Productivity improvement through scrap and delay reduction of greensheet manufacturing at the wet end Department of James Hardie Philippines Inc., Cabuyao Laguna
Date
4-2008
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 M. Elauria, Herbert T. Manaligod
Restrictions
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Abstract
James Hardie Philippines, Inc. is located at Brgy. San Isidro, Cabuyao, Laguna. It is a strategic branch of the James Hardie Industries NV, a major manufacturer of fiber cement boards.
For the fiscal year of 2008, the annual productivity was only 80.2%. The target set by the organization was 95%. The annual unrecoverable loss due to the gap between the target and the actual amounted to Php121,502,257.68. The two factors that affected productivity were scrapping and delays. The loss due to scrap amounted to Php92,142,271.50 while the loss due to delays amounted to Php29,359,986.18. To address this problem, this study was made to improve the productivity of the organization through the reduction of scrap and delays.
Interviews were made and historical data were reviewed. It was found out that 76% of the gap was attributable to scrap while 24% was attributable to delay. Using Pareto charts, it was found out that the major cause of delays were dimensional adjustment, jam ups, changeover, washdown, peel off, flushing, dimensional check, maintenance, and the absence of prepared mix to process. The leading causes of scrap was thickness, lumps, size roll peel offs, delaminations, and dimensions. Cause and Effect Diagrams were used to identify the potential root causes. The root causes were classified as either controllable, experimental, or noise. Cause and Effect Matrices were used to rank the root causes according to priority.
From the identified root causes, a set of recommendations were made. These recommendations were training and certification program for operators scheduling of activities, the use of logsheets for documenting activities, implementation of disciplinary actions, optimal batch sizing, and the use of settings guides in workstations.
The initial cost of all the recommendations will amount to Php3,020.00. The total saving will amount to Php2,862,038.92. The annual delay rate will be reduced from 23.22% to 17.47% while the annual scrap rate will be reduced from 7.35% to 6.20%. Hence, the annual productivity will increase from 80.2% to 87.29%.
Language
English
LC Subject
Industry analysis
Location
UPLB College of Engineering and Agro-Industrial Technology (CEAT)
Call Number
LG 993 2009 E66 A23
Recommended Citation
Abasolo, Regis Ediljoseph Javier, "Productivity improvement through scrap and delay reduction of greensheet manufacturing at the wet end Department of James Hardie Philippines Inc., Cabuyao Laguna" (2008). Undergraduate Theses. 876.
https://www.ukdr.uplb.edu.ph/etd-undergrad/876
Document Type
Thesis
Preliminary