Академический Документы
Профессиональный Документы
Культура Документы
Dasmariñas, Cavite
Submitted By:
IEE41
Submitted To:
October 2011
Table of Contents
Title Page.............................................................................................................. i
Chapter 1
Introduction ................................................................................................ 1
Chapter 2
Chapter 3
Chapter 4
Chapter 6
Chapter 7
Attachments ............................................................................................. 39
CHAPTER I
INTRODUCTION
industrial foam insulation and packaging products. The company own 2,500 sqm factory
Paliparan, Dasmariñas, Cavite. It was established in 2003 headed by the President and
cell, polyethylene foam made from extrusion a low density polyethylene resins that is
commonly used for packaging, heat insulation for roof, air-condition ducts, wall and floor
insulation. With over 8 years of experience, the company provide design, engineering
and cost-effective solutions for your manufactured insulation and packaging needs.
Betafoam Corporation has 87 regular working employees with no labor union and
has an 8 hour operation schedules every day. During the rush orders, the workers need
to extend their working hours to accomplish all the supplies that they need to finish.
1
Background of the Study
Betafoam Corporation has been serving the growing market for manufacturing
Polyethylene foam sheet and plastic foam sheet product with compliance to client’s size
packaging process. The focus of this study is in the sealing process where the most
extensive work is identified. There are several factors that affect the production of
plastic foam package in the sealing process, one of the factors that affect the workers is
that they use a non-ergonomically design manual sealing machine, within this process,
the worker exert excessive, repetitive and uneven pressure on the foot pedal in order to
seal the one end of the plastic foam tube, in addition the worker are not following the
safety regulation which one contributing factors to injuries andalso after a series hour of
work in the production line, workers complain for arch pain, leg pain and hand and
footblister. Another factor is that the absence of ventilation in the area. This cause
exhaustion in the workers due to extreme increase of temperature from the sealing
machine, and the air inside does not circulate leaving the odor of methane inside the
production area. Also,the workers sit on a chair that is not ergonomically designed which
is made up of monobloc and reject foam sheet to ease their comfort with result to non-
conformance to the worker height resulting to fatigue due to contorted postures with
This study shall focus on formulating solutions that are ergonomic in concept to
help the workers perform their task better. This also aims to prevent any ailments and
accidents that may occur inside the company. This shall gather all the necessary data to
be able to come up with the best solution and design for the workplace and provide the
2
STATEMENT OF THE PROBLEM
General Objective
Specific Objective
process in plastic production. The researcher only considered one sealing line which is
the sealing line 1 for gathering the data. It also includes the data gathered from the
whole month of January to June 2011 in the sealing process of plastic foam sheet.
3
SIGNIFICANCE OF THE STUDY
To the Students:
The students will have an overview of making plastic foam sheet. It will help
them by providing an additional reference, which they could use in their present or future
research work. Also, they can enhance the ability in analyzing problems in
manufacturing firms and provide solutions that will surely be of great help.
To the Readers:
This may serve as their guide to inform them in the actual operation of a
the study. This will also help the reader to have a preview of what the real situations and
problems exist within the company and how are these solved.
To the Company:
The company may know the problem that they have in their organization and
having an idea on how to have a successful and systematic organization. This study
may serve as a company’s basis in future decision making in improving operations used
in production area at the least possible cost. They will also know the importance of
This study aims to benefit future researchers for basis of making their own study
4
DESIGN AND METHODOLOGY
Interview
department. The researchers interviewed Engr. John Paulo Severino, the production
development manager and asked him some questions about the production. The line
leader and some office personnel of the departmentthat could give us some information
Observations
familiarize the equipments and machineries, and the processes and method used. To
know the cause for being unable to meet the target output. Observations were done on
the company’s facilities to know if they follow on the ergonomic standards. Some of the
workers are having fatigue because of the heat, excessive reaches, poor and awkward
posture. The researchers conducted the study at the sealing area of the company.
Data Gathering
In conducting this study the researchers gathered data were given by the senior
5
study by providing sufficient data for conducting the study. Analysis of the data gathered
DEFINITION OF TERMS
Blisters - Is a small pocket of fluid within the upper layers of the skin, typically caused
Extrusion – It is a process wherein the polyethylene resin and the other ingredients are
Methane - A light, colorless, gaseous, flammable hydrocarbon used for curing Poly
the ingredient monomer ethylene the name comes from the ingredient and not the actual
chemical resulting.
Sealing – It is a process wherein a thin sheet of foam is folded and cut through heated
Resin - A pellet like polyethylene plastic used as the primary ingredient in making
polyethylene foam.
