A system study on the production of flexible packaging products of Kristaflex Enterprises

• Main Authors: Reyes, Angelou J., Martinez, Martina Enrika A., Mendoza, Betina Purita Patricia S.
• Format: text
• Language: English
• Published: Animo Repository 2017
• Subjects: Package goods industry—Production control; Root cause analysis; Operations Research, Systems Engineering and Industrial Engineering
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/18623
• Institution: De La Salle University

Kriskaflex Enterprises is a commercial and industrial supplier. The main source of income is from manufacturing plain and printed packaging materials in the form of plastic (PE, PP, PET PE, NYLON PO, OPP, & CPP), aluminum foil (PET Foil PE, PET Foil, VMPET PE), and paper (Paper Plates, Hotdog Tray, Kikiam Tray, and Baking Cups). Since the company has various production lines, the researchers grouped the production lines into flexible products and paper products. The study mainly focused on the flexible products (which is further classified into basic and complex products) because it has a higher sales -to -production ratio. For the past three quarters, there were 14,058.37 kilograms of internal rejects in the flexible production that led to a total actual cost of 1,446,680.67 pesos. After the researchers analyzed the internal rejects, the problem can be classified into five root causes, namely; (1) the assumptions are usually correct, (2) the mixture is exposed too long in open air, (3) the cylinder guides are ignored, (4) the blade can only scrape up to a certain amount of ink and lastly, (5) the current roll is a reject of the printing process. However, solving the first four root causes aforementioned will eliminate the last root cause. Thus, only the first four root causes are needed to be resolved. To solve these issues, the researchers listed several solutions for each root cause and weighted out the most effective solution with the help of the Kepner-Tregoe Decision Analysis (KTDA). The results were to use document form, use of ink tray cover, use of support device, and periodical inspection of blades. The investment cost amounted to p J 22,300 with an annual disbursement of P 4,800. The computed expected benefit from the proposed solutions was P 1,545,847.49. The solutions were followed by a potential problem analysis wherein preventive actions were created to avoid any potential problems that may rise in the future.