GROUP 1

IPP AND MONOMER PREP DEPT

BACKGROUND

IPP and Monomer Prep Department is located at the ground floor of the Essilor
Manufacturing Phils Bataan. This is where all monomer product was degassing
and filtered through UDF machine. Every monomer product was already catalyst
and be delivered by the dispatcher to every workshop which were the lenses are
to be mold

STATEMENT OF THE PROBLEM

This study is sought to answer the following question.

 What are the dispatch rate time (minute/barrel) of each UDF machines?

 What are the total actual weight of average number of barrels within
the observe time?

 What are the average observe time for a barrel to reach its full
loaded range in each UDF’s?

 What are the flow rate (kgs/min) of each UDF machines?

 Did the UDF Machines reach its maximum capacity?

CONCLUSION

Red line represents the maximum range of Programming of monomer that UDF
should reach. While the blue line represents the Recent capacity of monomer
barrel per shift.

The data shows shift 6am – 2pm reach its maximum UDF capacity.

The data shows that there is no shift in reaching its maximum UDF capacity.
The data shows that the shift from 6am – 2pm reach its maximum UDF
capacity. Recommendation
 For dispatching barrel to be more efficient, I recommend that
preventive UDF maintenance is better than adjustment of dispatching
personnel because dispatcher only depends on production demand
and UDF itself, but if UDF machine is having fast flow rate it will result
higher productivity
 (GROUP 2)
INDUSTRIAL ENGINEERING – CASE STUDY
Optimization of Man power using Time study for Mahindra HINO Motors
Problem Statement
 The Mahindra organization engages in the production of two product lines: engine
blocks, heads of diverse categories

 The two products have similar production processes

 We discusses the use of Industrial Engineering tools used for the purpose of
productivity improvement

Solution adopted
• The Time Study (Work Measurement)

• According to British Standard Institute Time Study can be defined as “The application
of techniques designed to establish the time for a qualified worker to carry out a
specified job at a defined

• level of performance”.

RESULT
 After the application of Industrial Engineering tool, TIME STUDY ( WORK
MEASUREMENT) they obtained a solution which saves 2-3 man power per cycle.

 Minimized excessive man power

 Minimized the production time

 Improved the production method

 Effort is minimised

 Improvement of ergonomics

 Improved the relation between associates and managements

(GROUP 3)
Desktop bag Philippines
case study of machine failure
Statement of the problem;
 The machineries are too old that it already reaches their limits but the company is still
using it.

 unskilled worker/careless worker

 over heating

 too dangerous/no sensors

  not enough machineries

Objective of the study

 to minimize cost of the company

 To avoid accidents

 to improve the company’s work place for the workers

 to reduce waste or rejects

 to improve company’s productivity

Solution/Recommendation
 use of 5s to maintain the cleanliness of the machine and to avoid accidents

 renewal of machineries

 Proper training for the employees about the usage of machineries

 Provide needed machines

 more fans

Conclusion
 The researcher will conclude by emphasizing that much need emphasis need to be
given to training and development. For the company’s growth and continuous
improvement. Machineries are one of the most important thing in the company without it
nothing will be done, so it needs a better protection from the one who’s using it to
prevent everything that may cause trouble and for the machine to be user friendly.
Instead of using old machines, manufacturing company should buy new or upgrade their
machineries to provide the satisfactory of the employees and to reach the quota and
goal of the company.

(GROUP 4)

Capacity Analysis Aids

a Vehicle Processing Facility
PROJECT SUMMARY
• A major defense contractor retained PMC to perform a capacity analysis study of a
vehicle processing facility. The goal of the project was to allow for evaluation of the
vehicle throughput and processing bay utilization under different operating scenarios.
PMC utilized a discrete event simulation model to meet the project requirements.

SOLUTION
• The SIMUL8 model created by PMC’s simulation team allowed the facility to improve the
layout and design of the facility.

• Simulation was performed on the four scenarios:

 • fixed sequence + fixed inter-arrival times (FSFI)

• random sequence + fixed inter-arrival times (RSFI)

• fixed sequence + random inter-arrival times (FSRI)

• random sequence + random inter-arrival times (RSRI)

• The model illustrated that the 2-bay configuration did not have sufficient capacity to meet
with demand, which prompted the recommendation of increasing to 3 or 4 bays,
depending on the processing modification plan chosen.

(GROUP 5)
Material Flow Study Reveals
Over $4M Potenal Annual
Savings for Automove OEM

PROJECT SUMMARY
• PMC was retained by a major automotive OEM to perform analyses of material flow
within an integrated stamping and sub-assembly plant. The OEM not only wanted
recommendations on proposed bar-coding systems and reallocation of production
personnel, they also required a reliable tool with which to evaluate future proposed
changes to the system.

• Throughout the project, PMC’s team utilized a variety of industrial engineering

techniques. Recommendations were offered, and a custom fit tool was created. Through
use of these instruments, the client’s requirements were met.

