A system study on the CBU PDI assembly of Toyota Motor Philippines Corporation

• Main Authors: De Leon, Alveene Joyce C., Hadap, Krista Sienna C., Lim, Lloyd Anthony T.
• Format: text
• Language: English
• Published: Animo Repository 2013
• Subjects: Toyota Motor Philippines Corporation; Industrial Engineering
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/10523
• Institution: De La Salle University

The study covered the operations with relation to CBU Units of Toyota Motors Philippines. It mainly deals with the process after shipment of CBU units from other Toyota affiliates up to the value adding process of CBU PDI Assembly. The study has a time frame of 12 months (January December 2012) in consideration of the available documents and data. Using the SURG Matrix, the problem that should be prioritized is the difference of the actual and intended takt time wherein it incurs additional overtime cost of Php 73,610.74 and opportunity loss of Php 33,337,941.50. The problem was further analysed using Ishikawa diagram to determine its root cause. And based on the investigation done, the biggest contributor of unproductive time that makes the actual takt time higher than the intended time is the cause of No Available Units. The no available units in the system occurs when the intended time is the cause of No Available Units. The no available units in the system occurs when there are no units that enter in the CBU PDI Assembly Line. The units parked in the companys CBU yard from the Batangas Port will be the units to enter the assemble line. If there are no units that enter in the CBU yard, then there are no available units in the system that will be processed in the CBU PDI Assembly Line. This cause is further broken down to determine which of the processes under it should be solved. The Pareto Chart shows the contributions on unproductive time of the problem causes from the Ishikawa Diagram. From this chart, the [1] delayed funding process under customs releasing, [2] delayed deliver due to no available car carriers and [3] delayed stenciling due to wet units from the rain are the controlled factors that could be solved. A number of alternatives solutions are formulated and are the analysed using KTDA. The final proposed solutions for the problem are [1] Strict Implementation of Funding in Stenciling Process, [2] Additional Penalty Clause for every delayed units and [3] Transferring the Stenciling Process.