Waste reduction through the prevention of bubbling defects at the duraplus tire line of Goodyear Philippines, Inc., Las Piñas City.

Date

4-2010

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

Mike Angelo B. Yap, Diana Marie R. De Silva

Abstract

Goodyear Philippines, Inc. (GPI), located at Alabang-Zapote Road, Barangay Almanza, Las Piñas City, is the 13ᵗʰ of the 35 overseas tire manufacturing facilities of the Ohio-based Goodyear Tire and Rubber Company, which is the third largest tire manufacturer in the world. GPI has been producing tires since 1956 its current output reaching 5400 tires (82 metric tons) per day. After a quick review of GPI's set of key performance indicators (KPIs), it was determined that the plant's Percent Waste Generation (%W) rate exceeded the allowable 0.92 percent value. Particularly, from JAnuary to May 2009, an average of 1.21%W was recorded. When translated, this non-compliance results to losses amounting to PhP5.2 million per year. With the aim of exploring the possible ways to improve on GPI's waste generation rate, the study adopted a consultant's step-by-step process that focuses on improving KPIs based on its definition and formulation. Analysis revealed that a large portion of the wastes was due to defective finished products, 91 percent of which were bubbling defects. Using a modified fault-tree analysis, the root causes of bubbling were identified as improper machine maintenance, inadequate policies, inadequate ventilation, poor housekeeping, and poor training. Subsequently, five solutions were formulated using the cause-and-effect diagram with addition of cards (CEDAC). Only four were found viable. These are: to (1) improve or add ventilation, (2) improve work hygiene, (3) retrain employees, and (4) improve maintenance personnel. Implementing the four solutions would cost to PhP4,630.91 per day while the value of wastes beyond the 0.92 percent limit is PhP18,312.00 per day. Thus at least PhP13,681.09 can be saved daily equivalent to PhP3.85 million annually.

Language

English

LC Subject

Industry analysis, Production management--Case studies

Location

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

Call Number

LG 993.5 2010 E66 C65

Document Type

Thesis

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