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College of Engineering

ENGR-3210
ENG’G MANAGEMENT
SAFETY AND HEALTH
WRITTEN REPORT #2

Submitted By:
Aquino, Danica Rose
Dela Cruz, Queenzelle Grace
Lazaro, Catherine
Revadulla, Kaira Jayne

BSCE 2-4

Submitted To:
Engr. Roy Searca Jose P. Dela Cruz
INSTRUCTOR
Report 2: Technical Plan

Royal Green Roof Company


(ROGROCO)

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I. Technology/Process Associated With The Business

a. Production Process
e-Solar Roof tiles are an integrated photovoltaic (PV) building product, which means they
directly generate electricity from sunlight. They are made with specific materials that
naturally undergo an electronic process in the presence of sunlight. They are made to look
like a normal asphalt shingle. Essentially a small-scale version of solar panels, the solar
shingle was infused with copper indium gallium (di)selenide (CIGS), allowing the thin-film
solar cells to reach a conversion efficiency of 19.9 percent – just 0.4 away from the
maximum output of the standard solar panel. To achieve these, the following process was
used in producing the solar roof tiles.

1. Tempered glass (2mm thickness) from a certain supplier will be cut into the required
size for the roof tile. It will be washed with a glass-cleaning machine to avoid
impurities after the cutting process.
2. The tempered glass will need to be dried for 30 minutes after cleaning.
3. Crystalline solar cells that will served as the solar energy collector of the roof tile will
be cohered with the tempered glass.
4. Two cut sheets of tempered glass will be used to protect the crystalline solar cells.
One for the upper part and another one for the bottom part.
5. An anti-reflective coating (AR) will be layered to the roof tile before the tempered
glass is put. It helps reduce the amount of reflected light and increases the percentage
of absorbed sunlight from solar photovoltaic cells by 2.5%.
6. Wires that are needed to be connected to the battery storage (Royal Power) will be
installed to the crystalline solar cell before laminating it with the tempered glass.
7. In cohering the solar cell with the tempered glass, we will be using a glass lamination
machine to avoid breakage.
8. The finish product will be stored in a room with a temperature not below 0 degree
Celsius and not above 70 degree Celsius.
On the other hand, the non-solar roof tiles will be manufactured using the following process:
1. We collect decent amount of plastic from a local junkshop nearby, and asphalt residue
will be used as a substitute for sand.
2. Asphalt residue must be fine before mixing it to the shredded plastic. A grinder is
needed.
3. A plastic shredder is required to chop the plastic into small pieces. We will be using a
Plastic Extruder that will mix and melt the plastic, and combine it with the asphalt
residue.
4. After shredding the plastic, 70% of it and 30% of asphalt residue will be mixed.
5. We will pour it inside the extruder. The extruder will do its job and a molten mixture
of asphalt residue and plastic will be produced right after.

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6. A molder will be used then to shape out the roof tile in the desired style. Within 10
minutes, the roofing tiles will be ready.
7. A group of workers will be assigned to clean the recycled roof tiles to make it more
presentable in the market.

 Product Design

The product design of e-Solar Roof Tile


includes two layers of tempered glass (2 mm
thick), the crystalline solar cell, an anti-
reflective coating layer, and another layer of
tempered glass at the bottom. Tempered
glass are used to protect the crystalline solar
cell. Each e-Solar Roof tile is connected to
the solar roof wiring string via standard solar
MC connectors that come pre-installed from
the factory. These strings then connect down
through the roof via series of electrical
pucks mounted and sealed to the roof. From
there, the wiring configuration varies depending on whether Royal Power batteries are
being installed or not. Since we haven’t fully developed the Royal Power battery, buyers
are given options whether to purchase e-Solar roof tiles with the Royal Power battery or
without. They can buy a battery in other battery stores.
Meanwhile, the non-solar roof tile is produced the same size as the e-Solar Roof tiles.
The only difference is that non-solar roof tiles doesn’t contain solar cells, but are made of
recycled materials. The manufacturing team will ensure that they will both look like each
other despite the differences in the process and materials used.
 Production Schedule
ROGROCO aims to create 100-200 roof tiles per day and an estimate of 700-1400 roof
tiles will be produced

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 Quality Management
ROGROCO e-Solar Roof Tiles are consistently tested for quality consistency in both
our own laboratories and independent testing stations. Roof tiles from every batch
produced every day are picked at random and tested to ensure our quality standards
are met in a series of measures.
Concentrated Loading
Concentrated force on roofing tiles was tested to ensure that tiles will not break out if
there is anything with heavy weight fall on it.
Weather Security
High Speed Dynamic Rain Penetration and High Wind loading Tests was done to
secure the strength of the roof tile during calamities.

b. MATERIALS HANDLING DESIGN


 Construction Phase
• All of the materials needed will be supplied by our different suppliers around the
Philippines.
 Production Phase

• All of the materials needed in this project are commercially available here in the
Philippines.
• Report on Stock Availability
Every stock keeping unit has an individual code and a corresponding to a specific
subclass from a given drawer.
• Packaging
The company will be using two different packaging for e-Solar and non-solar
(recyclable) roofing tiles.
• Configuring and Managing Warehouses
The company will be assigning one employee for configuring and managing
warehouses.
• Security
We will also hiring some personnel for the safety of the company, especially for
the safety of our employees.

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 Processing Phase
• The materials, equipment and machineries and also the manufactured products
will be delivered via land transportation using a delivery truck.
• Proximity to market

We will build the ROGROCO office and factory along Bantug, Science City of Muñoz.

