Improvement of manpower and machine productivity through the reduction of occurrence of re workable defects in the soft down stay line on the assembly department of Trendy Plastic Manufacturing, Incorporated in Lantic, Carmona, Cavite, Philippines

Date

4-2011

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Aurelio A. Delos Reyes, Jr.

Committee Member

Haerold Dean Z. Layaoen, Kathleen B. Lee,

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Abstract

Trendy OPlastic Manufacturing, Incorporated which is located at sterling Techno park, Barangay Lantic Carmona, Cavite is one of the exporters of inner plastic parts of computers and automobiles. They also assemble cabinet hinges with soft closing features and other furniture hardware. The study focused on the Assembly Department of the company which incurs additional costs because of the time spent reworking defective products. The Soft Down Stay (SDS0 Line had the highest production and number of defects evaluated. Defect categories observed in the said line included sealing bond problem, wrong parts/lack of parts, wrong assembly of parts, calking problem, and margin screw problem. The root causes of the major defect categories were identified and analyzed using Ishikawa Diagram and CNX analysis. The factor, not properly implemented rules, was identified as controllable and was given recommended solutions like surprise inspections and reward actions. Insufficient training program, inappropriate hiring schedule, difficulty in detecting if dispenser is needed to be refilled, difficulty in estimating the amount of bond to apply, raw materials in the line were cluttered, and lack of preventive maintenance to the machines Calking Mould and Margin Screw Insert Apparatus were identified as experimental factors. Recommended solutions were a new training program, proposed hiring schedule, installation of weight detector to Sealing Bond Dispenser Apparatus, usage of pipette in sealing bond application, having separate racks for each product, preventive maintenance and regulator replacement of Calking Mould, and preventive Maintenance of Margin Screw Insert Apparatus. These recommendations if followed would require an initial investment of PhP96,,006.01 but will result to a savings of PhP 801,828.72 for the year. In addition, manpower productivity will improve from 2.32 to 2.97 units per man-hour and machine productivity will improve from 83.14 to 92.00 units per machine hour.

Language

English

LC Subject

Quality productions, Productivity progress

Location

UPLB College of Engineering and Agro-Industrial Technology (CEAT)

Call Number

LG 993 2011 E66 F87

Document Type

Thesis

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