A systems study on the customization unit of Bypro Incorporated

• Main Authors: Pua, Edison L., Santiago, Michelle Victoria V.
• Format: text
• Language: English
• Published: Animo Repository 2010
• Subjects: Production control; Failure analysis (Engineering); Industrial Engineering
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/5267
• Institution: De La Salle University

Bypro Incorporated has been in the industry since 2001 as a service provider to Proctor and Gamble. They are required to meet increasing demand by providing manpower solutions in accordance to the needs of its clients. Recently, they are the company in charge of Proctor and Gamble's Customization Unit.Bypro customizes Proctor and Gamble Products into different packaging depending on the orders of the customers. Depending on how the customers would want their Proctor and Gamble products bundled, Bypro Inc. is willing to deliver their products with high quality and are offered at a competitive price.The documentation of the company was done during the periods of January 2009 - December 2009. Data gathering was done of different parts of the system namely process, raw materials, information, manpower, equipment and its working environment. After documenting and discussing these, the strengths, weaknesses, opportunity and threats (SWOT) were identified.Through an analysis of the current system of the company, it has been rooted out that the system is unable to meet its designed goal as the throughput rate is lacking by 11.38% which would cause the company opportunity loss of PHP 363,030 annually.A cause and effect diagram was used to determine the cause of the problem. Then, a streamline analysis was conducted to see the interlinks of the identified causes. All the causes which affect the throughput rate were determined and classified into Mam, Machine, Material, Method and Environment. From the diagram, the highest contributors of the low throughput rate are changeover time, inefficient planning, equipment breakdown and poor material management.Solutions were presented to be able to correct the identified reasons. Solution aimed at correcting the lack of material and equipment management are issuing containers for sorting purposes, creating a racking map for easier location, requesting additional technician and forklift operators and scheduling preventive maintenance for the equipment. Inefficient planning is corrected by applying a planning program which runs on genetic algorithm.The proposed solution for the company to implement would cost at least PHP 130,500 annually, with a net benefit of PHP 241,966.15. The payback period for the total projects is 5 months and 3 days. The implement of the whole project would take at least 42 days."