 Equipment requirements

 Glass Cutting Machine


 Glass Cleaning Machine
 Glass Laminating Machine
 Asphalt Milling Machine
 Plastic Shredder
 Plastic Extruder
 Roof Molder

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c. RAW MATERIAL REQUIREMENT
 Construction Phase
• The roof tile factory will be constructed by a trusted construction firm. The
materials and equipment used for the construction will be provided by the firm.
But the roofing materials specifically the roof tiles will be provided by
ROGROCO. We will be using our own product in the manufacturing area and
offices to take advantage of its good impact to the environment. Also, to save
energy for future purposes, i.e. in the manufacturing process.
 Operation/Processing Phase
• Tempered glass (2 mm thick) will be supplied by a certain supplier. Crystalline
Solar Cell and anti-reflective coating will be supplied, as well. Equipment and
machineries will be purchased outside the country specifically in Japan to ensure
that the machineries will last long.

d. MANPOWER REQUIREMENT
 Construction Phase
• A Project Manager is needed to lead the construction project, as well as a Site
Engineer. The foreman, mason, carpenters, electrician, plumber and technicians
are already included in the construction firm of the site engineer.
 Operation/Processing Phase
• Service Manager, Bookkeeper/Accountant are needed in the main office of
ROGROCO. An electrician is also needed to have someone to check the e-Solar
Roof tile and maintain its good condition.
• On the other hand, ROGROCO roof factory needs a lot of manpower despite
having machines/equipment to manufacture the roof tiles. Fifty (50)
manufacturing workers are needed in the factory. Five (5) technicians/electricians
in the laboratory area to test the effectiveness of the e-Solar Roof tiles. We also
need another five (5) drivers that would supply the products to different stores,
and to homeowners that would directly purchase to us.
e. WASTE DISPOSAL METHOD
Recycling
Since ROGROCO uses recycled materials for the production of the roof tiles that are
non-solar, we highly recommend this type of disposal method. Recycling is the most
environmental friendly method because it doesn’t add any waste materials. The
excess/waste will undergo recycling using a machine after the manufacturing date of the
product.

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ROGROCO uses 20 machines that are ushered in a new era in Municipal Solid Waste
processing & recycling, as well as electricity generation. No more burning, no more
crippling costs. Each machine handles up to 1,000 tons per day, with no burning of waste,
and is verified 100% emission-free and able to generate over 65mwh of electricity. Costs
related to recycling, storage, transportation and processing have been dramatically
reduced.
ROGROCO is very particular with being the “greenest” company. Thus, even in the
waste disposal shall we generate electric energy for manufacturing purposes.

f. PROJECT SITE
 Climate
• The area is not prone to flood.
 Transportation and facilities
• Transportation is via land using delivery trucks.
 Site
Address: Bantug, Science City of Muñoz, Nueva Ecija
• Topography: Flat Area
• Paved and Concreted Roads

 Cost Estimates For Site Acquisition and Preparation

Item Description Qty Unit Cost

Land /ha P100k-10M

Legal Expenses P500K-1M

Tenant Right P50K-P100K

Road Construction /100M P800k -1.5M

Fencing l.m. P50.00-5K

Earthworks /m3 P150-P1000

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g. PROJECT LAYOUT

 Building and Surroundings


 ROGROCO’s store distributor measures 15 x 10 sq.m to be placed at Bantug,
Science City of Muñoz, Nueva Ecija, and the factory building of the company
measures 60 x 50 sq.m to be located at Bical, Science City of Munoz, Nueva
Ecija.
 Cost of Site Preparation, Construction and Improvements
o Estimated Land Cost
 P2,000.00/sq.m
o Store building lot cost 15x10 sq.m = P300,000.00
o Factory building lot cost 60x50 = P6,000,000.00

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 Elevation/Floor Plan
ROGROCO’s Main Store/Office

ROGROCO’s Roof Tile Factory

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h. MACHINERIES AND EQUIPMENT
 Production
• Glass cutting machine is use to cut the tempered glass into the standard size of e-
Solar roof tile.
• Glass cleaning machine is use to clean the tempered glass.
• Glass laminating machine is use to cohere the tempered glass with the
crystalline solar cell.
• Plastic shreddert is used for shredding the plastic materials.
• Plastic extruder is used for melting and forming the plastic materials.
• Asphalt Milling Machine is used to grind asphalt residue
• Roof molder is used to create shape to the roof tile that is identical to other e-
Solar roof tile style.

 Auxiliary
• Delivery truck
• Hydraulic system
• Electric system
 Service Equipment’s
• Computers, telephone
• Office tables and chairs
• Safety, firefighting equipment, medical equipment
i. UTILITIES
 Electricity
• Public/Private Utilities, Renewable (Solar)
 Communication
• Telephones/Mobile/Internet

j. PERMITS, TAX AND LICENSES


These permits and licenses are necessary for the operation of the company
 GENERAL BUSINESS LICENSE AND BASIC OPERATION LICENSE
This certifies that the business complies with the general business and basic operation
requirements.
 SAFETY PERMIT
This certifies that the business followed the safety precautions.

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 MAYOR’S PERMIT
This certifies that the business complies with the ordinances under the city where the
company is located.
 FIRE DEPARTMENT PERMIT
This clearance will let the city/Municipal Fire department will either approve or
disapprove the evaluated plans together with the Fire Safety Checklist (FSC) and Fire
Safety Evaluation Clearance.
 ENVIRONMENTAL PERMIT
 BUILDING OR CONSTRUCTION PERMIT
 PROFESSIONAL / OCCUPATIONAL LICENSE
 HEALTH PERMIT
 SANITARY PERMIT
 CERTIFICATE OF REGISTRATION
 BIR LOOSE-LEAF APPLICATION
 SALES TAX PERMIT
 PAYMENT SYSTEM
 SSS, PHILHEALTH, PAG-IBIG REGISTRATION

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