Ventilation - Is the process of changing or replacing air in any space to provide high
indoor air quality i.e. to control temperature, replenish oxygen, or remove moisture,
6
CHAPTER 2
PRODUCTIVITY
TARGET ACTUAL DIFFERENCE
LOSS
7
Computations:
=2,070,000 – 1,928,386
Cost of Loss
Computation of productivity
= (1,928,386/2,070,000) x 100%
Productivity = 93.16 %
=100% – 93.16%
8
TABLE 2.2: Distribution of loss within Six months (January 2011 – June 2011)
Computations:
= 58%
= 20%
9
TABLE 2.3: SUMMARY OF PRODUCTION LOSS DUE TO DELAY
Table 2.4 shows the summary of check sheet of acquired defects in 6 months in
producing the 500mm x 500mm x 1mm plastic foam sheet- white.
10
Table 2.5: Medical Records for the month of January to June 2011
MONTH WEEK CRAMPS BACK & NECK BLISTERS EXHAUSTION HEADACHE FREQUENCY
PAIN
JANUARY WEEK 1 8 4 3 1 1 17
WEEK 2 7 5 1 2 1 16
WEEK 3 5 7 2 1 1 16
WEEK 4 5 8 1 1 1 16
TOTAL 25 24 7 6 4 65
FEBRUARY WEEK 1 4 4 1 1 0 10
WEEK 2 3 2 3 1 1 10
WEEK 3 5 3 1 2 1 12
WEEK 4 6 2 3 2 0 13
TOTAL 18 11 8 6 2 45
MARCH WEEK 1 5 2 3 2 1 13
WEEK 2 4 2 2 1 0 9
WEEK 3 4 3 1 3 1 12
WEEK 4 5 4 2 1 1 13
TOTAL 18 11 8 7 3 47
APRIL WEEK 1 6 5 2 2 2 17
WEEK 2 4 6 3 2 3 18
WEEK 3 3 7 2 1 2 15
WEEK 4 4 5 1 2 3 15
TOTAL 17 23 8 7 10 65
MAY WEEK 1 5 6 1 1 1 14
WEEK 2 5 6 2 1 2 16
WEEK 3 4 6 1 3 2 16
WEEK 4 6 5 2 2 3 18
TOTAL 20 23 6 7 8 64
JUNE WEEK 1 7 3 1 2 0 13
WEEK 2 8 4 1 1 2 16
WEEK 3 6 4 0 1 1 12
WEEK 4 3 7 1 1 0 12
TOTAL 24 18 3 5 3 53
TOTAL 122 110 40 37 30 339
11
30
25
20 Cramps
Back & Neck Pain
15
Blisters
Exhaustion
10
Headache
0
January February March April May June
Graphical Representation of Medical Logbook of ailments by the Clinic Department. Based from
the datagathered, the highest incident of injuries where tabulated in the month of 1st week of
January 2011.
ACTIONS
AILMENTS FREQUENCY PERCENTAGE UNITS AFFECTED TAKEN
REST FOR
CRAMPS 122 35.99 % 29,560 15 MINS
REST FOR
15 MINS
AND
BACK PAIN 110 32.45 % 26,652 SALOMPAS
APPLY
FIRST AID
BLISTERS 40 11.80 % 9,691 TREATMENT
REST FOR
EXHAUSTION 37 10.91% 8,964 30 MINS
INTAKE ANTI
DROWSY
HEADACHE 30 8.85% 7,269 MEDICINE
TOTAL 339 100 % 82,136
12
Table 2.6shows a more specific clinical report of workers in the sealing
department. Shown are the Ailment experienced, frequency and the appropriate action
taken.
44.5
44
43.5
43
Scale in Celsius
42.5
42
41.5
41 TEMPERATURE
40.5
40
39.5
Januray Feruary March April May June
Temperature Inside the Sealing Department area from January to
June 2011
Based from the data gathered, the highest temperature recorded is 44℃ during the month of
January 2011
Table 2.7: Absence Record for the month of January to June 2011
January 5 6 3 3 17
February 7 8 6 9 30
March 8 6 7 8 29
April 3 4 4 5 16
May 4 5 5 4 18
June 8 9 9 7 33
13
Table 2.7 shows the tabulated form of the absences of the employee for the
month of January to June 2011
Figure A Figure B
In Figure A shows the existing chair in the sealing department, since the height
is fixed to the sealing table, therefore the operator bends his legs uncomfortably to fit the
fixed clearance of the table, also, the operator is elasticity stretch over to the table
making it susceptible to back and neck pains when sitting on the for a long time. In
Figure B shows a proposed chair that should be capable to hold out the operator’s
weight up to 320 Lbs., also with a smooth vinyl finish foam cover to avoid slippage and
14
NAME OF OPERATOR TYPE OF HEIGHT OF HEIGHT OF SITTING
CHAIR CHAIR MACHINE HEIGHT
ROBERTO M. MONOBLOC 45 cm 71 cm 70 cm
MENDOZA
MICHAEL C. ORTIZ MONOBLOC 45 cm 71 cm 66 cm
PRODUCTION
Machine
Ventilation
The Table 2.9 above shows the summary computation of the unitsloss due to
ergonomics contribution. The data proves that the use of ineffective sealing machine
shows the highest contribution proving that the operator is always complaining of
occurrence of foot and hand blister that leads to absences, another factor is occurrence
of cramps since the motion is repetitive and excessive discharge of pressure.
