Date

4-2010

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Kathleen B. Lee

Committee Member

Aurelio A. Delos Reyes, Diana Marie R. De Silva

Abstract

Hella-Phil Inc.located along Aguinaldo Highway Dasmariñas Cavite, Philippines is a 10,000 m² facility that manufactures automotive lighting and horn for various global car makers and motorcycle companies. It was three main types of products classified according to the recipient customer. These are Trade or Independent After Market (IAM) products, OE (Original Equipment) Product for Export and OE Products for Local Customers. Out of these products, the original Equipment for Local Customers made up 79% of the company's total sales from April to September 2009, 99.7% of which was for Honda Philippines Inc. There are five Honda parts manufactured by Hella, and of these the CDI (Capacitor Discharge Ignition) Honda Tail Light was determined to have the highest cost of rejects amounting to about Php189,916 annually. This study presents an evaluation of alternatives to improve the CDI Honda Tail Light Manufacturing process and reduce rejects. The processes were documented and the root causes of the problems were identified using Pareto-Ishikawa-CNX Analysis. In the Ishikawa analysis, the main causes of the problem were identified under Man, Machine, Method and Material. The breakdown of each of the four main sources of the problem was done in the CNX analysis and the root causes determined were defined as either C (for controllable), N(for noise) or X (for experimental) root cause. There are eight controllable root causes determined: 1) the operator was doing another process and neglects the moulding machine2)the operator was chatting with fellow workers3) the workers lacked knowledge/training on the job assigned to them4)the standard setup did not work for the machine anymore5) the failure of the maintenance department to conduct preventive maintenance regularly6) the use of raw material was not recorded 7) the existing SOP on raw material use is ineffective, and 8)) the use of regrind raw material introduced impurities to the reused plastic. The first,second and third controllable root causes can be categorized as human resource management problems. The first two can be solved by impressing upon the operators the importance of focusing on their work through the bulletin campaign that defines the worker's priorities and presents the consequences of neglecting their work, while the third cause can be solved by conducting an Annual Training Program for Moulding Operators and Technicians.The fourth and fifth causes fall under machine problems. They can be solved by implementing a recalibration of the injection moulding machines annually, and having preventive maintenance of the injection moulding machines every 6 months. The last three causes were material handling problems. The recommended solution to the sixth controllable root cause is to add the Date and Number of Times Used in the Control Number of regrind raw materials. On the other hand, making the current SOP on the usage of regrind raw materials stricter, e. g. by establishing how many times a particular batch of regrind raw material could be reused, would address the seventh root cause, while improving the system of collecting regrind raw material can reduce impurities in reused plastic. Four experimental root causes were identified, which were grouped into three experimental factors. Factor 1 focused on the alternatives to be implemented on the injection moulding machine. Specifically, these alternatives were: A) acquire a new thermal regulator for the injection moulding machine B) repair the injection moulding equipment, and CC) maintain using the moulding machine in its current state. Of these three alternatives, it was determined that Alternative A was the best option factor rating method. Factor 2 which concerned the mould, had two alternatives: A buy a new mould, and B)maintain using the damaged mould. It was determined that the better solution would be to buy a new mould. On the other hand, Factor 3 focused on the use of regrind raw materials, which also had two alternatives: A)use only virgin raw materials, and B) continue using regrind raw materials, with the lattwer proving to be the better choice. If the recommended solutions to the experimental factors were implemented, the company will have a yearly reduction in cycle time of 234 days due to the elimination of the trimming process, and an annual savings of around Php172,688.

Language

English

Location

UPLB College of Engineering and Agro-Industrial Technology (CEAT)

Call Number

LG 993 2010 E66 M36

Document Type

Thesis

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