A systems study on the production of Sony television cabinets of Solid City Industrial and Commercial Corporation

• Main Authors: Ancheta, Maricel Anne A., Cabrera, Josephine Grace M., Cua, Mary Ann Q.
• Format: text
• Language: English
• Published: Animo Repository 1995
• Subjects: System analysis; Television > Equipment and supplies; Systems engineering; Production engineering; Plastics industry and trade; Industrial engineering; Cabinet-work; Engineering
• Online Access: https://animorepository.dlsu.edu.ph/etd_bachelors/9185
• Institution: De La Salle University

Solid City Industrial and Commercial Corporation (SCICC) traces its roots from its mother company, Solid Corporation (SC). It started as a plastics division of SC but decided to span off in 1988 to increase their market. SCICC is engaged in manufacturing industrial products (T.V. and radio cabinets, refrigerator and automotive parts) and commercial products (ballpen caps, tupperware. beercrates). It ventures into the manufacture of export quality plastic casings and components establishing a sterling record of performance and capability in all aspects of plastic molding.SCICC competes in the plastic processing industry. In 1993, SCICC gathered the largest market share, ranking number one in the plastics processing industry, specifically in the production of plastic casings of television cabinets.The study focuses on the production of Sony T.V. cabinets as it constitutes an 80 share of the total T.V. cabinets produced. The study shall concern itself with the Operations Department, as well as its support function groups, namely, the Manufacturing Resource Planning Department (MRPD), the Quality Assurance Department (QAD), and the Engineering and Maintenance Department (EMD). These will be studied in detail in terms of man, machine, materials and methods. After a careful analysis of the weaknesses regarding their respective seriousness, urgency, resources and growth, the problem identified is: SCICC is experiencing an average rework and reject of 1050 unts/mo. and 21 units/mo. respectively for the 14BMX1 and 1184 units/mo. and 32 units/mo. respectively for the 21BMR1 front T.V. cabinets.The problem is caused by the following: poor layout of the Painting Department, poor design of the present jig, lack of training and quality awareness among workers, poor monitoring and controlling procedure, worn-out silk-screen and clogged nozzle of spray gun. The effects of the problem, on the other hand are overtime cost amounting to P 1,358,703.92 per year, opportunity loss of P 856,052.60 per year due to penalty, delivery cost of P 141,000 per year and loss of customer goodwill.To solve the problem of production delay of front T.V. cabinets, the group proposes the following: (1) modification of the present layout of the Painting Department (2) re-designing the present jig used in the painting booth (3) conduct a TQM seminar for top management and workers (4) implement autonomous inspection and post reminders (5) purchase new sil-screens and (6) purchase new spray guns.With the proposed system, a total initial cost of P40,200.00 and a total yearly cost of P294,060.00 will be incurred. Based from the proposed system, however, the company will be able to generate a yearly benefit amounting to P2,252,142.82. With this, the proponents affirm the feasibility and acceptability of the proposed system.In terms of implementation, the run of the proposed solutions will be executed for a period of 9 weeks. Finally, for further studies, it is recommended that future studies be focused on the recalibration of machines and upgrading of molds to minimize, if not to eliminate, the product weight deviation currently experienced by SCICC.