15
FIGURE 1: FISHBONE DIAGRAM
Method Man
Excessive
Repetitive Negligence of
Motion Workers
Poor Material (27.72%) (3.42%)
Handling (4.80%)
Awkward
Delay 6.84%
Postures
(22.0%) productivity loss
(18.82%)
in 500mm x
500mm x 1mm
plastic foam
sheet-white.
Absence of Machine
Ventilation Malfunction
(11.46%) (11.78%)
MTS
Environment Machine QC
HFE
Figure 1.0 shows the percentage contribution of Man, Environment, Machine, and Method to the production loss of 500mm x 500mm x 1mm plastic
foam sheet-white. The legend describes the causes that fall under MTS, QC, and HFE. The primary focus of the study is on HFE.
16
WORKING AREA
Figure 2.0
45 cm
Figure 2.0shows the illustration of the current sealing machine that is been using
by the company in their sealing process including the situation of the worker while
performing the task, also the use of a not ergonomically designed mono block chair.
Figure 3.0
17
Figure 3.0shows the illustration of the foot pedal that is needed to be step on
every single sealing process. Excessive pressure on the foot pedal may cause fatigue
Figure 4.0
Figure 4.0shows the illustration of the manual cleaning of the sealing machine to
prevent uneven color and burn ends of PE plastic foam sheet. The worker is not following the
18
Figure 5.0 shows the illustration of the outside and inside appearance of the Plant.
The Plant is designed as a warehouse for curing PE foam Roll. The 1st figure, the red
circle indicates the only entrance and exit to the production plan. Also, the absence of ventilation
In Figure 6 illustrates the existing lay-out of the plant. It shows in the red circle the
two main roll on door which serve as the primary entrance for the raw materials and
finished product, furthermore it also serve the primary ventilation system during
production.
19
CHAPTER 3
ANALYSIS OF DATA
Problem Tree
Causes
500mm x 1 mm Plastic Foam Sheet amounting to Php474,406.90 from the month of January to June
2011.
Effects
20
Causes
The company uses a improvise sealing machine where in the worker exerts
excessive repetitive & uneven pressure on the foot pedal in order to seal the one end of
the plastic tube for packaging customize foam sheet. Since the sealing machine is less
user friendly, after a cycle of hours of work in the production in working, complains for
arch pain, leg pain, fatigue and even potential for injury.
Inconvenient Chair
The workers sit on a chair that is not ergonomically designed which is made up of
monobloc which affects the worker’s productivity. The workers sit on a monobloc chair in
which the workers place rejected foams to ease their comfort while working. The
improper chair in the sealing area only gives the workers pain in the back area. This
Lack of Ventilation
The company has lacks ventilation system. This causes exhaustion in the
workers due to extreme increase of temperature and the air inside does not circulate
leaving the odor of methane inside the production area therefore it can affect the
21
Effects
Opportunity Loss
The company could lose opportunities because of the flaws in their overall
performance. Because of these, the opportunity for them to gain more customers may
reduce. The customers will not be satisfied with the service they receive. They may also
lose their valued customers because of the problems in the service they offer.
Profit loss
production target output in the most efficient way possible. However the company cannot
achieve this with their present sealing machine, non-ergonomically chair and lack of
Customer dissatisfaction
the manufacturing firm will not be able to deliver the products on time because of low
productivity, this delay in the delivery of the products will affect the company’s credibility
22
Objective tree
Means
Ends
23
Means
The company needs to purchasea pneumatic sealing machine in which the effort
to step on the pedal will be removed. Instead in the pneumatic machine there will be a
The researchers saw the need of an ergonomically designed chair in which the
workers will be more comfortable in working and injuries will be eliminated. As we can
The group proposesthat the company must install its ventilation system. Since
the current plant is a former warehouse which is also used for curing the foam sheets
ventilation was not present. With the installation of ventilation system it will reduce the
heat temperature inside the production area in order to have a cool temperature that the
workers will be comfortable at the same time will remove the smell of methane.
