Reduction in weld defects of waterwall panels manufactured in Babcock-Hitachi Philippines Incorporated (BHPI) Bauan, Batangas

Date

4-2011

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Mark Anthony M. Baldoz

Committee Member

Mikel Angelo B. Yap, Lizbeth A. Mariano

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Abstract

Babcock-Hitachi Philippines Incorporated (BHPI), located at the municipality of Bauan Batangas, is a joint venture of Babcock-Hitachi K.K. (BHK) of Japan and the Atlantic Gulf and Pacific (AG&P) Company of Manila Incorporated. It produces utility and Industrial Boilers Components such as Headers, HRSG Tubes, Coiled Elements, Pipings and Water Panels. Data showed that Waterwall Panels exceeded the allowable rejection rate of the operations from November 2009 to April 2010. Out of 1583 butt joints produced, 519 were rejected, which resulted to a significant increase in rejection cost. More than 84% of these rejects were due to weld defects such as porosity, lack of fusion slag inclusion, concavity, and root undercut. As a result of high rejection rate, this study focused on these components. These items are processes manually unlike the other components and therefore, offer more areas for improvement. In addition, waterwall panels are the most frequently produced boiler parts in the assembly line. The Ishikawa Diagram was used in the analysis of the occurrences of weld defects in waterwall panels. The root cause analysis showed the top five weld rejects that comprise the vital few, and with CNX Analysis, the causal factors were identified to evaluate Controllable, Noise and Experimental Factors affecting the problem. Uncontrollable actions and behavior of the workers were the main Noise Factors. Meanwhile, a good skills enhancement program, proper quality awareness program, more strict supervision, and proper housekeeping of the shops appeared to be the best ways to solve the controllable factors. Six experimental factors were recognized and were carefully evaluated based on: Percent Improvement, Cost and Ease of Implementation. The factor- rating method was used to determine the most recommendable solutions.Results showed that the company should conduct corrective repairs for welding machines twice a year, attach a digital temperature gauge on the welding machines, provide group incentives or other benefits, improvise proper covers for machines, install exhaust fans, assign a special job to a worker to daily check the drying oven, and conduct a regular skills enhancement and enrichment program for the welders. The implementation of Standard Operating Procedures and the 5S Program should also be highlighted. These recommendations will incur an initial cost of PhP 349,301.55 but in return, the company can save an estimated PhP 557,411.94 annually. In 10 years, the company can save a significant amount of PhP 3,353,717.85 with due considerations to the annual operating and maintenance costs. Weld rejects can also be reduced from 28.01% to 6.99% if the recommendations are properly implemented.

Language

English

Location

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

Document Type

Thesis

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