Productivity improvement by reduction of leak repair operations at radiator assembly line of Roberts Automotive and Industrial Parts Manufacturing Corporation Bo. Diezmo, Cabuyao, Laguna
Date
4-2009
Degree
Bachelor of Science in Industrial Engineering
College
College of Engineering and Agro-Industrial Technology (CEAT)
Adviser/Committee Chair
Mikel Angelo Yap
Committee Member
Herbert Manaligod, Marc Immanuel Isip
Abstract
Roberts Automotive and Industrial Parts manufacturing Corporation is in automotive industry located at Bo. Diezmo, Canlubang, Laguna. It manufactures leaf springs, radiator, mufflers, tamped parts for export, OEM assembles and aftermarkets. The company produces automotive parts for major companies such as Toyota, Honda, Mitsubishi, Nissan, Isuzu, Columbian Motors, Kia, Francisco Motors, Hino, Kawasaki, Suzuki, and Yamaha. The Radiator Production is an assembly line wherein Leak Testing (LT) operation significantly affects the production rate of the assembly line process. Leak Testing is an operation wherein products are inspected for leak occurrence, in addition leak repair is done in case that leaks are detected. The company incurred an average of 50.73% leak percentage which was significantly not within the company's allowable leak percentage of 20.4%. The total annual cost associated with leak repair was Php 721,721.31, and the total opportunity revenue lost associated to leak repair was Php 5,308,790.88; the total cost amounting Php 6,030,512.19. per year.In this case, the main objective of the study is to improve the producti8vity of the Leak Testing operatin by reducing the poercentage of leak occurrences in the radiator. Root Causes for the accumulation of leaks were identified and summarized using Ishikawa Diagram. CNX analysis classified the root causes into Controllable, Noise, and Experimental. Controllable factors further classified into Group A and Group B. Group A consisted of activities about the improvement of traioning procedures for the new workers. On the other hnd, Group B included the factors that insisted the need for the tank inspection before it proceeds to the next workstation. Experimental factors included Group A which was related since they were all associated in the problem found in tube Forming Operation. On the other hand Experimental factors under Group B dealt with the insufficient number of stainless and aluminum jigs per model. After the analysis of the root causes and evaluation of alternatives per group, it was recommended to improve the training program for hiring a new worker, and to install Quality Gates for Parts Soldering to check the dimension of tanks. Furthermore, an additional operator was needed for Tube Forming Machine and also there was aneed to manufacture additional jigs for the Core Assembly Operation. Cost and Benefit Analysis showed that the initial cost and annual cost for the implementation were Php66,200, and Php168,000 respectively and the company was expected to gain a net savings of Php391,889 per year.
Language
English
LC Subject
Productivity progress, Production management--Case studies
Location
UPLB College of Engineering and Agro-Industrial Technology
Call Number
LG 993 2009 E66 E23
Recommended Citation
Ebajo, Andro Sedol, "Productivity improvement by reduction of leak repair operations at radiator assembly line of Roberts Automotive and Industrial Parts Manufacturing Corporation Bo. Diezmo, Cabuyao, Laguna" (2009). Undergraduate Theses. 877.
https://www.ukdr.uplb.edu.ph/etd-undergrad/877
Document Type
Thesis
