Reduction of rejects at the hot- fill line of Coca Cola Bottlers Philippines, Incorporated Sta. Rosa Plant II, Laguna

Date

4-2011

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Romark O. Cayube

Committee Member

Lizbeth A. Mariano, Mark Anthony M. Baldoz

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Abstract

Coca-Cola Bottlers Philippines, Incorporated Sta. Rosa Plant II (CCBPI-SR2) Or SR2 is a beverage manufacturing and bottling company located in Barrio Pulong, Sta. Cruz, Sta. Rosa City, Laguna, Philippines. During the first quarter of 2010,it was observed that a significant number of rejected outputs was produced in the Hot-Fill Line (Line 5) which amounted to PhP11,566,651.55 in production cost and lost profits. Since 60.85% of the rejected outputs was classified as Full Goods/Chekmat Rejects, the study focused on finding ways to reduce these defects and consequently lower the wasted production cost and maximize the profit of the company. An Ishikawa diagram was established and root cause analysis was used to determine the root causes of the identified subproblems under the Man, Machine, Method, Material and Environmental categories. These root causes were then grouped into Noise, Controllable and Experimental factors according to their nature and degree of possible improvement. The Noise factors were listed but they were not given solutions because they were beyond the scope of this study. The controllable factors were identified and grouped into Supervision, Working Schedule and Training. For Supervision, the recommended actions included establishing a definite of monitoring the unproductive roaming around and compliance to policies on PPEs of operators. Check sheets were provided and the line leaders were tasked to fill them, up and submit a periodic report. Penalties and incentives were also recommended. Furthermore, posters about the responsibilities of the line leaders and the Do's and Don'ts of the operators were suggested to be placed around the production line. For Working Schedule, it was recommended that the company maintains the weekly meeting between the Production and Engineering Departments. The operators were required to give prior notice to his line leader about his future absence. For Training, important topics were incorporated in the training program of operators. Experimental factors were also identified and were grouped into Man and Machine categories before they were given solutions. The chosen best alternatives for the Man and Machine groups were to grant operator bonus and to install an alarm system, respectively. Implementation of the proposed solutions to experimental factors would result to an annual savings amounting to PgP14,538,426.69.

Language

English

LC Subject

Quality productions

Location

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

Call Number

LG 993 2011 E66 M46

Document Type

Thesis

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