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4.

1 INTRODUCTION
After determining the target demand for MosquiGUARD in the marketing study, the
technical specification of the product will be discussed in this section. The manufacturing
process and production schedule will be considered in this feasibility study it will also
determine the best plant location and layout among the alternatives. The best process of
producing the mosquito repellant from extracting the banana peel to producing the lotion to
packaging and the production schedule will be presented in this study. The best machinery,
capacity and design, machinery supplies, other company supplies including office supplies
were be selected, together with the quantity and quality of the products to be produced,
labor needed, utilities required, waste disposal method and transportation necessary are to
be determined. After the data were obtained, the total project cost will be computed.


4.2 PRODUCT
MosquiGUARD is a mosquito repellant formulated naturally for protecting kids and
families. Ìt is a mosquito repellant without DEET (N, N-Diethyl-meta-Toluamide) as its main
ingredient. Ìn line with this, Figure 4.1 shows the different perspectives of the product
packaging.

Perspective Drawing Engineering Drawing BottIe (body)







Engineering Drawing BottIe (cap) Sticker LabeI





ExpIoded Drawing
Figure 4.1 Product Packaging

4.2.1 Properties of the Product
MosquiGUARD is composed of banana peel extract, catnip oil, carbowax
(PEG), stearyl alcohol, glycerin, water, and methyl paraben. The following are the
functions of the stated raw materials:
a. Banana peel extract reduces swelling of mosquito bites. Ìt is used as an added
moisturizer to the lotion.
b. Catnip oil repels mosquitoes ten times more than DEET.
c. Carbowax is used also as a moisturizer to the lotion. Ìt is low in toxicity and is
safe to use for food and cosmetics.
d. Emulsifier is used as the binder of all the ingredients of the lotion. Emulsifiers are
usually used for pharmaceutics and cosmetics.
e. Glycerin is low in toxicity and used as a means of improving smoothness.
f. Water it is used to neutralized the pH level of the chemicals.
g. Methyl paraben is used as the preservative of the lotion. Methyl paraben is
produced naturally and found in several fruits, primarily blueberries, along with
other parabens. Ìt is practically non-irritating and non-sensitizing.

MosquiGUARD is a lotion type repellant. Ìt may be applied before or during
inside and outside activities to protect people from mosquito bites. Ìt may also be used
after getting bitten by a mosquito to cure skin irritation due to mosquito or bug bite/s.

4.3 MANUFACTURING PROCESS
Banana PeeI Extraction
Banana peels extraction is the process of separating the ripe white inner layer,
including the white inner fibrils, from the yellow outer layer. The resulting extract is combined
with lotion or ointment.
Lotion MateriaI Mixing
After the extraction of the banana the other materials will mixed together in order to
create the lotion, the combined mixture will be heated until it reaches its boiling point. Catnip
oil and banana peel extract will slowly be added to the mixture within the boiling process.
The resulting mixture will require cooling after the stated procedure.
BottIe Making
High Density Polyethylene (HDP) bottle is used. Ìn the process, the pellets were
injected into the injection blow molding machine. After the process, the finished products
were cooled rapidly to form a bottle. Subsequently, the piece will be separated from the
machine and will already be set to be filled up by the lotion.
Product Packaging
After performing the banana peel extraction and lotion making process, the finished
lotion is poured into a bottle and will be labeled with the company sticker. Figure 4.2 shows
the product packaging.

Figure 4.2 Product Packaging
Inspection
The inspection of the product occurs after mixing the chemicals and before storing
the finished product. For the chemical inspection, pH 5.5 should be maintained to avoid skin
irritation. Significantly high pH level might cause the consumers to develop skin allergies;
therefore these mixtures should be reformulated. Before storing the finished product, the
container should be inspected for defects such as wholes, distorted figure, and incorrect
sticker placement. These defects should be rejected because it may affect the market's
perception regarding the product content.

4.3.1 Production Requirement Information
Parts list, bill of materials, and route sheets are used to easily relate and
understand the production, specifications, quantity, and sizes of the product, raw
materials were also determined as guide for the production process.

