A Study in eliminating the 8.39% Production Loss experienced by CS Garment, Inc. in Manufacturing the BGMO1-259 Executive Shirts from July 2014 to December 2014 amounting to PHP 6,923,950.00

In Partial Fulfillment of the Requirements inFacilities Planning and Design

De La Salle University Dasmarias, CaviteCollege of Engineering, Architecture and Technology

Submitted by:Dela Cruz, Kristhian B.Garcia, Iris G.Santarin, Aniel John A.IEE42

Submitted to:Engr. Philip Ermita

March 2015

CHAPTER IINTRODUCTION AND BACKGROUND OF THE STUDY

1.1 INTRODUCTIONCS Garment, Inc. is located in Cavite Economic Zone, 4106 Rosario Cavite. The locality has an abundant of highly trained and proficient workers, and not to mention from the fact that Cavite is ranked top to have an atmosphere of industrial peace and productivity.For more than two decades, CS Garment, Inc. is continuously providing its clients with professional and quality shirts line and services. Strategically based in the Philippines, CS Garment, Inc. principally caters to the European market that seeks the most competitive and high quality products.CS Garment, Inc. will be instrumental also in providing local employment to the community. Thus keeping our commitment to provide each employee a better opportunities and live a fruitful life.The Company has become one of the most reputable garment firms that has been receptive to changes and has continuously met the quality standards. CS Garment, Inc. is recognized in supplying high-end shirts for various prestige brands.The impetus of moving forward will test our vision to be the best in our chosen endeavor in the garment industry. CS Garment, Inc. has installed a state-of-the-art networking system that will elevate dissemination of information to its highest degree of ambiguity within our organization and link to us throughout the cyberspace.

1.2 BACKGROUND OF THE STUDYFor 20 years, CS Garment, Inc. is a garment company uses sophisticated machines and materials in the mass production of their products.This study focuses on the layout-related factors of the company which contributes to the production loss of manufacturing BGMO1-259 Executive Shirts. The product undergoes to different processes where there are factors involving people and machines.During the visit, the researchers were able to observe and analyze the condition of the production area where they identify the layout-related factors contributing to the production loss. The 8.39% production loss was mainly due to method, material, man and machine used by the department. First is the long travel distance traveled from Final Inspection to Packing Section, the researchers observed that there is a barrier between the areas which makes it even further the distance between the two areas by 19.35m. Second is the backtracking It is observed that the material handling equipment that they used can only handle 30 units which slows downs the production. Third, is the unnecessary activities done by the workers because the working areas where the sewers are located are quite close with each other so the workers tend to do unnecessary activities during working hours. They chat with each other and use gadgets and phone in between the time that they are working that cause delay of work. Lastly, is the machine breakdown in the sewing machine, during the production the sewing machine used experience problem in machine breakdown because the company lacks preventive maintenance. They only have corrective maintenance that greatly affects the production. Idle time occurs whenever the machine is not working.These factors lead to the 8.39% production loss experienced by the CS Garment, Inc. in the manufacturing of BGMO1-259 Executive Shirts amounting to PHP 6,923,950 from October 2013 to March 2014.1.3 STATEMENT OF THE PROBLEMCS Garment, Inc. is experiencing an average of 8.39% production loss in the production of BGMO1-209 Executive Shirts amounting to PHP 6,923,950 from July 2014 to December 2014.1.4 OBJECTIVESGeneral ObjectiveTo eliminate the production loss by 8.39% in the manufacturing of BGMO1-259 Executive Shirts.Specific Objectives To reduce the backtracking activities of the operators To improve material handling equipment To minimize the unnecessary activities of the operators To maximize the efficiency of the machine1.5 SCOPE AND LIMITATIONSThis study is conducted on CS Garment, Inc. located at Rosario, Cavite. It focuses on the production of BGMO1-259 Executive Shirts, considering the facilities, design, and the layout of the manufacturing area which causes the production loss of the company. The data provided was limited from July 2014 to December 2014.1.6 SIGNIFICANCE OF THE STUDYTo the CompanyThis company study would enhance the layout of the company. This would help the company to identify where or what are their problems in their company. By knowing the problems within the company they can improve their operation and avoid the problems that may happen.To the StudentsThis study would help the students for their future study to analyze what could help the company in terms of facilities planning. It would also be a reference for the proper and appropriate layout with regards to the issue. It would help the student to make an analysis in the facilities planning when they take up the subject.To the ReadersThis study would help the readers to understand how important the facility planning is in relation to the area of production in the company. It would improve their critical thinking by understanding the study and it would also serve as a reference.1.7 DESIGN AND METHODOLOGY InterviewThe researchers conducted an interview with Ms. Carmen Reyes, the Production Supervisor of the Production Department. The purpose of the interview was to know the actual processes in manufacturing the BGMO1-259 Executive Shirts and determine the factors that might contribute to the production loss.Some of the questions asked during the interview were: In what type of products did you experienced low productivity? How did the production layout affect the output of production? Are the workers efficient in their work with the existing design and layout of the facility? Is the size of the warehouse sufficient enough to store all the materials and products? Is there a need for relocation or expansion of the company? Why? ObservationActual observation was conducted in the company during the month of November 2014. The researchers were toured by the plant manager on the Production Department in order to see the actual operations in manufacturing the BGMO1-259 Executive Shirts and the design of the facilities in the area. Data GatheringThe researchers gathered quantitative data regarding the monthly report of the monitored production output for the month of July 2014 to December 2014. Layout of the facility was also provided.1.8 DEFINITION OF TERMSBacktracking - to return by the same route by which one has come.Distance - the space between two objects; the length of a line, especially the shortest line joining two points or things that are separate; measure of separation in place.Facility layout and design - is an important component of a business's overall operations, both in terms of maximizing the effectiveness of production processes and meeting employee needs and/or desires. Material Handling - is the movement, storage, control and protection of materials, goods and products throughout the process of manufacturing, distribution, consumption and disposal. Productivity - is the ratio of measured outputs over measured inputs (i.e. - widgets produced per man-hour).Pressing- is the process or an instance of applying pressure by means of a press