A system study on the Production Department of Integrated Packaging Corporation

• Main Authors: Carvajal, Anya Vida M., Sy, Ronald Christopher S., Tamayo, Benedict Vincent G., Gobaco, Bryan O., panel chair
• Format: text
• Language: English
• Published: Animo Repository 2014
• Subjects: System analysis; Systems engineering
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/9142
• Institution: De La Salle University

Integrated Packaging Corporation (IPC), incorporated in March 2002, is a company located in Caloocan City. It is a family-owned corporation engaged in manufacturing plastic packaging materials primarily for various food manufacturers. This paper provides an evaluation and analysis of the company's current production system. The system's main objective is to produce quality products for their customers by doing it first time right and deliver it on time. It also has the following specific objectives of attaining the target of complete deliveries as well as on-time deliveries of regular orders to 90%, meeting the machine productivity target of 60% for each process, limiting the wastage during operation to 1%, minimizing machine downtime due to breakdown to a maximum of %, and addressing manpower issues related to workers' absences and tardiness. These are the desired monthly targets of IPC. The SWOT analysis was used in enumerating and elaborating on the significance, urgency, availability of resources , and growth rate of the weaknesses, opportunities and threat of the system. Using WOT-SURG analysis as a means of evaluating these weaknesses, opportunities and threats, results showed that the main problem was the delivery of complete regular job orders deviate by 1.50% for plain and 15.38% for printed from the standard of 90%. Ten main causes to the problem were identified and evaluated using the Pareto analysis lines in plastic (12.39%), bubbles (11.16%), worn-out gearbox (7.79%), misprint (9.20%) coating issue (7.73%), solvent retention (6.27%), failed QA test (5.97%), wrong adhesive length (5.00%), dirt (4.77%), ad printing machine computer failure (4.64%). Alternative solutions were then provided for each cause, and later evaluated using Kepner-Tregoe decision analysis to arrive at the best alternative for each cause. The current work instruction in the laminating process will be revised to eliminate the lines and bubbles in the plastic. For the worn-out gearbox, there would be a transfer of maintenance responsibility to the machine operator. A color pallette allowance range will be requested from the client for better inspection on print discoloration from misprint. As for the coating issue, the machine operator and helper will undergo retraining supervised by the head operator. There will also be visual aids made as guide, as determined by the head operator, and displayed around the laminating work area. In solvent retention, the main complaint was the odor that is emitted by he solvent. Therefore, charcoal will be used to absorb the odor coming from the retained solvent in the final products. More quality check will aslo be performed on the glue before the QA test in the bag making process. For the wrong adhesive length, an emergency stop system will be installed into the bag making machines' computers. Filters will also be installed in the fans and lights inside the factories to eliminate the dirt that accumulate and circulate from them. Finally, an external power technician will be hired to conduct monthly maintenance checks on the power supply of the printing machine to eliminate the machine's computer failure. The proposed solutions should reduce the occurence of the said causes to the problem by 100%. The annual savings produced from the proposed solutions were computed to be Php563,777.36. The net present value for the first five years was also computed to further evaluate the solutions, and amounted to Php2,010,152.18.