A STUDY ON REDUCING THE 6.

84% PRODUCTIVITY LOSS IN MANUFACTURING

500mm X 500mm X 1mm PLASTIC FOAM SHEET- WHITE IN THE SEALING

PROCESS OF BETAFOAM CORPORATION.

A HFE study presented to the faculty of the

College of Engineering Architecture and Technology

De La Salle University – Dasmariňas

Dasmariñas, Cavite

In partial fulfillment of the

Requirements in Human Factor Engineering

Submitted By:

Bañares, Mark Gil D.

Castañarez, Francis Dwayne F.

Pascual, Philip Jeffrey P.

IEE41

Submitted To:

Engr. Ma. Lourdes H. Parcero

October 2011
Table of Contents

Title Page.............................................................................................................. i

Table of Contents ............................................................................................... ii

Chapter 1

Introduction ................................................................................................ 1

Background of the Study............................................................................ 2

Statement of the Problem .......................................................................... 3

Objective of the Study ................................................................................ 3

Scope and Limitation ................................................................................. 3

Significance of the Study ........................................................................... 4

Design Methodology .................................................................................. 5

Definition of Terms ..................................................................................... 6

Chapter 2

Presentation of Gathered Data .................................................................. 7

Chapter 3

Problem Tree ........................................................................................... 19

Objective Tree ......................................................................................... 22

Chapter 4

Alternative Courses of Action................................................................... 26

Chapter 5

Conclusion and Recommendation ........................................................... 37

Chapter 6

Detailed Plan of Action............................................................................. 38

Chapter 7

Attachments ............................................................................................. 39
 CHAPTER I

INTRODUCTION

Betafoam Corporation is a leading fabricator and distributor of commercial and

industrial foam insulation and packaging products. The company own 2,500 sqm factory

and warehouse strategically located in Dasmariñas Technopark, Governor’s Drive

Paliparan, Dasmariñas, Cavite. It was established in 2003 headed by the President and

CEO Ferdinand Y. Marañon.

Betafoam Corporation is specialized on manufacturing a non-cross linked, closed

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.

Betafoam continues to add new insulation and packaging solutions to provide

better value quality products to its customers.

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

specification. Betafoam Corporation has several processes in its production area. It

includes extrusion, laminating, skewing, sealing, cutting, quality inspection and

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

increase physical stress on the body.

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

workers more comfort while performing their specific job.

2
STATEMENT OF THE PROBLEM

Betafoam Corporation is experiencing 6.84 % productivity loss in manufacturing

500mm x 500mm x 1 mm Plastic Foam Sheet amounting to Php474,406.90 from the

month of January to June 2011.

OBJECTIVES OF THE STUDY

General Objective

To reduce productivity loss by 58 % HFE related problems amounting to

PHP275,155.60 in manufacturing 500mm x 500mm x 1 mm Plastic Foam Sheet.

Specific Objective

 To increase productivity within the sealing process

 To reduce ergonomic-related injuries experienced by the workers

 To provide necessary equipment that fit the work and worker

SCOPE AND LIMITATIONS

This study focused on the production department specifically in the sealing

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

manufacturing/production company and to utilize their technical knowledge relative to

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

employee’s role in the company.

To the Future Researchers:

This study aims to benefit future researchers for basis of making their own study

or improving the said topic

4
DESIGN AND METHODOLOGY

Interview

The researcher conducted interviews to selected people under the production

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

and insights were also interviewed regarding the problem.

Some questions that were asked:

 How many workers the do you have?

 Are the operators experiencing fatigue on their work?

 What is the target output of the company per day?

 In how much do you sell the product?

Observations

Observations were done on the company’s production area, gathering of data;

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

process development engineer of production department for immediate purpose of this

5
study by providing sufficient data for conducting the study. Analysis of the data gathered

by the researcher is within thesealing area of the production department

DEFINITION OF TERMS

Arch Pain- Inflammation or burning sensation on the arch foot.

Blisters - Is a small pocket of fluid within the upper layers of the skin, typically caused

by forceful rubbing (friction), burning, freezing, chemical exposure or infection.

Extrusion – It is a process wherein the polyethylene resin and the other ingredients are

processed to form polyethylene foam.

