A system study on the production system of chocolate factory

• Main Authors: Galindo, Alezander Mikhail O., Nigam, Nisarg, Tan, Sean Bradley M.
• Format: text
• Language: English
• Published: Animo Repository 2020
• Subjects: Chocolate industry—Production control; Root cause analysis; Operations Research, Systems Engineering and Industrial Engineering
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/18670
• Institution: De La Salle University

A plant of Chocolate Factory is unable to meet its order fill rate target of biscuit products and is incurring a loss P 20,106,250 or 80,425 cases for the year of 2018. The main problem occurs due to rejects because of the varying parameters set in the machines along the production line. The objective of this report is to document the current process and identify and address the root causes that lead to the problem in order to provide the host company a method to address said root causes of the system. The rejects occur in the baking and capping process of the biscuit production when the time spent in these machines are excess or lacking, causing overcooked or undercooked bases and underfilled, overfilled or misaligned cookie sandwiches. After a Taguchi Method of Experimentation, the optimized parameters and the time spent in the various machines were identified. A simulation on Arena software verified these results and demonstrated a 10% increase in production. This allows the system to completely meet the order fill rate target, recover the losses, and even gain an additional opportunity profit of P 4,463,750.