A system study on the production operations of payao ropes in ROTP Manufacturing Company, Inc.

• Main Authors: Aleman, Jerone Loise P., Cruz, Angelo Miguel T., Javier, Anna Patricia A.
• Format: text
• Language: English
• Published: Animo Repository 2019
• Subjects: Rope trade—Production control; Root cause analysis; Operations Research, Systems Engineering and Industrial Engineering
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/18650
• Institution: De La Salle University

A system study was conducted on ROTP Manufacturing Company Inc. They began their production of synthetic ropes and nets in the year 1970, mainly targeting the agri-business sector in the domestic market. The company's main product line is made up of either polyethylene or polypropylene products. The study focuses on the Production Department, particularly in the production of payao ropes, which is under the polypropylene line. The pertinent data used in this study is the period from January 2018 to January 2019. Using SWOT analysis, it was determined that the type 1 payao ropes being produced deviates from the target quality products by 16.4%, gaining an opportunity loss of Php5,553,652.16. To address the problem, the researchers used a why-why diagram as their tool in order to identify all the possible causes of the problem. These causes were then individually validated with the use of available pertinent data, relevant computations, thorough observations. Afterwards, a pareto analysis was generated in order to identify which of the validated causes had the highest contribution to the problem. The root causes identified were, twisted filaments in the bobbins are not twisted properly, which consists of a 37. 71 % contribution to the problem, the production department incorrectly assigned a significant amount of Class A ropes to Class B ropes, with a 28.74% contribution to the problem, and lastly the heat of the oven was not sufficient enough to strengthen the filaments, which consists of 21.03% contribution to the problem. Solution generated for these were, in respective order, increase the time allotted for the twisting of the rope; implement a full inspection methodology in the quality testing method; implement a regular check-up assignment. A cost-benefit analysis was conducted for each proposed solution. In the increase of the time allotted for the twisting or rope, a net benefit of Php2,094,282.23 is obtained. For the implementation of a full inspection methodology in the quality testing method, a net benefit of Php2,151,484.85 is obtained. Lastly for the implementation of a regular check-up assignment, a net benefit of Php1,167,993.00 is obtained. The recommendations given for future studies were to utilize better simulation and sampling techniques, to gain access to data from other relevant departments, as well as to accurate and complete data sets needed to assess the system, and to analyze the effect of purchased raw materials on the quality of the product.