as shown below. The option with the highest total should be implemented first,
and in our case it is nutritional value.
41
Processes
Resources
People
Environment
Nutritional Value
Automation
New Technologies
Hybrid seed
New Rice Types
Super Rice
Bio Technology Issues
Water Shortage
Soil Characteristics
Fertility Change
Declined Investments
Land Constraints
Inflation raising Costs
Farmer Skills
Labor Expertise
Rice Yield
Information Lag
Training
Methane Production
Water Logging
Salinity & Alkalinity
Ground Water Depletion
Imbalanced Soil Nutrition
Biotic Pressure
12.6
9.8
9.8
11.2
11.2
12.6
11.2
11.2
9.8
9.8
11.2
9.8
9.8
12.6
11.2
9.8
12.6
11.2
9.8
9.8
11.2
8.4
11.2
9.8
11
8.8
7.7
7.7
8.8
8.8
7.7
11
9.9
9.9
8.8
8.8
7.7
8.8
9.9
7.7
8.8
8.8
6.6
7.7
7.7
11
9.9
7.7
12.6
10.8
12.6
14.4
12.6
12.6
12.6
12.6
10.8
10.8
14.4
9
12.6
12.6
10.8
10.8
12.6
12.6
10.8
10.8
10.8
9
10.8
10.8
5.6
7
6.3
6.3
6.3
5.6
6.3
5.6
5.6
4.9
6.3
5.6
5.6
5.6
6.3
5.6
6.3
6.3
4.2
5.6
5.6
5.6
6.3
5.6
To
ta
l
og
y
Te
ch
no
l
Co
st
Ac
t io
na
ble
/
Strategies
Ac
ce
pt
an
ce
by
Us
er
s
Fe
as
ibi
lit
Prioritization Matrix (Weighted Score): Improving Rice Quality Using the Consensus Criteria Method
41.8
36.4
36.4
39.6
38.9
39.6
37.8
40.4
36.1
35.4
40.7
33.2
35.7
39.6
38.2
33.9
40.3
38.9
31.4
33.9
35.3
34
38.2
33.9
13 Improvement Strategies
13.1 Repair:
Oryza Rice Mills main process is refining of rice which is done by automated means. The
machines in the process are for refining and inspecting quality. If the output is not according to
the standards as required by Oryza then the company looks for technical problems in the
machines if the machines are the cause of the problem then an engineer is called and the machine
is fixed. The General Manager of Oryza told us that they have never faced any complaint about
their products from their customers as they export the product after complete inspection.
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13.2 Refine:
Oryzas main process is to refine paddy rice. Oryza has about 8 machines in its process but a few
months back it had less machines but with time Oryza added a few inspection machines for
improving their process as they realized that improving was the need of time. This helped them
with yielding good quality output and lesser rework. The quality is inspected through machines
which completely eliminates human error in inspection.
13.3 Renovate:
Oryza added a machine called Sortex Z4+ at the end of their assembly line which is worth Rs. 2
Crores. Oryza bought this machine for quality inspection. Most of the rice mills in Pakistan do
not have this machine but Oryza bought this machine to yield the best export quality output rice.
It was one of the major improvements in the process of refining paddy rice in Oryza.
13.4 Reinvent:
This is the most demanding strategy in the market at the moment. This strategy focuses on the
thing that the current approach never satisfies customer requirements so a new product or service
or activity is needed. Oryzas operations are just about refining rice. Oryza from the beginning
has been exporting six type of rice. They havent implemented reinvention strategy in their
company but we would suggest then that they should try to refine paddy rice of other types as
well and should not just focus on 6 types of rice. Oryza only exports rice so it would also be
good if they expand their business and try to sell out their rice in the local market as well.
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44
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15 Conclusion
The costs of developing new areas under irrigation and rehabilitation of large-scale irrigation
schemes are high. It is therefore important to improve water use efficiency in rice production
systems through the use of appropriate water control and crop management techniques, with
emphasis on irrigation technologies combined with genetic improvement. At present, the
improvement of water use efficiency has drawn little attention from rice breeders.
An increase in rice production should meet the demand of the worlds current population growth
rate. A less costly means to achieve this aim is to increase rice productivity, wherever possible.
Many rice-producing countries, even in the developed countries, still show a big gap between the
present and potential yield. Hence, efforts should be focused on identifying the causes of this
gap, especially in the production factors and the various features of crop management. An
adequate understanding of physiological aspects of rice productivity and its components will
facilitate the above efforts and provide relevant measures for the improvement of rice production
at the field level. At present, many national rice research programmes are well organized and
developed. Upstream research deserves more attention from funding donors and researchers in
order to increase the rice productivity and production, with more emphasis being placed on rain
fed and marginal ecologies to support the worlds current population growth. As financial and
human resources are limited in many countries, regional/inter-regional and international
collaboration and cooperation in rice research would offer practical solutions to meet the worlds
increased food demands.
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16 References
Oryzaworld.com
http://prr.hec.gov.pk/Chapters/128S-2.pdf
http://prr.hec.gov.pk/Thesis/128S.pdf
http://prr.hec.gov.pk/Chapters/129S-2.pdf
http://prr.hec.gov.pk/Thesis/129S.pdf
http://dawn.com/2012/09/30/steep-fall-in-rice-exports/
http://tribune.com.pk/story/445440/rice-exporters-to-target-2-5b-in-exports/
http://en.wikipedia.org/wiki/Rice_production_in_Pakistan
http://www.reap.com.pk/
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