A system study on Fortune Lighting Inc.

• Main Authors: Ang, Tomas, Cheung, Kenneth, Tan, Jimson
• Format: text
• Language: English
• Published: Animo Repository 1996
• Subjects: System analysis; Production control; Electric lamps, Incandescent; Fortune Lighting, Inc; x3 Light bulbs; Engineering
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/9169
• Institution: De La Salle University

Fortune Lighting, Inc. is a new company in the Philippines that engaged in the manufacture light bulbs. Presently, Fortune is experiencing downtime in one of its most important machine, the mounting machine. It is in this machine where most of the important and critical activities take place. For the past years of operation the mounting machines of FLI is experiencing a total downtime of 386.825 hours per month which translated to an opportunity loss of P2,794,078 per month.In line with this the group conducted a thorough investigation with the aid of a Maintenance Worksheet on the possible causes of the downtime of mounting machine. Through this investigation the proponents were able to come up with 9 major causes of the problem of downtime of mounting machines. After further observations, interviews, data acquisition the group was able to establish 4 final causes of the downtime of mounting machine as presented in the Problem Analysis part. These are: Power Failure (17.18), Defective Output (38.60), Filament Defect (11.41), and Blower Malfunction (13.50).With this group derived several alternatives to solve the problem of mounting machine downtime. These alternatives were then validated using the Kepner-Tregoe Decision Analysis. It was noted that for the power failure problem the best alternative was to retain the old generator set and buy an additional one with a capacity of 150 KVA. Then for the defective output, blower malfunction, and filament defect the group proposes that a Total Productive Maintenance Program be implemented by Fortune to be able to eliminate the problem of downtime of mounting machine. This Total Productive Maintenance program shall include 5 major activities. The first activity is the establishment of the basic equipment condition. Second, the company has to adhere to the usage condition of the equipment. Third, the deteriorated parts must be restored immediately so that there will be no further destruction and interruption of production operation. Fourth, the design weaknesses must be corrected in order to promote the elimination of downtime of mounting machine. Lastly, the skill of the maintenance personnel and equipment operators must be enhanced to effectively carry out this Total Productive Maintenance Program. Aside from this the TPM program also include an autonomous maintenance program which shall address the cooperation and participation of the equipment operators in an attempt to eliminate the downtime of mounting machine and in turn the utilization of the equipment shall be enhanced. This program requires the overall participation of all people in the plant for it to be carrired out successfully. Preventive maintenance is not just the job of the maintenance department but it must also be the responsibility of the equipment operators and company's top management. Another feature of this TPM program is the preventive maintenance schedule derive using QR tools. This preventive maintenance schedule shall serve as a time calendar for carrying out the maintenance work. Finally, it also included certain forms which will be used for evaluation and feedback purposes. After the proposed system the group came up with a Cost-Benefit analysis to see if their proposed system is feasible or not in terms of quantitative and qualitative aspect. The computed net present value for 1 year of implementation is P 7,959,792.81. This means that the proposed system is feasible and could be adopted by the company if they wanted to reduced if not eliminate the downtime of mounting machines.