Reduction of occurrence of defects in the manufacturing section of Arkray Industry, Incorporated, FPIP, Brgy. Sta Anastacia, Sto.Tomas,Batangas, Philippines.

Date

4-2013

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Baldoz, Mark Anthony M.

Committee Member

Pesigan, Clarissa M. Yap, Mikel Angelo B.

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

Arkray Industry. Incorporated (AIIP) is part of a global company that manufacturers medical devices. It began its operation in the country last September of 2011. AIIP faces the problem of high occurrence of defects that exceeds its allowable defect percentage of 2%. At present AIIP has an average daily defect percentage of 5.11% that made AIIP incur ₱1,647,972.64 from March to June of 2012. Through the Pareto Analysis of the occurrence and the cost of rejects per process, the vital few processes were pointed out. Each process was also analyzed using the Pareto principle to know what defects under each process must be considered. Root causes of defects were gathered using Ishikawa diagram and by doing a Why-Why analysis of each. They were then further identified as controllable, noise and experimental factor. The proposals made for the Controllable factors were workstation redesign and barrier installation, clean room uniform redesign, hand guard and placards installation, use of destructive hooks for glove disposal, use of base film holder, use of ionizers, restructuring of coordination meetings, monitoring using CCTV, and revision of request and issuance of supplies. The alternatives for the experimental factors were evaluated using three factors, percent improvement, cost and ease of implementation. The Proposals include the use of a larger sized brush for cleaning use of time-based monitoring of glue consumption, use of roller guards, manual monitoring of reagent consumption and establishment of worker initiated improvement reward system. With these proposed alternatives, the gluing process will have a defect reduction of 76.06%, the pasting process will have a defect reduction of 52.09% and AIIP will have a reduction in the daily defect percentage from 5.11% to 2.42%. In a span of four months, these reductions can translate to ₱787,382.54.

Language

English

Location

UPLB College of Engineering and Agro-Industrial Technology

Call Number

LG 993.5 2013 E66 D43

Document Type

Thesis

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