SOLUTION
Upon project completion, PMC’s team delivered:
• Headcount reallocations

The plans exceeded the initial goal of 22 operators reallocated

• Simulation models

The analytical tool allowed for quick analysis of material handling resources required by
changing production conditions in the plant from both short-term and long-term changes to the
production schedule
• Bar Code and ID System Analysis

Full alternative, decoupled solutions that could be pursued in sequence or in parallel

(GROUP 6)
 CASE STUDY: REDUCING LABOR
COSTS USING INDUSTRIAL
ENGINEERING TECHNIQUES

The Purpose of a Productivity Audit

Productivity audits are conducted so that productivity improvement activities may be undertaken
and monitored based on statistical data. Accurate data derived from an audit also
makes the following actions possible:
● Determine the target for productivity improvement.
● Select techniques for the introduction and control of the productivity improvement actions.
● Quantitatively forecast the potential for productivity improvement if the chosen techniques are
applied.
● Draft the general plan for the productivity improvement project.
● Promote common “ownership” of the project (throughout the entire organization) based on a
clear understanding of current problems, as disclosed in the audit report.

The audit is conducted in three parts: considering manufacturing methods (methods), work
performance (performance), and application of resources (utilization). These three aspects of any
business unit (abbreviated as MPU) are the three sources of productivity “losses,” meaning levels of
productivity that are lower that what could potentially be achieved. Specifically, we refer to
● Methods losses: excess labor hours or machine time required due to inefficient methods
● Performance losses: losses in potential productivity due to low performance of operators
and/or equipment
● Utilization losses: losses derived from underutilization of labor and/or equipment

RECOMMENDATION

 In the current business environment, there is a never-ending escalation of customer needs;

customers continue to demand improvements in cost, delivery, and quality. Consequently,
in manufacturing situations, a continuous review of how work is done and how it can be
improved is a subject of high priority. Use of new technology and application of automation
and mechanization are indispensable for productivity improvement. However, correctly
evaluating the existing production situation and proceeding to improve it through better
methods and management are also important. To accomplish such activities, the effective
application of IE techniques can play a key role, both in productivity audits and in making
significant productivity improvements.
 (GROUP 7)
Case Study of Printing Industry, Plant Layout for Effective Production
Introduction
Layout planning is the arrangement of industry facilities like machine tools, service departments,
tool rooms or other objects required for the smooth production process

Results from Data Analysis

The capacity of the lift has a capacity of carrying maximum weight up to 2900 kilograms. The
material takes 40.2 seconds to travel from one floor to another.

Conclusion
The model of modified printing floor layout is the most efficient as it has the highest efficiency of
25% when compared to other layout so this model is preferred to others.

(GROUP 8)
HOW TO INCREASE PRODUCTIVITY IN APPAREL INDUSTRY
(FASHION-TECH, MISTE. CHENNAI, INDIA)

MAIN PROBLEM
During the work shift, the operators may not be able to do work on their assigned
task with full efficiency due to various reasons like machine delays, waiting for work, repairs on
doing operations one is not fully trained in, etc. This time is called “off incentive” or “off standard
time”.

CONCLUSION:
To increase the higher productivity in apparel industry must adopt the above mention
applications inside the plan. This implementation are surely increased the constant threat of
higher productivity in the world wide apparel industries.

(GROUP 9)
CASE STUDY: USE SIX SIGMA TO REDUCE TEMPORARY LABOR EXPENSE

Background

Last year a flavors and food additives company in Asia, Amgis, had a surge in
production in one of its product lines (liquids) due to the transfer of production from an affiliate
and, simultaneously, an increase in sales. Because of the strict labor laws and strong union
power in the Asian country, the company was reluctant to hire additional permanent employees
as that could lead to over-employment within its workforce. Asking employees to work overtime
also held little appeal, due to severe penalties related to overtime imposed by the government.
Amgis chose to go with a third option – hiring casual (i.e., temporary) labor to handle additional
production loads when needed. The casual labor market in this locale is predominantly provided
by one third-party service provider that has long had a good relationship with Amgis. This
arrangement was supposed to help maintain the cost-effective use of casual labor by Amgis.
Instead, Amgis was seeing an unreasonably high increase in casual labor cost.
Conclusion

This case study demonstrates the deployment of Six Sigma tools in finance for
improvements in labor costs. The analysis involved four internal stakeholders (local operations,
planning, finance and the regional management team) as well as one external stakeholder. All
data was collected either from the company’s existing workflow system or provided by the
casual labor vendor. Five people actively worked on this project while more than 10 contributed
their time during a period of one month. No additional costs were spent on this improvement
project.

(GROUP 10)
(CASE STUDY - MONEY)
Situation:
The Hawkins Supply company is currently faced with an inventory rotation problem.
This difficulty stems from the fact that some supplies must be used prior to a stated expiration
date. Upon receipt, a new shipment of these perishable items must be stacked beneath the
boxes that are currently in inventory. A substantial amount of time is consumed in restacking
the items according to their expiration dates.

Problem:
The company would like to reduce the double and sometimes triple handling of items.
How can this goal be achieved? Are there alternative solutions which might also be effective?

Solution:
Material monitoring through the methods of:
 6S (Sort, Set-in-order, Sweep, Standardize , Sustain, Safety)
 FIFO
 Proper Handling of materials in the warehouse.

Conclusion:
Through implementing the new methods such as FIFO and 6’S. The Hawkins Supply
company maximizes the use of the materials in the warehouse that result to lessen the
expenses or cost.

Recommendation:
Flow Racks for boxes or pallets.