A system study on the production of 1 gallon bottles of Infinity Plastic Packaging Concepts Inc.

Date of Publication


Document Type

Bachelor's Thesis

Degree Name

Bachelor of Science in Industrial Engineering

Subject Categories



Gokongwei College of Engineering


Industrial Engineering

Thesis Adviser

Dennis Beng Hui

Defense Panel Chair

Charlle Sy

Defense Panel Member

Emil Fernandez


Infinity Plastic Packaging Concepts Inc. is a company that produces different plastic materials, and this study focuses on their 1-gallon plastic bottles, the product that contributes mostly to the revenue of the company. In the manufacturing process of this product, the company encounters production rejects, which results the company to incur costs. From producing rejects, IPPCI has to network them and turn them into good outputs for customers. The annual cost incurred for this problem amounted to Php1,313,467,05.

The problem was rooted to four different causes, which were (1) flashing, in which the bottles have excess materials that cannot be cut off (2) blackspot, in which the bottles have foreign material in the component of the bottle (3) die line, in which there is a foreign material stuck in the extruder die of the machine used to produce the bottles and, (4) incorrect weight, in which the bottles did not attain the standard range of acceptable weight. Therefore, in line with those four main causes, the solution design proposed included induction training of total productive maintenance, autonomous maintenance, raw material managament and proper segregation of materials.

With the use of historical data and a week of data gathering and observation, the behavior of the production rejects was evaluated. Using the information obtained, the research mimicked this through simulation. The results from this were used to compare the effect of implementing the proposed solutions. Results showed that the implementation of the proposed system would amount to a total investment cost of Php41,550 which would yield to a decrease of reject rate by up to 69.86%. Investing on the suggested proposed solution would yield to a reject rate of 4.18% which is within the allowable reject of 5% which was simulated using the past data of September 2016.

Abstract Format






Accession Number


Shelf Location

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

Physical Description

270 leaves : illustrations (some color) ; 28 cm.


System analysis; Systems engineering

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