Expert System Application In Quality Control And Monitoring (A Case Study Of P Z Company, Aba)

Project and Seminar Material for Computer Science and Computer Engineering

Project and Seminar Material for Computer Science and Computer Engineering


An expert system is a knowledge – based program that provides “Expert Quality” solutions to problems in a specific domain George F. Luyer etal (1989).

The exponential advancement in technology has led to the development of computer system with the ability to explain their reasoning or suggested decisions, display intelligent behavior, draw conclusions from complex relationships, provide portable knowledge and exclusively deal with uncertainly.

Thus expert system as component of artificial intelligence (A.I) incorporates all these capabilities and be used to solve problems in every field and discipline such as in quality control and monitoring.

Expert system in quality control and monitoring is aimed at developing a system that checks and controls quality in raw materials, unfinished and finished products of P Z Plc, Aba. It will boost effective productivity by reducing cost of production with respect to the manpower and time, monitoring the control measures and recommends appropriate corrective action when limits are exceeded.

Thus, putting in place appropriate control measure to prevent, eliminate or reduce the barriers of quality and optimum production cost to an acceptable limit through the statistical analysis of quality produce and quality cost to enhance the decision of the management.

During the investigation of the existing system, a thorough study was carried out on basic operations of the department. The researchers employed various methods of data collection which included interviews, questionnaires, sampling and observation of work environment.

Table Of Content

Preliminary Page(s)

  • Title page
  • Certification
  • Dedication
  • Acknowledgement
  • Abstract
  • Table of content

Chapter One

  • 1.1 Introduction
  • 1.2 Background of the study
  • 1.3 Statement of the problem
  • 1.4 Objectives of the study
  • 1.5 Significance of the study
  • 1.6 Scope of the study
  • 1.7 Limitations of the study
  • 1.8 Definition of terms

Chapter Two

  • 2.1 Literature review

Chapter Three

  • 3.1 Introduction
  • 3.2 System analysis
  • 3.2.1 Detailed definition of the problem
  • 3.2.2 Feasibility study
  • 3.3 Method of data collection
  • 3.3.1 Interviewing
  • 3.3.2 Observation
  • 3.3.3 Review of procedure manual or existing system / procedure
  • 3.3.4 Evaluation of form
  • 3.4 Problem of the existing system
  • 3.5 Data preparation
  • 3.6 User preparation
  • 3.7 Objective of the new design
  • 3.8 Program structure
  • 3.8.1 Modulation
  • 3.8.2 Top down program design
  • 3.9 System flowchart
  • 3.10 Program flowchart
  • 3.11 File maintenance module
  • 3.12 Main menu specification
  • 3.12.1 Output specification
  • 3.12.2 Input specification
  • 3.12.3 File/database specification
  • 3.13 Overview of the proposed system flowchart

Chapter Four

  • 4.1 Introduction
  • 4.2 Justification of the programming language
  • 4.3 System control
  • 4.4 System requirement
  • 4.4.1 Software requirement
  • 4.4.2 Hardware requirement
  • 4.4.3 People
  • 4.5 Implementation details
  • 4.5.1 Coding
  • 4.5.2 System testing
  • 4.5.3 Training and re-training of staff
  • 4.5.4 File conversion
  • 4.5.5 Change over procedure
  • 4.5.6 Commissioning
  • 4.5.7 User manual
  • 4.5.8 Maintenance details

Chapter Five

  • Summary, conclusion and recommendation
  • 5.1 Summary
  • 5.2 Conclusion
  • 5.3 Recommendation
  • References

Chapter One


1.1 Introduction

Technology has had a tremendous impact on the society from the changes instituted during the industrial revolution to today’s information age, new technology has been adopted to solve a problem or speed a process.

In business, technology includes the skills, procedures, equipment and systems used to perform the work. As manufacturing companies strive to improve, they seek the most appropriate technology to accomplish the work.

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

Hence, the expert system in quality control and monitoring has made it possible to effectively combine the software and hardware in quality control department to measure the quality of products. The quality control and monitoring knowledge base. And the software requires quality controllers to input the results form various tests carried out .the data is analyzed to identify opportunities for improvements.

This advancement in technology has helped quality controllers and manufactures to locate problems in manufacturing stages, increase the quality of the products and dominate problems in the productions process. The pay off of this system can be a reduction in cost a boost in production and sales.

