Date

4-2010

Degree

Bachelor of Science in Industrial Engineering

College

College of Engineering and Agro-Industrial Technology (CEAT)

Adviser/Committee Chair

Romark O. Cayube

Committee Member

Kathleen B. Lee, Diana Marie R. De Silva

Abstract

Plant efficiency is one of the most vital considerations in every manufacturing plant. In industries like feeds manufacturing where competition is too tight due to high demand, raw materials cost almost the same for all the companies and the ones who are able to make the the most put of these and their respective resources by working efficiently, generally wins among contenders. In the recent review of their plant performance Vision 2000 Feed Mills Corporation had found out that in the average, their plant is only 51.57% efficient. To increase plant efficiency, this study performed cause-and-effect analysis to know the root causes responsible for this problem. It was found out that there were worker-related and machine-related root causes of low plant efficiency. These root causes were determined to have existed due to attempts of the plant to meet quality standards, meet demand, and other positive significant activities for operations. Controlled root causes could be resolved through Station Definition and Job Rotation, Training and Ultimatum, and Preventive Maintenance program. To solve the contradictions of the experimental root causes, the Theory of Inventive Problem Solving (TRIZ) method was used. Each root causes contradicting parameters were identified and each contradictions were plotted in the TRIZ matrix. Principles were obtained and projected in the company problem. The useful principles and their corresponding possible solutions for both areas of contributing root causes were named and evaluated using factor rating method through the following criteria Cost of Installation (25%), Effect on Total Daily Production Time (25%), and Increase in Plant Efficiency (50%). USing these, it was obtained that the best on hand solutions are to install racks inside to manage materials while making the workers exert less effort associated with finding, bending, etc and to install a new mixer parallel to the current one to increase capacity and solve worker-related and machine-related root causes of low plant efficiency respectively. These alternatives were chosen above the rest since they were able to solve the contradictions in the lowest possible cost and at the best scenario in accordance to the criteria set above. It was projected that the efficiency would be increased by 30%. Installation cost for the recommended solution will be P 161,740.00. The investment will generate an annual benefit of P 138,150.00 on overtime elimination alone. At the end of the payment span of the loan, the net benefit gained using the recommendations will be P 324,866.96.

Language

English

Location

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

Call Number

LG 993 2010 E66 U54

Document Type

Thesis

Download

Share

COinS