Methane - A light, colorless, gaseous, flammable hydrocarbon used for curing Poly

Ethylene Foam sheet

Packing - A term for sealing a material.

Polyethylene - Thermoplastic polymer consisting of long chains produced by combing

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

wire to form container bags.

Stool- A backless and armless single seat supported on legs or a pedestal.

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,

odors, smoke, heat, dust, airborne bacteria, and carbon dioxide.

6
 CHAPTER 2

PRESENTATION OF GATHERED DATA

TABLE 2.1: SUMMARY OF PRODUCTIVITY AND PRODUCTIVITY LOSS

TARGET ACTUAL PRODUCTIVITY

MONTH OUTPUT OUTPUT VARIANCE PRODUCTIVITY LOSS

January 345,000 323,756 21,244 93.84 % 6.16 %

February 345,000 317,735 27,265 92.10 % 7.90 %

March 345,000 319,378 25,622 92.57 % 7.43 %

April 345,000 321,605 23,395 93.22 % 6.78 %

May 345,000 322,701 22,299 93.54 % 6.46 %

June 345,000 323,211 21,789 93.68 % 6.32 %

TOTAL 2,070,000 1,928,386 141,614 93.16 % 6.84 %

PRODUCTIVITY
TARGET ACTUAL DIFFERENCE
LOSS

TOTAL 2,070,000 1,928,386 141,614

6.84 %
AVERAGE 345,000 321,398 23,602

Source: Sealing Department as of January to June 2011

7
Computations:

Number of workers: 87 workers

Numbers of Worker in the Sealing Process: 2

Working hours per day: 8hrs

Average Output per day: 17,250 pieces

Target Output: 2,070,000 pieces/ in 6 months

Actual Output: 1,928,386 pieces/ in 6 months

Amount of Productivity Loss

=target output – actual output

=2,070,000 – 1,928,386

Amount of Loss = 141,614 pieces

Cost of Loss

= (amount of loss x cost of product)

= 141,614 pieces x Php3.35per piece

Cost of Loss = Php474,406.90

Computation of productivity

= (actual output/target output) x 100%

= (1,928,386/2,070,000) x 100%

Productivity = 93.16 %

Computation of productivity loss

=100% – 93.16%

Productivity Loss= 6.84 %

8
 TABLE 2.2: Distribution of loss within Six months (January 2011 – June 2011)

DISTRIBUTION PROFIT LOSS

PROCESS TARGET PRODUCED DIFFERENCE OF LOSS

Loading of Plastic Foam Roll

Tube 345 rolls 345 rolls 0 0% 0

Cutting of Plastic Foam Roll

Tube 2,070,000 2,038,845 31,155 22 % Php104,369.25

Sealing of Plastic Foam

Sheet 2,038,845 1,956,709 82,136 58 % Php275,155.60

Quality Inspection 1,956,709 1,928,386 28,323 20 % Php94,882.05

Packaging 3,856 packs 3,856 packs 0 0% 0

Computations:

Cutting of Plastic Foam Roll Tube Distribution of Loss = 31,155/141,614 = 22 %

Sealing of Plastic Foam Sheet Distribution of Loss = 82,136/141,614

= 58%

Quality Inspection = 28,323/141,164

= 20%

Number of sheets produce in 1 roll = 6000 sheets

9
TABLE 2.3: SUMMARY OF PRODUCTION LOSS DUE TO DELAY

Process Standard Time Actual Time Percentage Units Affected

(in mins) (in mins)
Loading 1.45 1.43 0 0
Cutting 5.45 6.57 21.99 % 31,155
Sealing 2.3 2.4 0 0
Quality Control 2.2 2.1 0 0
Packaging 2.51 2.71 0 0
Total 13.91 15.29 21.99 % 31,155
Table 2.3 is a comparison between the Standard and Actual time in producing 500mm X
500mm X 1mm PLASTIC FOAM SHEET- WHITE. The company is experiencing delay in the
cutting sections. The Cutting section contributed the largest percentage of Delay.

TABLE 2.4: SUMMARY OF DEFECTS

Causes Defects Total Unit of % Contribution

Defects
Machine Burn Seal 8,695 30.7%
Malfunction Lack of Seal 7,987 28.2%
(Machine)
Negligence of Out of Tolerance 4,843 17.1%
Workers (Man)
Poor Material Scratch 4,107 14.5%
Handling (Method) Dent 2,691 9.5%
TOTAL 28,323 100%

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

Source: Clinic Department’s Record of ailments Logbook as of June 2011

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.

