A systems study on the production department of Total Powerbox Solutions, Inc.

• Main Authors: Balagtas, Bryan, Vitanzos, Joel
• Format: text
• Language: English
• Published: Animo Repository 2013
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/10579
• Institution: De La Salle University

The System Study on the Production Department of Total Powebox Solutions Inc. is focused on the documentation and analysis of the manufacturing processes of industrial electrical products, such as control panels, switchgears, and motor control centers. The system includes from the issuance of the job orders to the production line up to the final quality inspection of the products for delivery. The general manufacturing process of the products are as follow: metal fabricating, which includes punching, bending, and welding, painting (powder coating) and dry-off, sub-assembly of wiring and electrical components, final assembly of the enclosure and the components, and final inspection of the products. The data used in the study is within the time period of one year, from January 2012 to December 2012. The study was conducted in Cavite Light Industrial Park (CLIP), Maguyam, Silang, Cavite. After careful assessment and evaluation of the present system, the prevalent problem of the system is the persistent occurrence of production delay of all electrical products from January 2012 to December 2012. The problem statement is as follows: The production system of Total Powerbox Solutions, Inc. exceeded its target delivery lead time by 7.91 days (14 days lead time), incurring a cost of delay of P378,345 for the year 2012. Using pareto analysis, the four (4) major contributors to the production delay are: (1) delayed processing of jobs, (2) delay of Jos in the Quality Control, (3) reworks, and (4) unutilized production capacity as caused by the poor scheduling of jibs and production errors committed. Proposed solutions were generated to address the need to reduce the number of days delayed of jobs, resulting to a decrease in the cost of delay and possibly a decrease in the number of jobs late. The selected solutions are (1) use of LEKIN scheduling software, (2) training on reading technical drawings, manuals, and instructions, (3) checklist of reminders or critical features of the products, (4) addition and redesign of sorting racks for painting, and (5) detachment rack enclosures. The computed NPV of the proposed solutions is P194,987.02. The computed IRR is 200%, which is far greater than the management. The initial investments of P27,914 can be recovered in the first half of the year (6 months). The proposed solutions can be implemented approximately within 8 weeks.