4.3.1.1 Parts List
Table 4.1 below shows the listing of the different components of
MosquiGUARD. Ìt is also shown in the table the make or buy decision made by the
company for each part, together with this were the corresponding part number,
material type, quantity, drawing number reference, and size/dimension.
Table 4.1 Parts List of MosquiGUARD

4.3.1.2 BiII of MateriaIs
Table 4.2 shows the bill of materials of MosquiGUARD. The level of each part
was based on the products structure of MosquiGUARD which would be shown in
Figure 4.2
Table 4.2 Bill of Materials for MosquiGUARD

Part
No.
Part
Name
Drawing
Number
Quantity MateriaI Type
Size / Dimension
(cm)
Make /
Buy
1
Bottle
(body)
1
PET (polyethylene
terephthalate) bottle
4. x .1 x 11.1 Make
2
Bottle
Cap
4 1
PET (polyethylene
terephthalate) bottle cap
2.4 x 2.4 x 2 Make

Sticker
Label
5 1 sticker paper 8 x 4
Make

4 Lotion - 1 mL
PEG - 4, catnip oil,
stearyl alchohol, water,
glycerin, methylparaben,
polyglyceryl, methacrylate
- Make
LeveI Part Number Part Name Drawing Number Quantity Make / Buy
1 1 Bottle (body) 1 Make
1 2 Bottle (cap) 4 1 Make
2 Sticker Label 5 1 Make
2 4 Lotion - 1mL Make

4.3.1.3. AssembIy Chart
Figure 4. shows the assembly chart for the MosquiGUARD which gives as
an overview of the assembly process of the whole product. Ìt shows the order of the
sub-assemblies, assemblies and inspections of the parts that would make the
product whole

Figure 4.3 MosquiGUARD Assembly Chart

4.3.1.4 Product Structure
Figure 4.4 shows the hierarchical classification of Camana. The product
structure helps us better understand the different components that form the whole
product needs.
Figure 4.4 Product Structure

4.3.1.5 Route Sheets and Operation Process Chart
Route sheets determine the specific manufacturing sequence of operations.
The route to be followed in the production process is specified in the route sheet.
The following tables present the route sheets for the production of MosquiGUARD. Ìt
also presents the set-up, operating and standard time for each operation. To have an
overview on how the process making of MosquiGUARD flows, the route sheet can
be related with the operation process chart which can be found in Figure 4.5.

Operation
No.
Operation
Description
Machine
Type
TooIs &
SuppIies
Set-up
Time
(sec)
Operating
Time
(sec)
Standard
Time
(sec)
1
Peeling :Process of
peeling the banana
- - 2 5 7.77
2
Washing: Process of
washing the peel of
the banana
- - 1 4 5.55

Chopping: Process of
chopping the peel of
the banana
-
knife,
chopping
board
1 4.44
4
Place the Solvent:
placed in a 7
isopropyl alcohol, at a
preferred ratio of
approximately 1 gram
of peel per about 4.5
ml of Stearyl alcohol
- Bowl 1 1 2.22
5
Blending: Process of
blending solvent with
chopped banana peel
mixer
bowl,
spatula
1 2 .

Agitate: Process of
mixing the slurry form
reaction
tank
Mixer 1 2 .
7
Filtration: Process of
filtering the banana
-
filter
paper
and
screen
1 1 2.22
TOTAL: 8 18 28.8
Table 4.3 Banana peel Extract Route Sheet

Operation
No.
Operation
Description
Machine
Type
TooIs &
SuppIies
Set-up
Time
(sec)
Operating
Time
(sec)
Standard
Time
(sec)
1
Simmering:
Process of
heating distilled
water with catnip
herbs and
carbowax
Stove
Teaspoon,
Spatula,
Pot
5 22
29.97

