A systems study on the production department of J.F. Rubber Philippines, Inc.

J.F Rubber Philippines is a company that manufactures rubber parts for the automotive and electronics industries. It is located at the People\u27s Technology Complex - Special Economic Zone in Carmona, Cavite. The system study is concerned with the company\u27s production department, more specifically on the products that undergo compression curing. The products identified to have the highest output are the grommets, o-rings, and packings which are all automotive parts used as sealants and coverings for the car or motorcycle\u27s electronic components. The system exceeded its .25% target reject rate for compression by 2.36% during the year 2005. The company has therefore incurred Php9,653,914 in costs of rejects for the whole year. This is found to be the system\u27s main problem. The main types of rejects that affect the products are Air Checks, Flow Cracks, Short Shots, Overtrim, Release Marks, Embedded Flashes and Deformation. After the evaluation of the probable causes, the identified causes for these rejects are Low Mould Temperature, Low Pressure, Improper Handling of Product While Still Hot, Improper Releasing Technique of Operator, Application of Too Much Silicone, Flashes and Foreign Materials in the Mould, Lack of Material Fed Into the Machine, and Operator Errors in Finishing. The proposed solutions include the installation of an alarm system for the machines, man-machine charts with an assignment guide database, a rejects prevention guide, 100% weighing of its products, implementation of statistical process control, and a revision of the system\u27s acceptance sampling method. The computed net present value of the proposed solution is Php12,647,578 while the Php131,095 investment made is recoverable in 0.0318 years. Given these values, it shows that the proposed solutions for the main problem of rejects in grommets, o-rings, and packings are feasible to implement. Finally, when it comes to the implementation period, based on the Gantt chart that was constructed, these solutions can be applied within approximately 5 weeks