A systems study on the production system of Metrocolor Corporation

Date of Publication

2007

Document Type

Bachelor's Thesis

Degree Name

Bachelor of Science in Industrial Engineering

College

Gokongwei College of Engineering

Department/Unit

Industrial and Systems Engineering

Thesis Adviser

Eric A. Siy

Defense Panel Chair

Julito Ramon Rummel V. Atienza

Defense Panel Member

Willy F. Zalatar

Abstract/Summary

Metrocolor Corporation, through 13 years of service, has obtained excellence on product quality and professionalism regarding every transaction which results in customer satisfaction. It provides products that would conform to its customer requirement and to deliver them on time and at competitive price.

The production section of the company currently incurs an average of 53.48% overruns exceeding its 5% limit within the buffer material resulting to a cost of Php. 505,739.36. With the use of WHY-WHY and Pareto Analysis tools, the problem areas to be prioritized were determined along with their root causes namely the number of materials used in offset and Letterpress initial runs. Uneven inking rejects, Misregistration rejects, and Wrong Sequencing rejects-all of which contribute to the overestimation of buffers resulting in unfavorable overruns.

With analysis and experimentation, proposed solutions were made to address the different problem areas. These solutions were the direct supervision of offset initial runs with the supervisor, molding for a fixed numbering machine jig, optimal side-guide settings for paper registry alignment, replacement of roller bearings within the offset printer, resurfacing of offset printer roller, replacement of side-guide, and replacement of all 12 numbering machines.

With the cost-benefit analysis done, the comparison between the total investment costs against the annual benefits resulted to savings of Php. 480,409. Analysis with the use of Net Present Value and Payback Period establishes the solutions to be effective, profitable, and feasible for implementation.

Abstract Format

html

Language

English

Format

Print

Accession Number

TU14416

Shelf Location

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

Physical Description

v, 206, [26] leaves : ill. (some col.) ; 28 cm.

Keywords

Printing industry--Management; Production management; Manufacturing processes; Metrocolor Corporation

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