A systems study on the hot dip galvanizing division of BF Metal Corporation

• Main Authors: Bello, Cecil Joan S., Igot, Cecil Joan S., Villanueva, Michael Joseph Nonatus C.
• Format: text
• Language: English
• Published: Animo Repository 1998
• Subjects: Galvanizing; Metal trade; Metal work; Systems engineering; Engineering
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/7801
• Institution: De La Salle University

This study involves the Production Department of the Hot Dip Galvanizing Division of BF Metal Corporation. In 1996, the company experienced a loss of 675.73, corresponding to P 4,013,836.20 in opportunity losses. The reason for this is that the Production Department was unable to fulfill its objective, to meet the 90% target production level, for 78 out of 308 working days for that year. This can be attributed to technical problems encountered specifically in the production process. This study aims to solve at least 80% of the problem. After conducting a Pareto Analysis, it was found that breakdowns of the crane system and occurrences of low acid concentration make up for 89.72% of the tonnage losses. Crane breakdowns result to 509 MT of lost production, while low acid concentration contributed 97.25 MT to the total losses for 1996. The occurrences of crane breakdowns result to zero production for the days that it occurred. Meanwhile, low acid concentration slows down the acid-dipping process prior to galvanizing, a result of which decreases the production by as much as 31.03%. The group came up with a proposed solution, which involves the use of a remote control system and a Preventive Maintenance program, to resolve the crane breakdowns. The crane breakdowns considered in this study are those caused by breakage of the control cable that controls the multi-directional movement of the crane, and derailing of the crane system. The use of a remote control system will replace the present use of a control cable, thus eliminating the occurrences of control cable to breakage. With the implementation of the Preventive Maintenance (PM) program, it hopes to reduce the occurrences of derailment of the crane system by regular inspection and repair of the ralling system. Likewise, this PM program will also focus on other maintenance aspects of the entire system.