Date

4-2009

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Marc Immanuel G. Isip

Committee Member

Haerold Dean Z. Layaoen, Arvin Joseph Elauria,

Abstract

Yazaki-Torres Manufacturing Inc. (YTMI) is a automotive wiring harness production company. It has three satellite factories, Yazaki-Torres Parts Manufacturing Inc (YTPMI), Yazaki-Torres Manufacturing Parts Manufacturing Inc.-Lima (YTP-Lima) and Yazaki-Torres Component Manufacturing Inc (YTMCI). The company produces 97% of the wiring harness foe export and only 3% for domestic use. The study focused on YTPMI where Toyota wiring harnesses are exclusively produced. The study found out that the company is experiencing high labor cost. The main concern of the study is to reduce the unproductive time of the employees. These unproductive times cost the company 13.44M Php in the year 2007. It was found out that overtime pays are the main contributor to the high labor cost. In the year 2007,overtime cost the company 8.4MPhp. Overtimes are caused by production delays and increase in demand. The demand on wiring harness of Toyota rarely increases. Most of the Overtimes are caused by production delays. It was also found out that most of the production delays are caused by conveyor problems. From all of the conveyors used in YTPMI, Slanted Type Conveyor contributes most on the conveyor problems. STC contributes 87.3% of the total breakdowns conveyors experiences and 71.4% of the production lines uses STC. Ishikawas Diagram, Pareto Charts, and CNX analysis are used to identify and analyze these problems. Most of the problems were contributed by man and machine. Maintenance personnel have not done their job well. STC's current damages the rubber pads of the assembly jigs and the conveyor's sensors creating different problems. The damage occurs in the lower conveyor specifically on Point A and Point B. Two alternatives solutions were made to solve both machine and man problems. The first alternatives is to separate the chains of pointA and Point B to avoid the chains emaciate the rubber pads. The second alternative is to transfer Point A 16.3 m from lifter 1. To come up the best alternative benefit-cost and factor rating were computed for each alternative to determine their impact on the company. Alternative 2 was identified as the better alternative between the two. Certification Course for the maintenance personnel are also recommended to control the problems on the employee. With these solutions, the company is expected to save up to 8.9M Php annually.

Language

English

Call Number

LG 993 2009 E66 V55

Document Type

Thesis

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