A systems study on the Interpacklaminating Plant of Flexible Packaging Products Corporation

A system study on the Interpack Laminating Plant of Flexible Packaging Products Corporation is a study about the production plant of Interpack Laminating that produces packaging products for companies such as Unilever, URC and Monde Nissin. The study is limited to the production plant. The main problem was found using WOT-SURG analysis which states that the defects occurring in their plant exceeds the standard limit given to them. Overall the company exceeded 1.46% from the allowable limit of 8% or 3,478kg per month, which amounts to Php608.650 per month. Further collection of past data, shadowing and work sampling were done in order to have a more concrete data and information about the defects. In order to solve the problems, the printing machine was thoroughly studied upon and inspected with the help of the plant engineer and the production manager. Following this, help from Fil-Chin Corporation was also sought in order for further consultation about the solutions. KTDA was used in order to determine the best solutions to be used in the company. After which, validation was done to see if the solutions are feasible and capable in solving the problem. Total effectiveness was also computed as some of the solutions overlap and affects each other. Overall, after the solutions are implemented, the defects could be lessened by 22.75% from 22,054 kg to 17,037.15 kg per month, thus, meeting the target defect rate of 8%. Furthermore, in five years net present value was found to be at Php25,579,474.20 in amount of savings which means that the company will regain the investments it made in only 1 year from the implementation of the solution