TABLE 2.6: Summary of Units Affected due to Ailments

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

Graphical Representation of Temperature recorded inside the Production Department.

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

Summary of absences for the month of January to June 2011

MONTH Week 1 Week 2 Week 3 Week 4 Total

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

Table 2.8: Sitting Specifications and Measures

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

furthermore, it is built with an manual pneumatic for adjustable height perpendicular to

the height of the sealing machine

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

ROGER T. SANCHEZ MONOBLOC 45 cm 71 cm 65 cm

MARIO L. CHAVEZ MONOBLOC 45 cm 71 cm 71 cm

Table 2.9: Summary of Units Affected contributed by HFE

PRODUCTION

CAUSES UNITS AFFECTED % CONTRIBUTION LOSS

Ineffective Sealing 39,251 47.79%

Machine

Inconvenient Chair 26,652 32.45% 82,136

Absence of 16,233 19.76%

Ventilation

Total contribution of HFE 58%

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

and foot blister

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

safety regulation of wearing safety gloves.

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

system causes an extreme increase of temperature inside the company.

FIGURE 6: EXISTING PLANT LAYOUT:

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

Ineffective Inconvenient Chair Lack of Ventilation

Machine Foot
Pedal

Betafoam Corporation is experiencing 6.84 % productivity loss in manufacturing 500mm x

500mm x 1 mm Plastic Foam Sheet amounting to Php474,406.90 from the month of January to June

2011.

Effects

Opportunity loss Profit loss Customer

Dissatisfaction

20
Causes

Ineffective Machine Foot Pedal

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

discomfort and stresses their muscles and causes them strains.

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

efficiency of the worker, stamina, energy and other factors.

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

The Company’s main interest is to earn maximum profit by achieving their

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

ventilation that causes them to lose profit.

Customer dissatisfaction

It is almost certain that customers that pre-ordered products will be dissatisfied if

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

and the company needs to avoid this from happening.

22
Objective tree

Means

Conversion to Provide an Installation of roof

` Pneumatic sealing ergonomically turbines and
machine designed chair industrial exhaust fan

To reduce productivity loss by 58 % amounting to PHP 275,155.60 in

manufacturing 500mm x 500mm x 1 mm Plastic Foam Sheet.

Ends

Opportunity gain Increase in profit Customer satisfaction

23
Means

Conversion to Pneumatic sealing machine

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

push button and the sealing of the plastic will be automatic.

Provide an ergonomically designed chair

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

see in their working area a lot of things must be improved.

Installation of Ventilation System

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

Upholding customer is one of the things a company needs to do. By achieving

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

producer of such plastic products.

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

company and the goods they will receive.

25
 CHAPTER 4

ALTERNATIVE COURSES OF ACTION

ACA #1:Conversion to Pneumatic sealing machine.

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

results decrease in their productivity.

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

press it and the sealing process will be done.

Advantages:

 Increase in workers productivity

 Improved working conditions

 Convenience of workers

Disadvantages:

 Additional cost to the company

 Opportunity cost

26
 Automated Pneumatic Foam Sealing Machine

Model: Toplink-PPP-1700

Frequency: 50Hz

Sealing Speed: 5-15 second cycle

Heaters: Resistive Strip

Voltage: 220 V 3-Phase

Power: 3400 W

Compressor Rate: 0.1 to 0.6Mpa

Max Sealing Length: 1700 mm

Origin: China

Source: http://alibaba/industrial_sealing_machine/pneumatic-semiautomated/.com

27
Computations:

Cost:

 Cost of buying One Brand New Sealing Machine: Php 200,000

Benefit:

 Contribution in Average Production Loss= 47.79%

 Production Loss= 6.84%

 Cumulative % eliminated in Average Production Loss

= 47.79% x 6.84%

= 3.27%

 Quantity Produced per month in Average Production Loss(in sheets):

= 3.27% x 13,690

=448 sheets

 Total benefit in a month:

= 448 x PHP 3.35

= PHP 1,500.80

 Total benefit in 12 months:

= PHP 1,500.80 x 12
= PHP 18,009.60
 Return of Investment

PHP 200,000 = (No. of Years) x 18009.60

=12 Years (144 Months)

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:

 Improved working conditions

 Convenience of workers when working

 Less injuries and ailments

Disadvantage:

 Additional cost

Industrial Stool Chair

29
 Model:Safco® Mesh Stool Chair FDC-0122-C
Style: mesh breathable vinyl upholster

Seat Height: manual pneumatic adjustable height 35.25 cm to 62.50

Seat Width: 42.50 cm

Seat Weight Capacity: Up to 320 lbs with 360° swivel

.Source: http://furniturestocks/industrial/stool/.com

Cost:

Cost of buying One Brand New Sealing Machine: Php8,850

Benefit:

 Contribution in Average Production Loss= 32.45%

 Production Loss= 6.84%

 Cumulative % eliminated in Average Production Loss

= 32.45% x 6.84%

= 2.21%

 Quantity Produced per month in Average Production Loss(in units):

= 2.21% x 13,690

=303 sheets

 Total benefit in a month:

= 303 x PHP 3.35

= PHP 1,015.05

 Total benefit in 12 months:

= PHP 1,015.05 x 12

30
 = PHP 12,180.60
 Return of Investment

PHP 8,850 = (No. of Months) x PHP 1,015.05

= 9 months

ACA #3:Installation of roof turbines and industrial exhaust fan.

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:

 Convenience of workers when working

 Less heat will be felt by the workers

Disadvantage:

 increase in the production output

 Long installation time

31
 Industrial Roof Turbines

Model: BMG-01269 Straight Flue Turbine Ventilator

Height: 54.26 cm
Color Finish: Silver- Tungsten Plated
CFM High (Airflow): 1314 CFM
Diameter: 38.1 cm
Origin: United Kingdom
Warranty: 10 Years
Price: PHP 32,250

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:

Cost of buying 2 Brand Roof Turbine Ventilator: PHP32,250 x 2 – PHP 64,500

Cost of buying 2 Brand Roof Turbine Ventilator: PHP22,550 x 2 – PHP 45,100

Total Cost of Acquired Ventilation System: PHP 109,600

Benefit:

 Contribution in Average Production Loss= 19.76 %

 Production Loss= 6.84%

 Cumulative % eliminated in Average Production Loss

= 19.76% x 6.84%

= 1.35%

 Quantity Produced per month in Average Production Loss(in units):

= 1.35% x 13,690

=185 sheets

 Total benefit in a month:

= 185 x PHP 3.35

= PHP 619.75

 Total benefit in 12 months:

= PHP 619.75 x 12
= PHP 7,437

 Return of Investment

PHP 109,600 = (No. of Years) x PHP 7,437

= 15 Years

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TABLE 4.1: Cost Benefit Analysis

ACA COST BENEFITS

TANGIBLE INTANGIBLE

1. Conversion to Cost of buying an - Increase in profit -Continuous

Pneumatic Industrial Pneumatic - Less downtime that production operation
sealing Machine will result to more -High Quality
machine Price: PHP 200,000 output Product
-High Morale
operator
2. Provide an Cost of buying 2 -Increase in served -better performance
ergonomically Safco® Mesh Stool number of machine by workers
designed chair Chair cycles resulting to -workers satisfaction
= PHP 8,850 x 2 more outputs
=PHP 17,700 - Increase in profit

3. Installation of Cost of Buying 2 - faster production -less job element

roof turbines roof turbines - increase in -improve working
and industrial =PHP 32,250 x 2 production environment
exhaust fan. = PHP 64,500 -Increase works
Cost of Buying 4 morale
Exhaust Fan
= PHP 22,500 x 4
= PHP 90,000

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 CHAPTER 5

CONCLUSION AND RECOMMENDATIONS

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

ineffective machine pedal it is highly recommended to implement ACA1 which is 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

suggested to reduce the productivity loss such as to provide an ergonomically designed

chair and installation of roof turbines and industrial exhaust fans.

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 CHAPTER 6
DETAILED PLAN OF ACTION

ACTIVITY WEEK 1 WEEK 2 WEEK 3 WEEK 4

Planning of the
implementation of
ACAs

Review of the study

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

Testing and making

of a new SOP

Training for the

operator

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.

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