2
Mixing: Process of
combing
emulsifier, vitamin
E and catnip oil
Mixer
Bowl, pot,
Teaspoon
1 1 2.22

Boiling: Process
of heating all
ingredients to the
boiling point
Stove Pot 5 25 .
4
Mixing: Process of
mixing the
ingredient while
slowly adding
Catnip oil and
Banana peel
Extract
Mixer
Bowl,
Spatula
2 5.55
5
Cooling: Process
of cooling the
lotion
Refrigerator
Bowl,
Funnel
1 14 19.14
TOTAL: 4 215 24.18
Table 4.4 Lotion Mixture Route sheet
Operation
No.
Operation
Description
Machine
Type
TooIs &
SuppIies
Set-up
Time
(min)
Operating
Time
(min)
Standard
Time
(min)
1
Ìnjection Molding: to
mold the plastic in
shape of the
container
Ìnjection
Molding
Machine
PET
pellets
5 15.45
2
Degate: Seperates
the piece to the
sprue.
- - - 9 99.9
TOTAL: 125 25.5
Table 4.5 Packaging (Body) Route Sheet

Operation
Number
Operation
Description
Machine
Type
TooIs &
SuppIies
Set-up
Time
(min)
Operating
Time
(min)
Standard
Time
(min)
1
Ìnjection Molding:
to mold the plastic
in shape of the
container
Ìnjection
Molding
Machine
Hard
Plastic
5 15.45
14
Degate: Seperates
the piece to the
sprue.
- - - 9 99.9
TOTAL: 125 25.5
Table 4.6 Packaging Cover Route Sheet
Operation
No.
Operation
Description
Machine
Type
TooIs &
SuppIies
Set-up
Time
(sec)
Operating
Time
(sec)
Standard
Time
(sec)
1
Printing: Process
of printing the
design to the
paper
Printing
machine
Sticker
paper,
Ìnk
1 1 2.22
2
Cutting: Process
of cutting the
paper
Cutter
Paper
cutter
1 1 2.22
TOTAL: 2 2 4.44
Table 4.7 Sticker Label Route Sheet

Operation Process Chart

Figure 4.5 Operations Process Chart

4.4 PRODUCTION SCHEDULE
Demand
Production per
Day (100mL)
Production per Day
+ 3% Scrap (100mL)
Production per Year
+ 3% Scrap (100mL)
255,74,4 1, 1,7 25,14
292,95,19 1,19 1,1 15,18
5,4,579 1,25 1,9 8,22
84,5,4 1,527 1,9 471,921
44,549,585 1,8 2,95 574,79
54,729,8 2,259 2,98 98,
578,259,59 2,79 ,488 87,195
2,51,22 ,241 4,17 1,1,1
759,1,112 ,89 4,982 1,195,575
89,591,17 4,9 5,94 1,424,17
99,274,8 5,48 7,55 1,9,279
Table 4.8 Production Schedule +3% scrap
Ìt was forecasted that MosquiGUARD will have a maximum production schedule of
5,94 bottles per day during its first ten years, and a cycle time of .4 seconds per bottle.
This production layout was designed using Ìncremental Utilization Method (ÌUM). Through
this method, the optimal number of workstation for the first ten years of the company was
determined to be 4 workstations. Having the layout shown in Figure 4., you will have a
percent utilization of 8.79. The breakdown of task is shown at the Figure 4..








Figure 4.6 Production Schedule Using Incremental Utilization Method

4.5 RAW MATERIALS AND SUPPLIES
4.5.1 Raw MateriaIs for MosquiGUARD
Ìn manufacturing MosquiGUARD the materials needed by Camana are seen in
Table 4.9. The quantity or size needed per 1 ml of the lotion may also be found in the
said table together with the supplier of the raw material. On the other hand, Table 4.1
shows the annual material requirement of each raw material for the first ten years of its
operations.
Raw MateriaIs Source
Cost of
Minimum
Quantity (Php)
Minimum
Quantity
Quantity
Needed for
100 mL Lotion
Cost
Per 100
mL (Php)
Carbowax (PEG
÷ 4)
Alysons Chemical 192 1, mL . mL .12
Catnip oil Ebay (China) 294.4 118 mL 1.5 mL .7424
Glycerin Alysons Chemical 754 1, mL 1.7 mL 1.298
Banana
A.P.C. Ìndustries,
Pasig City
28 1,4 mL 259 g .971
Stearyl Alcohol
Sulit.com.ph
(Philippines)
18 1,4 mL 45 mL 77.885
High density
polyethylene
Alibaba.com
(China)
2, 5,, g 5g .2
Methyl Paraben Alysons Chemical 5 1, mL .28 mL .2
Sticker Paper
Sulit.com
(Philippines)
2,75 1 mL
1/ of letter
size
.917
Ìnk Hewlett-Packard 15 25 mL . mL .125
Table 4.9 Raw Materials Information
The following supplier are capable to deliver the quantity of chemicals needed,
hence if they fail to supply the said amount, the company has alternative of supplier which
can supply the said chemicals this are ChriselSci-Lab Center and Crismon Enterprises
which are both located at Sta. Cruz Manila. For catnip oil, there is a supplier in Ìndia that can
provide the needs of the company by contacting them through alibaba.com. Camana
decided to buy class B (very ripe) banana since the inner part is not needed. The alternative

