Title

A system study on the Production Department of Jardis Printing Corporation

Date of Publication

2016

Document Type

Bachelor's Thesis

Degree Name

Bachelor of Science in Industrial Engineering

College

Gokongwei College of Engineering

Department/Unit

Industrial Engineering

Thesis Adviser

Dennis E. Cruz

Defense Panel Chair

Eric A. Siy

Defense Panel Member

Julito Ramon Rummel V. Atienza

Abstract/Summary

Jardis Printing Company was founded in year 1983 and is situated at Boni Avenue, Mandaluyong City. It provides printing services such as official receipts, brochures, and creation of packaging materials for various companies.

The study covers the production department of the company from June 2014 to May 2015. It is focused on the production of the job orders and the processes followed therein. A detailed present system was obtained using PRIMEU and all processes included in the study are the cutting section, offset section, varnishing, UV/matt/plastic lamination, die cutting, folding/gluing, stitching, perfect binding, and bindery. A situation appraisal was conducted based on the present system to determine the problems that are occurring in the system. The top problems are that the bindery section of the system exceeded the allowable lost man-hours of 2% by 0.79%, the total rejects incurred is 6.11%, which is above the 3% standard as well. Through the WOT-SURG analysis, it was deduced that the main problem of the system is the quantity of total rejects, which goes beyond the allowable limit. It is defined as the number of non-conforming finished goods in pieces that the system produces. This problem happens on all the months in the study period, and covers 2,084,695 pieces of rejects amounting to Php4,815,624. Those numbers are based from the job orders that exceeded the 3% standard. Meanwhile, the identity of the problem is that it can happen regardless of the defect type such as out of specs, off color, and scum/smear. In addition, the problem on rejects can come from the production of any job order of the customers or from any product category, specifically commercial, packaging, and promotional.

The problem was studied further to identify the root causes that increase total rejects. From the cause analysis and validation, the root causes include too much outflow of ink, trial and error adjustment, loose blanket, unclean machine parts, inconsistent monitoring, overlooked other defects, and wrong mixing of special ink. The first three root causes were grouped together because they all belong to the set-up process and they can all be solved using the same solution.

To solve the problem on rejects, the solutions presented for the proposed system are assigning a supervisor for the setup process, use of ink blotter pads, continuous and acceptance sampling, and performing ink drawdown test. All except the drawdown test incurs an annual cost and all of them can help the system gain an annual benefit. Based from the cost benefit analysis on all of the solutions, the annual benefit amounts to Php1,532,607, the investment cost amount to Php15,134, and the annual cost is Php130,429. The system can greatly benefit from implementing these solutions given that the annual benefit value is far grater than the annual cost value, and it is expected that after 18 days the investment will be profitable. Extensions of the study can be focused on expanding the system scope to encompass other business operations such as purchasing, and logistics. Data can be collected prior to the system being studied to further broaden the analysis of the problem.

Abstract Format

html

Language

English

Format

Print

Accession Number

TU17404

Shelf Location

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

Physical Description

viii, 236, li leaves : illustrations (some color) ; 29 cm.

Keywords

Industrial engineering; Jardis Printing Corporation

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