Reduction of process rejections on the punching process at INOAC Philippines Corporation, Brgy. Pittland, Cabuyao, Laguna, Philippines.

Date

4-2013

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Micah A. Ramirez

Committee Member

Mariano, Lizbeth A. Mikel Angelo B. Yap

Restrictions

Restricted: Not available to the general public and to those bound by the confidentiality agreement. Access is available only after consultation with author/thesis adviser.

Abstract

For the first three quarters of 2011, Inoac Philippines Corporation (IPC) encountered process rejection cost amounting to Php 103, 900. Roughly 82% of the costs, Php 85, 198, are caused by rejections due to tear, out-of-tolerance and cutting difference. Upon investigation, it was found out that the punching section has the most number of process rejections which exceeded the 0.10% tolerance set by the company. Upon implementation of the improvements and controls which include strengthening the adherence of the operators and staff to the standard operating procedures and the sampling plan, around 30% of the total process rejections was eliminated. On the other hand, addressing the experimental factors, alternatives were formulated and evaluated and it was recommended to have a revised training program for operators which includes pictures and video supplements during training for better understanding of workers, to provide guides on the die mold for PP board alignment which ensures proper positioning during punching, to evaluate die mold after every 5000 punches and to provide a reserve die mold for each month and to hire a male quality asurance staff to intensify incoming inspection. Implementing the recommended solutions reduce the overall rejection from 0.4030% to 0.0939%. Also, with this reduction, IPC can realize a savings of Php6,535,740.497 in five years.

Language

English

Location

UPLB College of Engineering and Agro-Industrial Technology

Call Number

LG 993 2013 E66 M47

Document Type

Thesis

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