supplier will be other banana suppliers within Luzon. The Table 4.1 shows the Camana's
yearly demand of raw materials for the production of MosquiGUARD.
Year
High Density
PoIyethyIene (g)
Banana
PeeI (g)
Carbowax
(mL)
GIycerin
(mL)
2012 9,574,911 ,7,58 1,1 ,57,87
2013 11,781,5 81,589,54 1,985 4,15,74
2014 14,444,87 1,2,8 2,4 5,291,2
2015 17,49,845 122,227,57 2,97 ,45,18
2016 21,497,8 148,872,254 ,21 7,874,71
2017 2,1,5 18,791,47 4,98 9,5,99
2018 1,11,77 21,8,9 5,274 11,49,5
2019 7,459,87 259,414,47 ,1 1,721,9
2020 44,714,512 9,5,97 7,52 1,79,8
2021 5,2,844 8,859,244 8,972 19,511,87
Year
MethyI Paraben
(mL)
Sticker
LabeI (pcs.)
StearyI
AIcohoI (mL)
Ink (mL)
2012 72 85,8 115,2,147
15,.82
2013 88 15, 141,757,898
18,91.5
2014 18 128,742 17,81,88
2,17.58
2015 12 157,7 212,4,447
28,15.2
2016 11 191,599 258,58,5
4,487.78
2017 195 22,79 14,11,9
41,882.19
2018 24 279,5 7,77,5
5,21.7
2019 28 ,87 45,72,429
,9.
2020 5 98,525 58,8,84
71,74.51
2021 99 474,722 4,875,14
85,45.2
Table 4.10 Annual Demands of Raw Materials of MosquiGUARD
The values for annual demand of raw material were calculated by getting the annual
production schedule, which can be seen in Table 4.8. The rate of production was multiplied
to the requirement of each raw material per 1mL bottle to get the annual requirement of
each raw material. Ìn relation, the values in Table 4.11 show the annual costs for raw
materials requirement.

Year
TotaI Cost
per year
Year
TotaI Cost
per year
Year
TotaI Cost
per year
2012 24,725,75.99 2016 55,51,554.44 2019 9,74,17.88
2013 ,424,24.2 2017 7,41,22.8 2020 115,48,75.8
2014 7,1,559.72 2018 8,855,849.2 2021 17,545,59.7
2015 45,577,92.27
Table 4.11 Annual Costs for Raw Materials Requirement
4.6 MACHINERY AND EQUIPMENT
Production Equipment
StainIess steeI reaction tank
The company will be using reaction tank for the Banana peel in order to produce
banana extract. The tank is composed of the head, shell, jacket, agitator, gear and
bearing seal, etc. it is also corrosion proof, leak proof, Complete in
specifications, excellent quality and service with a Reasonable price. Fig 4..1 shows the
machine that the company will use in the production.




Fig 4.7 Stainless Steel Reaction Tank
Source: Henan Wanda Chemical
Equipment Co., Ltd.
Quantity: 1 machine
Total Cost: Php 4,
Lead time: 25 days





Machine Size (mm) 4x 5x
Power Consumption 1.5 kw
Capacity 1-2 L
Rotation speed R/min

Refrigerator
The refrigerator will be used for the storage of the chemicals. Ìt is Environment-
friendly, has good quality at the same time, effective processor. Figure 4.8 shows the
machine that the company will use in the production




Figure 4.8 Chest Refrigerator
Source: Ningbo Gongxing Electric
Appliance Co., Ltd. China
Cost: Php 29,9
Quantity: 4 machines
Total Cost: Php 119,
Lead time: 1 days
Specifications:
Machine Size (mm) 99x 55x 81
Power Consumption 145W
Electric Source 22'
Capacity 21L

