Being an intern in actual setting in the industry was never easy it makes me feel excited and at the

same time nervous. Nervous because of the expectations although I know I can do it. But then in
my experience as an intern in Union Galvasteel Corporation give me an eagerness on the role of
an Industrial Engineer in the industry. It gives me clear vision on the course I am pursuing and on
the future waiting for me. It also gives me knowledge and lesson which serves as a tool in
problem-solving situations not only in the work but also in everyday life.

Union Galvasteel Corporation (UGC) started as the Union Steel Plant Division of Bacnotan
Cement Industries, Inc. a pioneer in the Philippine Cement Industry and commenced commercial
operations in 1963 with a galvanizing plant in Poro, San Fernando, La Union for the manufacture
of Galvanized Iron (GI) sheets. It subsequently expanded operations with galvanizing plants in
Ilang, Davao City in1968 and in Calamba,Laguna in 1990. The division was spun off in 1993 as a
separate business unit and incorporated as Bacnotan Steel Corporation. The company in 1995
established a moderncontinuous galvanizing line and a color coating line for the manufacture of
pre-paintedgalvanized steel coils in Calamba, Laguna. In present time, the company name is
Union Gavasteel Corporation and it has three production line the Color Coating line(CCL), the
Polyurethane line (PUL), and the Roll Forming Line(RFL).

In my first day in the company, I was assigned to the Quality Assurance Department of
Polyurethane(PU) line. The line is headed by ma'am Lennie, the Quality Assurance Manager, and
she has two officer for the PU line ma'am Jovy and ma'am Rachel. She also holds the QA of the
CCL. The PU line produces sandwich panel. Sandwich Panel is a composite roof and facade
cladding material produced by applying polyurethane injection in various thickness between
double-dyed galvanized sheet or aluminum plate. It is called sandwich panel because of its
sandwich-like appearance the Polyurethane or the foam serves as the filling between two GI
sheets. It is best use as a refrigeration panel for it traps the coldness of the room. It also reduces
the heat coming to the room. The PU line divided into two subline the Continuous line and the
Discontinuous line. The Continuous line is for roofing panels production and the Discontiuous line
for the walling panel production. The Discontinuous line has two profile a Standard sheet,those
sheets that has been roll formed and the Plain sheet, those plain GI sheets. A standard panel has a
standard measurement of 2.57x1.157 m and a thickness of 50 mm. Some customers has made their
own specification.

The first task that I do is to create an Operator Process Chart for the discontinuous line. It is an IE
tool to Identify idle time cause by transportation, delay, storage and etc. Methods study is one of
the useful IE tool in the industry. This contributes to the large improvement of 5M's the Man,
Machine, Materials, Money and Methods. For further understanding of my task I am here to
elaborate the process of producing the PU panels which I learned during my stay in UGC. The
first process is the Roll forming, this process involves the shaping of the coil which is needed on
the job order.This process create the sheaths which serves as the top and bottom skin of the panel.
Next, the set up and preparation, After the roll forming the rollformed sheaths are needed to create
the mould. The set up and preparation has two Press machines the 12 meter press and the 8 meter
press.Their only difference is the capacity of panel to be produce. The set up and preparation
involves the setting up of the jigs and the mould.The jigs and mould to be use is depend on the
required thickness in the job order. After setting up the jigs and the mould the bottom skin is put
laying down then put the spacer, the spacer serves as the support of the top skin so that it will not
fall down to the bottom skin. Lastly, put the top skin and ready for the pressing. Third process is
the Pressing, the moulds are put in the press machine.The press machie prevents the foam from
overflowing from the mould during the reaction time after injectiom of chemicals. The chemicals
which is the Isocynate and Polyol was used to create polyuretane. The process of mixing the two
chemicals with an agent is happened in this process. Fourth process is the demoulding, the process
involves the removing of injected panels from the jigs and moulds. The final process is the
Finishing, this involves the final touch in the product if it conforms to the quality standards, the
defects are to be check and if there are unnecessary material in the product.

The main focus of my task is the set and and preparation and the demoulding process. This two
process involves manual operation.The machine operators are the person who make the mould so
ma'am Jovy told me to create an OPC so that they will know the actual time, the delays, and some
idle time of that process to be able to make an improvement. The purpose of my task is to see the
actual work of the workers if they conform the work set by the production officers. My first
observation was done in the 12 meter press with the profile of standards, and standard
measurement. At first it is hard to take the time and record it because I don't know the every detail
of the process so I wrote first the elements based on the quality procedure plan.The best thing that
happened to me is while I am doing the observation I can say that little by little I learned the every
detail of the set and preparation. and the areas need for improvement. The 12 meter composed of 8
machine operators including the press technician. Then I do the same in the 8 meter but then the
machine operators are not fully skilled unlike in the 12 meter. I can see it in their work and ma'am
Jovy told me that some of th are new in the process so the process of set up and preparation in 8
meters takes longer time than the 12 meter. After that they told me that I will have to create a Time
and Motion Study.

The next task that I do is the Illustration of the checklist for the whole PU line from the producing
of the panels up to the widthrawal of the panel. They give me the checklist in excel file then I need
to study how to put up an Illustration. The checklist composed of the list of requirements for a
quality product that must needed to comply to provide a reject-free output and to understand their
job title. The checklist is printed in a tarpauline in each process because every pocess has different
checklist. It is too hard to create an illustration if I don't have the tools like photoshop and
autoCAD. Since I am an IE, I learned t what I have but without suffering the quality of the output.
I use the 3d paint, I know this task is not sound IE tools to used but we all know that IE is versatile
in different areas. IE tools use to help IE but and IE must know that simple work needed a simple
solution. The purpose of my task is for improving the work of the machine operators by giving
them a checklist that they will easily undestand and to know the scope of their job title. This task
gives me opportunity to interview each machine operators from the roll forming up to the
widthrawal. The interview is use because some details in the work cannot be understand through
observation. I talk to roll formng machine operators, the press technician, the process technician,
the finisher, and the loader. While talking to them I learned to socialize with them and with other
machine operators which gives me happiness. I leaned also some