24
Ends
Opportunity Gain
the target output to be delivered, customers will be satisfied with the service they
receive. With this the customers may also recommend their company to other firms as a
Increase in profit
If the production loss will be eliminated the company will gain the maximum
possible profit, this will mean an increase in profit from the previous months.
Customer Satisfaction
If the company will be able to match their target output in the exact time as
ordered by the customer, the customer will be satisfied by the service provided by the
25
CHAPTER 4
The old sealing machine requires too much effort and foot strength in order to
accomplish its task. In this situation the workers suffer and experience cramps that
The best solution to this problem is to convert the old sealing machine to a
pneumatic machine wherein the excessive force and effort of stepping on to the pedal
will be removed. The pneumatic machine has a button wherein the workers will only
Advantages:
Convenience of workers
Disadvantages:
Opportunity cost
26
Automated Pneumatic Foam Sealing Machine
Model: Toplink-PPP-1700
Frequency: 50Hz
Power: 3400 W
Origin: China
Source: http://alibaba/industrial_sealing_machine/pneumatic-semiautomated/.com
27
Computations:
Cost:
= 47.79% x 6.84%
= 3.27%
= 3.27% x 13,690
=448 sheets
= PHP 1,500.80 x 12
= PHP 18,009.60
Return of Investment
28
ACA #2:Provide an ergonomically designed chair.
The company uses monobloc chair for the workers to sit on during the sealing
process. From this causes the workers to feel uncomfortable within the long hours of
work they also feel back pains that leads them to absenteeism.
With the new chair which is guaranteed to be an ergonomically fit to the workers ,
also it will feel comfort and remove the pain that they feel with their backs.
Advantages:
Disadvantage:
Additional cost
29
Model:Safco® Mesh Stool Chair FDC-0122-C
Style: mesh breathable vinyl upholster
.Source: http://furniturestocks/industrial/stool/.com
Cost:
Benefit:
= 32.45% x 6.84%
= 2.21%
= 2.21% x 13,690
=303 sheets
= PHP 1,015.05 x 12
30
= PHP 12,180.60
Return of Investment
= 9 months
Since the current plant is lacking of proper ventilation the workplace is obviously
very hot for different operations. In this situation, there is the need for the company to
provide proper ventilation by installing roof turbines and providing industrial exhaust fan.
With the installation of roof turbines and industrial exhaust fan, the workers will
not anymore suffer the heat in the plant and will reduce suffering ailments due to
excessive temperature.
Advantages:
Disadvantage:
31
Industrial Roof Turbines
32
Industrial Exhaust Fan
Model: CFD-Ka001136
Mounting: Wall-type
Blade Material: Plated Stainless Steel
Air Volume: 43,170 CFM
Voltage: 380 V 50Hz 3-Phase AC
Type: Axial Flow Fan
Origin: Japan
Warranty: 10 Years
Price: PHP 22,550
33
a. EXISTING LAYOUT
b. PROPOSED LAYOUT
34
Computations:
Benefit:
= 19.76% x 6.84%
= 1.35%
= 1.35% x 13,690
=185 sheets
= PHP 619.75 x 12
= PHP 7,437
Return of Investment
= 15 Years
35
TABLE 4.1: Cost Benefit Analysis
TANGIBLE INTANGIBLE
36
CHAPTER 5
Conclusion
Generally, the objective of the study is to reduce the productivity loss by 58%
HFE related problems that Betafoam Corporation had experienced in past months of
operation. Each of the ACAs will increase the productivity in the production of plastic
foam sheet if implemented. The implementation of all ACAs will reduce the productivity
loss, provide ergonomical equipments and eliminate injuries in the production of plastic
foam sheet.
Recommendation
Since the major factor that contributes to the production loss is caused by the
conversion into pneumatic sealing machine. This will remove the excessive force that is
needed in stepping to the pedal because the pneumatic machine provides a button that
gives the same operation that the pedal is purposed to do. Other alternatives are also
37
CHAPTER 6
DETAILED PLAN OF ACTION
Planning of the
implementation of
ACAs
Presentation of study
to the company
Consultation to the
production dept.
about matters
regarding machine
implementation
Implementation of
the proposed method
Construction of the
pneumatic sealing
machine
Evaluate of
implemented ACAs
The table above shows the detailed plan of action of the chosen alternative courses of
action. The implementation of the ACAs is projected to be completed within four (4)
weeks.
38