FiIIing machine
The components of the filling machines are from Korea and Taiwan, the parts of
the filling machine are made of 1L Stainless steel. Figure 4.9 shows the machine that
the company will use in the production



Fig 4.9 Filling Machine

Source: Shanghai Saidone
Technologies Co., Ltd. China
Cost: Php 45,1
Quantity: 1 machine
Total Cost: Php 45,1
Lead time: 2 days
Specifications:

Cosmetic Mixing Machine
The mixing machine is used to mix cream, honey, lotion, and emulsion in the field
of Pharmacy, Chemical, and Cosmetics. Mixer cosmetic machine will be used for mixing
process where the banana peel extract will be blend to other chemicals in order to make
various body lotions. Figure 4.1 shows the machine that the company will use in the
production.



Fig 4.10 Cosmetic Mixing Machine
Source: Hangzhou Yintong Machinery
Co., Ltd., Zhejiang, China
Cost: Php 4,
Quantity: 1 machine
Total Cost: Php 4,
Lead time: 2 days
Specifications:
Machine Size (mm) 1997178
Power Consumption 17kw
Electric Source 8'
Capacity 1L

Machine Size (mm) 549
Power Consumption .4KW
Electric Source 22'
Capacity 5ml
Filling speed 15-2 bottles/min

BIow moIding machine
This machine will be used to make the packaging of the product particularly the
body, and the cover. High density polyethylene is the material that will be used for the
packaging of our product. Figure 4.11 shows the machine that the company will use in
the production.






Fig 4.11 Plastic Injection Molding Machine

Source: Hangzhou Yintong Machinery
Co., Ltd., Zhejiang, China
Cost: Php 414,
Quantity: 1 machine
Total Cost: Php 414,
Lead time: days
Specifications:
Machine Size (m) 1.85x 1.47x 2
Power Consumption 7.5 Kw
Electric Source 22'
Capacity 1 bottles

OriginaI PIain Paper Laser Printer
The printer will be use for printing the sticker that will be placed in the bottle, it
has a high Appearance and Excellent Quality. Fig 4.. shows the machine that the
company will use in the production.

Fig 4.12 Original Plain Paper Laser Printer
Source: Hangzhou Yintong Machinery
Co., Ltd., Zhejiang, China
Cost: Php 4,94
Quantity: 1 machine
Total Cost: Php 4,94
Specifications:
Machine Size (m) 1x 1.5x 2
Power Consumption 94 Watt
Electric Source 22'

Office Equipment
Equipment Source Cost (Php) Quantity TotaI Cost (Php)
Refrigerator Sanyo 9,495 1 9,495
Clerical Chair Lims 1,7 1 17,
Executive Table Set eBay 1, 5 5,
Desktop Computer Gilmore 2,5 12 282,
Printer Gilmore 2,4 7,2
Office Table Set sulit.com.ph 2,5 12 ,
Filing Cabinet Japan Surplus 5 4 2,
Fax Machine Asianic Philippines 4,95 2 9,9
Sofa Set sulit.com.ph , 4 24,
Gang Chair x 4 Lims 9,1 2 2,
Conference Table sulit.com.ph 15, 1 15,
Paper Cutter National Bookstore 1
White Board National Bookstore 8 2 1,
TOTAL: 468,495
Table 4.12 Office Equipment Cost

