A system study on the polyethylene production department of Techno Plas Manufacturing

• Main Author: Go, Michael
• Format: text
• Language: English
• Published: Animo Repository 2001
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/1801
• Institution: De La Salle University

TechnoPlas Manufacturing Company is a registered company producing polymeric package products for wet and dry markets in the Southern parts of Luzon. The study focuses in the production system of the polyethylene products. The problem of the study is the high reject rate. It was found that 3.80% of the total output in the polyethylene department for the year 2000 exceeded the allowable reject rate of 1%. This reject rate amounts to an opportunity loss of P870,954.00. The main causes of high reject rate are short shots and color mixes in extrusion area which comprise of 85% of the total rejects. Further investigation showed the true subcauses. The carelessness of the extrusion operators accounts to 24.4% of the short shots incurred. The use of recycled resin accounts to 60% of the total short shots. The improper settings of extrusion machine parameter accounts to 24.4% of the total short shots. The lose thread of dial pins, malfunctioning of the hydraulic pumps, and uncleaned machine parts accounts for 60% of the total rejects. To address the reject rate, the study proposes to implement the following courses of action: a. The management should impose a penalty for the commission of negligence to the offending operators. b. The extrusion operators should adjust the melting time parameter of the extrusion machine when processing recycled resins. c. The extrusion operators should replace dial pins for all the machines once every two years. d. The system should adopt preventive maintenance by regular checkup and cleaning of vital machine parts especially the dials of the extrusion machines. 3. The plant manager should conduct design of experiments for setting of standard for different product specifications. The solutions are expected to result to the following benefits. The system will gain a net benefit amounting to P 2,590,352 for a period of 5 years. The system will attain qualitative benefits of improved process capability, improved information system, and maintenance system. This implementation of the recommended solution is proposed to start on September for the preparation and on October for the final implementation.