Exas Philippines, Incorporated is a privately owned company by Japanese investor and run and managed by Japanese consultants and experts. It’s main business since the birth of their mother company are METAL STAMPING PRODUCTION (transient or manual and progressive dieset) and TOOL and DIE DESIGNING, PROCESSING and VALIDATION. I belonged in these two production businesses.
Our department receives customers’ product technical drawings. We make tool and die design as basis for quotations then customers feedback for approval for the design price. Then processing follows on metal parts components of the go project(s). Assembly will follow of the processed tool and die. Validation follows to deliver engineering samples based on specifications required. Once the delivered samples are approved in their line assembly, mass production will follow at our metal stamping production area.
Today, Exas Philippines has been adopting several methods and techniques to add and improve its methods of productivity and quality that is far better than existing technology. This development however, fully sustained daily activities that affect daily production output of the manufacturing industry including transportation. In fact, the effect of certain method and process shows as one of the largest components that helps the company to be more competitive in the market today. Within it, this methods and innovation plays a main role in satisfying customer demand developing trust and confidence among others.
One known product that this company produced is MAIN PLATE, a metal stamped part that serves as the major component of digital camera to be assembled in Pentax Philippines, one known customer of ours. Among other parts suppliers, Exas Philippines remains one of its biggest and trusted plastic molding and metal stamped parts supplier for almost a decade. Trust and confidence we did to sustained and keep for future partnership ahead. In this matter, some market, somehow develop a unique and effective process approach in all its product and services. In such, inquiring new and state of the art tools and machineries, successful management program and improved process which could allure investors and potential customers in general.
Moreover, products and services providers in an open market like us, need to innovate and enhance operation to the maximum utilization of resources and cost to be more competitive, especially commercial value of our products and services were greatly controlled and dictated by our customers. Where at point, it is a need for the manufacturing industry to forecast total profit prior to producing or launching a certain project through extensive process evaluation and analysis of every aspect of manufacturing and somehow build and innovate unique and well-develop processes.
Since main plate manufacturing process and cost involves values need to be considered and improved, moreover, it has the longest and overmanned process to date as evidenced by the results of the operation production and delivery during the first two months. And with the company’s aim for “ Continuous Improvement” and “Process Optimization”, the researcher conducted this study for possible remedies and measure which has to be developed to improve this poor performance process operation.
THE PROBLEM AND ITS SCOPE
II STATEMENT OF THE PROBLEM
The study helps to improve the present methods to be more efficient and productive. Thus, it is the goal to optimize production output of Main Plate. The study conducted specifically and systematically to provide answer to the following:
1) Are the present methods or set up efficient in terms of the following? 1) Process lay-out activities evident for cheaper and safer process. 2) Process flow chart implemented specifies steps required in terms of lay-out cost. 2) Can the material be improved for cost analysis?
2) Material kind
3) Material rejection or scrappage
3) Is the manpower available sufficient enough?
1) Manpower vs. Process lay-out
2) Manpower vs. Machines
3) Man-hours requirement vs. Production plan
4) Machineries and fixtures fully utilized?
1) Press stamping machine utilization per day
2) Bench drill for chamfering and tool bits utilization
3) Pneumatic tool grinder, cutting and polishing tools utilization
4) Degreasing Machine Utilization
b) What would be the proposal to modify or improve the high cost of production of Main Plate in terms of ? b.1) Labor cost b.2) Machine and Equipment set up c) How would modification of the process benefits the company, the department, the employees, the valued customer as well as the researcher?
II SIGNIFICANCE OF THE STUDY
The study helps the company understand the nature and true cost of work and reducing unnecessary costs, and balancing processes in the line to make work flow smoother. It also helps the company to be more competitive in an open market, highly productive and profitable in return. Also using effective techniques that will enhance processing time will eventually increases productivity with less cost, less manpower and man-hour requirements. This study serves as the guidelines for the manufacturing department to determine man and machine effective planning, established time and motion standards to improve production planning and material preparation in general.
It will also provide relevant information in settling financial statement, resource allocation and product estimating cost and value. For the employees, it will boost their morale for work since there is that proper division of work load, improve their working conditions and environment. This will also benefit me since I learn time and motion study from this project. I could apply this at my working section, at my home as learning for my family for time management for better results. To the company’s valued customers and business partners, the assurance of on-time deliveries with satisfying high quality product is highly guaranteed.
Scope and Limitation:
The study conducted by the researcher is focusing mainly on ten (10) different processes involve in producing MAIN PLATE product. The following are the processes: 1) Blanking 6) Flattener 2 2) Piercing 7) Tapping 3) Chamfering 8) Degreasing 4) Flattener 1 9) Visual Checking 5) Polishing 10) Final Packing The entire processing of the product is the main scope of the project where most of the critical problems has been found and identified. The primary targets of the research are to established standard time and methods to be followed in the processing of the said product as well as to improve productivity and reduce manufacturing cost.
The project involves considerable cost . Some of them involve a large number of activities which must be carefully planned and coordinated. There are few which can be completed on time, cost and performance targets. Furthermore, another aim of the study is to determine how profitable are the new and improved methods established by the researcher.
Courtney from Study Moose
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