Office SuppIies
SuppIies Source Cost (Php) Quantity TotaI Cost (Php)
Calculator National Bookstore . 15 9.
Cash Box National Bookstore 2. 1 2.
Puncher National Bookstore 8.75 2 77.5
Stapler National Bookstore 54. 15 81.
Staple Wire (1 pcs.) National Bookstore 4.75 15 71.25
Scissors National Bookstore 1.5 15 22.5
Paper Clips Sun Royal 12.5 7.5
Record Book 'eco 55.5 1 55.5
Folder (short) Merit 1.75 1 175.
Folder (long) Merit 2. 1 2.
Cellophane Tape National Bookstore 5.5 2 11.
Fastener National Bookstore 7. 2 74.
Glue Stick National Bookstore 1. 1 1.
Cutter National Bookstore 8. 2 1.
Packaging Tape National Bookstore 25.25 5 12.25
Bond Paper (8.5¨ x 11¨) National Bookstore 1.5 4.5
Bond Paper (8.5¨ x 1¨) National Bookstore 157.5 1 157.5
Fax Paper National Bookstore 55. 1 55.
Letter Envelope National Bookstore 9.75 4 159.
Envelope National Bookstore 5. 8 448.
Carbon paper National Bookstore 45. 1 45.
Ballpen HBW 1. 2 2.
TOTAL: 5,818.50
Table 4.13 Office Supplies Cost
PIant CIeaning Equipment
Equipment Source Cost (Php) Quantity TotaI Cost (Php)
Broom and Dustpan Ace Hardware 15 2 15
Kitchen Faucet Wilcon 45 2 4,9
Trash Bin SM Department Store 99 1 99
TOTAL: 6,040
Table 4.14 Plant Cleaning Equipment Cost
AuxiIiary Equipment
Equipment Source Cost (Php) Quantity TotaI Cost (Php)
Generator Sulit.com , 1 ,
Air Conditioner Carrie 25, 1 25,
Exhaust Fan Hanabishi 848 2 1,9
Socket Akari 85 25 2,125
Switch Akari 125 15 1,875
Fluorescent Osram 125 ,75
TOTAL: 619,446
Table 4.15 Auxiliary Equipment Cost

Restroom Equipment
Equipment Source Cost (Php) Quantity TotaI Cost (Php)
Sink and Bowl Royal Tern ,14 1 12,5
Table 4.15 Auxiliary Equipment Cost

Transportation Equipment


Table 4.15 Transportation Cost
4.6.7 MateriaI HandIing System
The processing plant is responsible for material handling once the chemical
ingredient arrives in the plant. The chemicals are initially stored in the chest
refrigerator to maintain its quality and to keep it from contamination. Other raw
materials such as banana and HDP (High Density Polyethylene) pellets will be
separately placed in a storage cabinet.

Using a storage cabinet, the materials and products will be properly kept and
accessible for usage. Ìndustrial waste container will aid to the cleanliness of the
workplace because a more organized and clean workplace will lead to an effective
and efficient production system.

The HDP bottles are used for final packaging of MosquiGUARD to restrain
external chemical reactions like sunlight and radiations. Upon capping the product,
they are placed in a carton boxes, and directed to the storage area to wait for
delivery time.

Equipment Source Cost (Php) Quantity TotaI Cost (Php)
Delivery 'an Ìsuzu Philippines 857, 1 857,
Tool Cart Metalcraft Enterprise 1,5 2 1,7
TOTAL: 858,700

4.7 PLANT LOCATION
Three locations were considered for the project possible site determination. These
are as follows:
1. Camalig, Meycauyan City, Bulacan
2. Summerville, Barangay Mambugan, Antipolo, Rizal
. Guiguinto, Bulacan
After confirming the availability of the said locations, a comparative analysis was
made to enable the proponents to determine the most ideal and practical site
Several factors were considered in choosing the best site:
CRITERIA PERCENTAGE
Proximity to retailers 25
Proximity to suppliers 25
Size 2
Utilities 15
Price 1
Labour Cost 5
TOTAL 100

Criteria
Percentage
Meycauayan AntipoIo Guiguinto
Proximity to retailers 2 20 15
Proximity to suppliers 15 15 15
Size 2 20 15
Price 15 12
Utilities 8 10 5
Labour Cost 2 5 2
TOTAL 8 82 58
Table 4.15 Criteria for Evaluation and Evaluation Result

Since the raw materials are bought from Alysons' Chemical Enterprises, Ìnc. located
at Araneta Avenue, near Del Monte Avenue Quezon City, the site should provide the
greatest access to it. Among the three proposed sites, the chosen location should incur the
least cost, distance and time traveled for the supplier and at the same time the customers.
These are crucial to ensure the freshness of the raw materials and the same time provides
savings for the company.

