A system study on the switchgear plant operations of Total PowerBox Solutions, Inc.

• Main Authors: Gonzalez, Allison Shelley Lourdes D., Riguera, Raiza R.
• Format: text
• Language: English
• Published: Animo Repository 2019
• Subjects: Electric switchgear industry—Production control; First in, first out (Accounting); Operations Research, Systems Engineering and Industrial Engineering
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/18666
• Institution: De La Salle University

Total Power Box Solutions, Inc. is a sector that provides solutions and products, innovation and high-end engineering services to the communication and energy industry. Total Power Box Solutions, Inc. offers customers a wide range of best value high quality electrical products, such as panelboards and switchgears, at a competitive cost with shorter delivery lead times, efficient technical support and services by closely working with them from the design stage to project completion. For the year 2018, switchgear products generated the greatest number of sales as opposed to panelboards that is why this study would only tackle to plant operations of the nine types of switchgears which begins with receiving of orders up until product delivery and warehousing. A SWOT analysis was done after documentation of the switchgear plant operations to determine any problems within the company. A WOT-SUG analysis was then performed to rank the issues and concerns found. The highest ranked problem that was found is that the finished goods inventory level per month exceeds the monthly allotted by I 14.64% for the months of July to November 2018, incurring an additional cost of Php64,391,539.60 for the year. To further analyze the problem, a why-why analysis was done in order to identify the root causes of the problem. The initial why-why was validated and further reconstructed to form the final why-why diagram or the final analysis of the system. The root causes identified were the use of FIFO as production schedule, and workers unaware whose task it is to talk to clients. Alternative solutions were then generated and a KTDA approach was used to identify which solutions should be selected. The selected solutions are the use of E-Kanban TKS and the use of MRP system such as SAP Business One. E-Kanban IKS would be the solution implemented for the root cause workers unaware whose task it is to talk to clients. The purpose of this is that it gives an automated email to respective departments as well as the client regarding the talus of the switchgear once the e-Kanban card is scanned by the supervisor of that specific process. To implement this solution, an orientation will be given to teach the employee how to make use of the system. The department heads will be the ones in charge of canning the e-kanban cards and the production team will be the ones to input the job orders into the system. The Use of MRP system such as SAP Business One would be implemented to solve the root cause use of FIFO as a production schedule. The purpose of using this system is to eliminate or minimize the products from being made too early. To implement this solution, an orientation will first be given to the production team because they will be in charge of the actual usage of SAP Business One. The production team will be the one to input into the system the job order of the client and the software will generate the bill of materials, master production schedule and the inventory records. These proposed solutions would result in a 95% reduction of the cost incurred due to high finished goods inventory. This would save the company a total amount of Php122,343,925.23 annually. Based on the cost-benefit analysis done the payback period of the proposed system would be 0.004 years or 1.46 days.