Reduction of scrap through total quality management on Del Monte 202 label production line of United Graphics Expression Corporation (UGEC) Dasmariñas, Cavite.

Date

4-2010

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Elauria, Arvin Joseph M,

Committee Member

Isip, Marc Immanuel G.

Abstract

United Graphic Expression Corporation (UGEC) is a printing company located at Governor’s Drive, Dasmariñas, Cavite. It prints packaging and marketing materials for different organizations. It also offers product shooting, designing and art services bundled with printing and pre-media works. UGEC has 37 products; however, only eight of them are being produced regularly. These are the GSM Round, GMAT 350mL, GMAT 1L, GMAT 700mL, Mighty Menthol 100s, SOB Round, Coke Banner and Del Monte 202 labels. Del monte 202 labels acquired the highest cost due to rejects. It was found out that the scrap incurred in del Monte 202 labels amounted to about 8.08% of the total inspected units or 5,906,084 units. About 84% of these scraps were printing scraps like streaking, scumming, dot skip, picking, mottling and lines. Root causes of the high printing scrap were identified using Ishikawa Diagram. The cause factors were identified using CNX Analysis - C if the factor is controllable; N if it is Noise; and X if it is experimental. The factor under Noise is human error. There were no recommendations for this factor since it is difficult to control. Controllable factors identified were poor information dissemination about the importance of quality, workers lack proper training and lack of strict supervision. These were grouped into two based on the solutions generated. Re-training for the workers and surprise inspections were the proposed solutions. Four experimental factors were identified. These were the malfunctioning of the densitometer, workers estimated the blade contact angle, camera of the machine was not working and the color mixer lacked formal training. For the experimental factors identified, three alternatives were given for each factor. Factor Rating method was done in order to come up with the selection. Based from the ratings made, acquiring a print inspection system and densitometer, improvising an angle measuring tool and training the color mixers were recommended. The recommendations will require an initial investment of PhP 1,087,788 while having an annual savings of PhP 2,451,656.80. Upon the implementation of the recommendations, percent reject will be reduced from 8.08% to 1.03%.

Language

English

Location

UPLB College of Engineering and Agro-Industrial Technology

Call Number

LG 993 2010 E66 T35

Document Type

Thesis

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