ActuaI Project Site
Camana chose the site in Antipolo, Rizal among the other alternatives due to the
following factors:

1. The place is accessible to the workers, suppliers, and retailers.
2. Utilities such as electricity, water supply, and communication lines are already
available.
. The place is wide enough for the production.
4. The garbage collector can easily collect the waste disposal of the company.
5. The price of the area is reasonable.
. The labor cost is not that expensive compared to other sites.

The percentage breakdown of criteria was based upon consensus decision-making.
After giving weights for each criterion, an evaluation of the location was conducted. Based
on the result, it is concluded that the best location of the manufacturing building is located at
Summerville, Barangay Mambugan, Antipolo, Rizal. Ìt has been decided that the company
will buy a warehouse with a lot area of 1, square meters and floor area of 575 square
meters for Php 5.5 million. Figure 4.1 shows the location that the company will buy for the
production.
Fig 4.13 Summerville, Barangay Mambugan, Antipolo, Rizal.

4.8 PLANT SIZE AND LAYOUT
Proper arrangement of department in the office area is important. They must be
strategically arranged to permit proper sequence and coordination of task. Camana's plant
layout includes parking area, offices, storage for raw materials, the manufacturing area, and
storage for finished goods, comfort rooms and pantries. Production control, buildings and
surroundings, service areas and employees' comfort are some of the factors being taken
into consideration in the design of the plant layout. The proposed warehouse structure is
shown in Figure 4.14 with plant layout and dimensions presented in Figure 4.15 and Figure
4.1 respectively.
Figure 4.14 Proposed Plant Building






Figure 4.15 Plant Layout First floor

Figure 4.16 Plant Layout Second Floor
The detailed room layout can be seen at Appendix A.

4.9 BUILDING AND FACILITIES

4.10 UTILITIES
The utilities used in the production and administration are, electricity, water and
telecommunication. The corresponding service companies that provide these basic utilities
are Meralco, Manila Waters, and Philippine Long Distance Telecommunication Company
(PLDT). Desirable amount of supplies of utilities were assured in the location chosen.
Considering the utilities is important to make sure that no interruptions in production will
happen to avoid delays and additional costs. Tables 4.1 show the yearly consumption of

telephone, electricity and water for Camana. Ìn relation, Table 4.17 show the total annual
utility cost for the first 5 years of operations of CamanaŦ

EIectricity Cost for Office Requirements
AppIiances Quantity
Energy per
Machine (kW)
Operating Hours
per Month (hr.)
EIectric Consumption
per Month (kWh)
Aircon 7 .28 1 2.29
Computer 14 .472 1 15.728
Fluorescent Lamp .2 1 9
Printer .4 1 19.2
Fax 2 .4 1 12.8
Refrigerator 1 .14 1 22.4
Reaction Tank 1 1.1 9 15.
Mixing Machine 1 1.7 9 1.2
Filling Machine 1 .4 9 8.4
Exhaust Fan 2 1.1 9 211.2
Blow Molding Machine 1 7.5 9 72
Printer 1 .94 9 9.24
Refrigerator 4 1.45 9 55.8
Total 3,238.86
Cost per kWh (Php) 200.6 TotaI Cost 649,716.12

Rate Components

Base Price Amount
Generation Charge 12 9.277 14,95.7
Transmission Charge 12 .214 47.5
System Loss Charge 12 1.188 1,79.2
Distribution Charge 12 .21 1,24.
Metering Charge 12 .22 7.81
Supply Charge 12 .19 25.52
Subsidies 12 .1515 245.4
SubotaI 19,020.74

Government Taxes
Base Price Amount

Generation Charge 12 .1 12.
Transmission Charge 12 .11 178.2
System Loss Charge 12 .1 12.
Distrubution and Subsidies 12 1.58 2,559.
SubotaI 3,061.80

UniversaI Charge

Base Price Amount
Missionary 152.4 .4 5.82
Environmental Fund 152.4 .25 .81
SubtotaI 60.63

Total Cost of Charge per month 22,14.17
Total Cost of Machines and Other Charges per month 71,859.29

TabIe 4.10.4 Water Cost
TotaI Water Consumption
per Month (cm
3
)
First 10
cm
3
(Php)
Next 90
cm
3
(Php)
Next 100
cm
3
(Php)
Next 100
cm
3
(Php)
TotaI Cost per
Year (Php)
99.4 41.94 4.44 4.5 4.97 52,148.39

