A system study on the production of Muhlach ensaymada in the Philippines

Date of Publication


Document Type

Bachelor's Thesis

Degree Name

Bachelor of Science in Industrial Engineering

Subject Categories

Operations Research, Systems Engineering and Industrial Engineering


Gokongwei College of Engineering


Industrial Engineering

Thesis Adviser

Dennis E. Cruz

Defense Panel Chair

Richard C. Li

Defense Panel Member

Willy F. Zalatar


The Muhlach Ensaymada is a company engaged in baking industry with over 40 outlets nationwide, which specializes in manufacturing dairy products including the well-known Muhlach's regular ensaymada. Its sole production facility is located at El Nino Apartment in Cubao, Q.C. The scope of this study will focus only on the daily production of 18 recipes regular ensaymada within 8 hours working time. The key performance indicators in achieving the target output of the production are raw materials availability, daily output of regular ensaymada, rejection percentage and spillage rate, manpower working hours and machine uptime.

For the year 2016, Muhlach ensaymada incurred an average rejection percentage of 5.98%. This deviated from its allowable 2% rejection percentage by 3.98%, equivalent to a total reject of 3 78, 777 pieces. This resulted to a wastage cost of PhP2,093,410.43 for the company. This was considered to be the problem statement of the study.

Upon analysis conducted by the researchers through a series of observations and time studies, it was determined that the root causes that contribute to the rejects of ensaymadas affecting the packaging process include the manual grip of the workers being too tight (contributing to 6.18% of the rejects) and the worker being too fast in packing (contributing to 9.87 % of the rejects). For this cause, the proposed solution is to provide a tool for grabbing the ensaymada. For the baking process, the contributory factors include uneven beat distribution (contributing to 64.45% of the rejects), gauges malfunctioning and limited stock of pans in the facility (contributing to 12.04 % of the rejects). In order to address these problems, changing the oven and the current gauges as well as adding a cooling process for the reuse of pans is considered to be beneficial. Lastly, for the dough rising process, the causes which need to be addressed include machine being old and not having enough grease on the machine (contributing to 4.33 % of the rejects) as well as inaccurate baking scales (contributing to 3.21 % of the rejects). In order to address the aforementioned, ensuring a frequent greasing schedule and maintenance providing markers which are visible on the baking tools as well as posting standard measurements in the work area will cover for these causes.

The length of the time period for this project is seven years in order to determine if the proposed system is profitable in the long run. With these parameters, the net present value is calculated to be Php 8,787,290.80 in seven years, which indicates the value of the company's profit in that time.

Abstract Format






Accession Number


Shelf Location

Archives, The Learning Commons, 12F, Henry Sy Sr. Hall


Bread industry—Production control; Root cause analysis

Embargo Period


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