1.2 Background Of The Study

Since the advent of computer, effort has been to fashion the tool that could able to solve most of the intriguing problems that comfort man. In the early days, researchers in the field of Artificial intelligence (AI) were using mere illustrations that shown ideas. As time passed by different experimental systems were developed many of which hypothesized answers to truly handle problems that defy superficial speculations. Presently, systems exist which can handle most of the problems considered impossible by early researchers. Such intriguing task as playing chess with computer can now be programmed with relative ease.

Other expert systems have also been developed in areas such as medicine, finance and education.

However, one problem area yet to be properly addressed and for which this project is concerned is in manufacturing as regards to quality control and monitoring. Thus, the application of expert system in quality control and monitoring in a manufacturing industry is the focus of this research work.

1.3 Statement Of The Problem

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

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

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

1.4 Objective Of The Study

The purpose of this study is to alleviate problems besieging production as regards to quality control and monitoring system. Thus, the expert system is designed to handle the following problems viz.

  1. To duplicate the knowledge of a domain (quality control manger) in order to ascertain efficiency and effectiveness of production in his absence.
  2. To provide Q.C. personnel with vital tools for fast decision – making.
  3. To trace error in over – all production stages.
  4. To create easy communication channels for all the managers as the quality control reports are made to reach them on time.
  5. To reduce paper work.

1.5 Significance Of The Study

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

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

1.6 Scope Of The Study

This project work is purely on expert system is quality control and monitoring as it is concerned with a soap manufacturing firm. It would be applied to other manufacturing companies but the scope is on detergent as it covers the following:-

  1. Quality specification
  2. Problems in production process
  3. Decision – making and possible solutions.

1.7 Limitation Of The Study

Be that is it may, there were short – comings which arose as a result of problems encountered in the course of this work.

Accesses to the data / information collected were somehow restricted as some of them have been classified. Also, without such constraints like insufficient time and money the course of this work would have been immensely expanded.

1.8 Definition Of Terms

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

Expert System:

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

Domain Expert:

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

Knowledge Base:

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

Knowledge User:

The individual or group who uses and benefits from the expert system.

Inference Engine:

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

User Interfaces:

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

Chapter Five

Summary, Conclusion And Recommendation

5.1 Summary

In all this project with its fruits aimed at saving the entire staff of Production Company the stress of manual entry of data as well processing their orders, and advertising their goods.

On the other hand, the benefits acquired from quality control system which was stated in the previous chapter have been the way of overcoming the problems of using manual method for processing production order.

5.2 Conclusion

The system has been developed based on the knowledge- base acquired by quality control. It also performs the processing of rules, data and relationship stored in the knowledge – base.

The following is a list of factors that normally make expert systems worth the expenditure of time and money; a high potential pay off or significantly reduced downside risk, the ability to develop a system more consistent than human expert.

The expert system solution can be developed faster than the solution from human expert. An expert system also provides expertise needed for training and development to share the wisdom and experience of human expert with a large number of people.

More so, the benefit of an expert system goes beyond the typical reasons for using a computerized processing solution. Expert system display “intelligent” behavior. Manipulate symbolic information and draw conclusion, provide portable knowledge and can deal with uncertainty.

Finally, the impact of this new system is to enhance efficiency, boost effectiveness in production and greatly reduce cost of production and materials, even the unperturbed quality control manager. It is an improved aspect of day-to-day activities of the company as it relate to quality check and its ability to help managerial end users make effective decisions.

5.3 Recommendation

What is needed to be competitive in today’s manufacturing market? More than even successful competitors must continuously improve manufacturing performance by running their operations with higher levels of availability, more consistent level of product quality and a greater overall efficiency.

Improving the performance depends on knowledge. Quality controllers need to capture knowledge about their production processes and apply it in a way that can effectively drive real- time operational decision. They need to apply knowledge that detects and diagnosis production problems early and then help operators recover quickly so that production can be kept going.

Also, quality controllers need to apply knowledge that predicts product quality in real-time to drive the control decisions that maintain consistency. There is also the need to apply knowledge that drives the raw material flow decision in order to optimize production economics.

Accordingly, in order to achieve the about advantageous application, the Expert system on quality control and monitoring be fully implemented in the factory.

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