Date

4-2009

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Dean Haerold Z. Layaoen

Committee Member

Mikel Angelo B. Yap, Herbert T. Manaligod

Abstract

Yazaki-Torres manufacturing, Inc. (YTMI) is a manufacturing company for automotive wiring harness located at YTMI Realty Special Economic Zone in Makiling Calamba, Laguna. YTMI also manufactures PVC electrical tapes, low0tension wires and battery cables. The company supplies its main product to multinational car manufacturers in the Philippines and also outside the country. The production line of YTMI for automotive wiring harness experiences delays, mostly occurring in the crimping process, which is one of the initial processes of the whole production system. The delays in this operation are mostly caused by the breakdown of crimping machines. Two incidents of line stoppage due to unavailability of crimping dies, the spare parts for the repair of crimping machines, were reported for the months of April and May 2008. The cost for these incidents was approximately Php6,707,400, including labor cost (overtime) and opportunity cost. Through the aid of Industrial Engineering tools, the root causes of the problem with the ordering system were identified and evaluated as to importance to the main problem. The major problem identified and evaluated as to importance to the main problem. The major problem identified is the problem with the forecasting methods used as basis for the ordering policy. The forecasting technique used does not fit the trend of actual usage of critical crimping dies. Different forecasting techniques were presented and evaluated to come up with the best alternative for each of the top most frequently replaced crimping dies (anvils, wire crimpers, and insulation crimpers). Exponential Smoothing with trend adjustment (α=0.5, B=0.5) is the most suitable forecasting technique for anvils, ESTA (α=0.25, B=0.75) for wire crimpers and Naive method for insulation crimpers. Then three alternative ordering policies were compared using the Least Cost Method. The single-order policy was selected for the anvils and insulation crimpers and the fixed-time period model was chosen for the wire crimpers. Savings from this solution is approximately Php559,016.67 per year.

Language

English

LC Subject

Industry analysis, Productivity progress

Location

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

Call Number

LG 993 2009 E66 L35.

Document Type

Thesis

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