TabIe 4.10.4 TeIephone Cost
Breakdown of Fees: Amount (Php)
Ìnternet plus Telephone 1995
Telephone Monthly Fee 121.71
Additional 12 'AT 145.452
TotaI MonthIy Fee 3,354.36
AnnuaI TeIephone BiII 40,252.26

TabIe 4.10.4 TotaI UtiIities Cost
UTILITIES Electricity Water Telephone TOTAL
PRICE 71,859.29 52,148.9 4,252.2 764,259.94

4.10.1 Waste Management:
The company's sources of wastes are the yellow layer of the banana skin, the
edible part of the banana, and the excess and rejected plastics from the bottle
manufacturing. The wastes from the banana will be collected to be sold to garden and
landscaping companies for them to convert it to fertilizers. On the other hand, the excess
and rejected plastics will sold to local junk shops. Financially, this process will be able to
give Camana extra income, and help gardening companies to cut cost. Furthermore, it
helps the environment by being able to reduce the waste to be thrown.

4.11 DIRECT LABOR REQUIREMENTS
The number of employees is dependent on the company's machinery and equipment. The
machine operators work in an 8-hour operation with a one hour lunch break and thirty minutes
personal allowance allocation. Office hours and production starts from 8: a.m. to 5: p.m.

4.11.1 Direct Labor
These are workers who are directly involved in the production of goods or
services.

DIRECT LABOR MANPOWER REQUIREMENT
Quality Control Ìnspector 1
Production Personel 4
Table 4.11.1 ÷ Direct Labor

TabIe 4.11.1 - Direct Labor Requirements
No
.
Monthly
Salary
per
employe
e
SSS
Contribution
Monthly
PhilHealth
Contribution
Monthly
Pag-ibig
Contribution
Monthly
Total Cost for
Manpower per
month
Total cost for
manpower per
year
Production
Personel
4

9,18.
1,8.

75.

1,92.9

51,8.4

12,9.48
Quality Control 1

Ìnspector 22,77.

5. 275. 455.4 21,59. 258,475.2
TotaI 25
6,669,570.96

4.12 PRODUCTION COSTS
Determining the production cost is important so that the company would know if the
product will profit. Ìf it will not, the company could determine what course of action would be
suitable. The over-all production cost is comprised of the cost obtained in the purchase of raw
materials, labor costs, and utilities' consumption. Table 4.12.1 shows the production cost and
the computed cost per unit. The cost per unit was computed using the formula:
V
;
V
;
ÈV
;

Where: V
;
Cost per unit at year n
V
;
Total Cost of Production at near n
V
;
Estimated Market Share in units at year n (see table ...2)
Table 4.12.1 Production Costs
ÞkCDUC1ICN CC51 2012 2013 2014 2015 2016
kaw Mater|a|s Needed ţţŦ ţţŦ ţţŦ ţţŦ ţţŦ
Manpower
ţŦ ţŦ ţŦ ţŦ ţŦ
Ut|||t|es ţŦ ţŦ ţŦ ţŦ ţŦ
Mach|ne Deprec|at|on ţŦ ţŦ ţŦ ţŦ ţŦ
1ota| Cost of Þroduct|on 15ţ257ţ324Ŧ52 18ţ449ţ085Ŧ00 22ţ292ţ882Ŧ75 26ţ910ţ348Ŧ65 32ţ445ţ197Ŧ74
ÞkCDUC1ICN CC51 2017 2018 2019 2020 2021
kaw Mater|a|s Needed ţţŦ ţţŦ ţţŦ ţţŦ ţţŦ
Manpower ţŦ ţŦ ţŦ ţŦ ţţŦ
Ut|||t|es ţŦ
ţŦ ţŦ ţŦ ţŦ
Mach|ne Deprec|at|on ţŦ ţŦ ţŦ ţŦ ţŦ
1ota| Cost of Þroduct|on 39ţ067ţ212Ŧ69 46ţ539ţ385Ŧ23 55ţ359ţ156Ŧ71 65ţ756ţ855Ŧ67 78ţ001ţ732Ŧ34

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