Minimization of rejects in the sweet tropical fruit preserve line in Plant 1 of Global Foodsolutions, Inc. in San Pablo City, Laguna

Date

4-2011

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Diana Marie R. De Silva

Committee Member

Haerold Dean Z. Layaoen, Mikel Angelo B. Yap

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Abstract

Global Food Solutions, Inc. (GFSI) is a medium scale company that manufactures various processed food products. These products include nata de coco tropical fruit preserves, frozen root crops, vegetable sauces, condiments and native delicacies.The company is divided into three plants and the Plant 1 was assigned area of study. It was observed that among the three Lines in Plant 1 namely, Sweet Tropical Fruit Preserve Line, Whole Nata Preserve Line and Condiments Line, Sweet Tropical Fruit Preserve was the greatest contributor of rejects, which was 96% of the rejects produced. It was identified that the following reject categories contribute to the total amount of reject in the Sweet Tropical Fruit Preserve Line: foreign material, low vacuum,bubbles, bulged, cap defect, filling defect, raw material defect, broken, overcook, and off color. These defects were found to be 7.25% of the total inspected units. Upon evaluation of the defects mentioned, it was found that foreign material and low vacuum accounted for 89.6% of the total rejects accumulated in the Sweet Tropical Fruit Preserve products. The root causes of the accumulation of rejects that is caused by foreign material and low vacuum were identified and analyzed using Fish Bone Diagram and CNX Analysis. The causal factors were identified as noise, controllable and experimental. The Controllable factors (c factors) were classified into five categories and were given immediate solutions. The categories were training, supervision, cleaning maintenance, insect control plan, and preventive maintenance for the Capping Machine. The Experimental Factors (X Factors), on the other hand, were also classified and were given recommendations. The X Factors were categorized as: improvement of working conditions, provision of new tools and equipment used by the worker, proper storage bins for caps, and the implementation of breakdown maintenance. If the recommendations are implemented, an annual benefit in the form of savings would be PhP808, 716.31 and the rejection rate of 7.25% would be reduced to 2.18%.

Language

English

LC Subject

Food-Processing Industry

Call Number

LG 993 2011 E66 A35

Document Type

Thesis

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