Thesis Archive
A System study on Rivera Filipina, Inc. (2010)
John Vincent R. Aprieto
Enrique Rafhael C. Sanchez
Mari Faith F. Zosa
Abstract:
-RIVERA FILIPINA, INC., a roof tile manufacturing company of more than 30 years, grown into one of the countrys top trading and manufacturing firm of world class roofing systems, wall bricks and floor paving systems. Its mission is toexceed our customers expectations through highly capable and innovative associates trained and committed to excellence, quality and reliability of performance in order to build and strengthen customer relationship; to grow and prosper so we can continue to employ people and contribute to the health and growth of the general economy.
The companys performance is found to be inefficient by 14.54% from the companys target of 90%. Experiencing inefficient system, a loss of PHP 1,827,938.04 was incurred.
Using Why-why diagrams ad Pareto analysis, the root causes of the problem were identified and only the root causes that contributed to 80.46% of the efficiency gap were proposed with solutions. The cause that contribute to 80.46% of the efficiency gap are: sealed roof tiles are stored inside the warehouse for long periods of time, late preparation of production schedules, poor control and monitoring over production processes, poor planning or sequencing of customer orders, and coating mix clogs spray guns after some time of use.
Solutions or alternative were intricately chosen in order to increase the current efficiency of the company. Solutions in terms of man, machine, method, and material were considered. These are: methods improvement through stocking roof tiles right after curing and sealing only when roof tiles are to be delivered, setting guidelines on the preparation of production schedules, acquiring preventive maintenance software, purchasing of an automated roof tile coating machines, developing consistent procedures and guidelines for the installation of moulds and mistake proofing, implementation of tandem CONWIP line system, using visual aids to help sequence customer orders and performing changeovers only after the end of shift, and, lastly, purchasing additional spray guns for each coating booth.
Using simple Cost Benefit Analysis, the cost to be incurred for implementing the solutions as compared to the current loss of company resulted in a total annual net benefit of PHP 1,229,678.43. The solutions were able to solve 76.34% of the problem which resulted in a decrease in the efficiency gap to 11.10% and an increase in the production lines efficiency to 78.90%. All proposed solutions are expected to be feasibly implemented within 4 months time.
Adviser:
Mr. Willy Zalatar