A system study on the processed glass division of Republic Asahi Glass

• Main Authors: Catli, Dawn Marie, Chavez, Joseph Lorsen T., Lim, Debbie Joyce
• Format: text
• Language: English
• Published: Animo Repository 2002
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/12086
• Institution: De La Salle University

Executive Summary. This study is concerned with the production department of Processed Glass Division (PGD) of Republic-Asahi Glass Corporation. The problem of the study is: The cutting section incurred an average of 28.51% reject rate, which is 3.51% higher than the desired value of 25%. The problem is both urgent and serious because an additional cost of Php 3,834,132 from June 2000-June 2001 was incurred. Both the management and the proponents of the study believe that sufficient time and resources are available to solve the problem. The problem has the following specifications: WHAT: The average reject rate of glass from June 2000-June 2001 coming from the cutting section exceeded the allowable reject rate by 3.51%. Specifically, scratches and breakage made up 90% of the rejects of the raw glass that was cut in the cutting section. WHERE: the rejects occur in the cutting section of the production area of PGD. WHEN: The excessive reject rate was evident from June 2000-June 2001 base from the data gathered, but it was also happening before this period. HOW MUCH: From June 2000-June 2001, a total of 119,048.55 square meters out of the 417,622.53 square meters of glass fed into the cutting machine turned out to be rejects. The main causes for the scratches and breakages are: 1. PERSON: Carelessness of workers 2. EQUIPMENT: Culler chips accumulated in cutting table and caster wheels 3. EQUIPMENT: Poor condition of bottom support of pallets The following solutions are recommended to partly solve the problem: 1. Use an Industrial vacuum cleaner to clean the cutting table once every 10 loads of glass. 2. Check and clean caster wheels before feeding new load of glass. 3. Support the bottom of the pallet with rubber and tie the glass using nylon strips. The proposed solution is expected to bring about the following: 1. The initial cost of implementation amounting to Php 82,350 and yearly cost of Php 12,825. 2. Net Benefits of Php 5,309,728.70 at the end of the 5th year 3. Qualitative Benefits include good house keeping, proper maintenance of machines and worker involvement. A five-day implementation plan was tested to validate if the proposed system will be effective or not. A decrease of 1.97% in the excess reject rate was achieved after implementation. Full implementation is feasible with in two weeks.