Republic of the Philippines

CAVITE STATE UNIVERSITY

Don Severino de las Alas Campus
Indang, Cavite
 (046) 4150-010 / (046) 4150-013 loc 206
www.cvsu.edu.ph

COLLEGE OF ENGINEERING AND INFORMATION TECHNOLOGY

Department of Industrial Engineering and Technology

Final Application Project for IENG 80A - Methods Engineering

Molding Process
Hocheng Philippines Corporation

Submitted by:

Cayetano,John Benedict B.
Lubigan,Mary Jane
Nicolas,Jomari

BS Industrial Engineering 3-2

May 2018
 Table of Contents
Contents Page
Title Page ………………………………………………………………………….…. i
Acknowledgement …………………………………………………………………… ii
Table of Contents ……………………………………………………………………. iii
I. INTRODUCTION ............................................................................................. 1
II. BACKGROUND AND SCOPE OF THE STUDY
A. Background of the Study ………………………………………………………. 2
B. Scope of the Study ………………………………………………………………3
III. LITERATE REVIEW …………………………………………………………. 4
IV. STATEMENT OF THE PROBLEM ……………………………………….... 11
V. OBJECTIVES …………………………………………………………………. 12
VI. SIGNIFICANCE OF THE STUDY …………………………………………… 12
VII. PROCESS ANALYSIS
A. Fish Bone ……………………………………………………………………. 12
B. Operation Process Chart…………………………………………………..13
C. Flow Process Chart ………………………………………………………..14
D. Flow Diagram ………………………………………………………………. 15
E. Worker and Machine Process Chart …………………………………….. 16
F. Gang Process Chart …………………………………………………….....16
G. Operation Analysis
G.1. Tolerance and Specification ………………………………………… 16
G.2. Manufacture Sequence and Process ………………………………. 16
G.3. Set Up and Tools ……………………………………………………... 17
G.4. Plant Layout ……………………………………………………………. 17
G.5. Work Design …………………………………………………………….. 18

H. Time Study…………………………………………………………………………18
I. Work Sampling …………………………………………………………………….20
J. Two hand Process Chart ….…………………………………………………... 25
VII. RECOMMENDATIONS
A. Fishbone Analysis ………………………………………………………………27
B. Operation Process Chart ………………………………………………………. 27
C. Proposed Flow Process Chart …………………………………………………29
D. Proposed Flow Diagram ……………………………………………………….. 30
E. Operation Analysis

E.1. Tolerance and Specification ……………………………………….

E.2. Manufacture Sequence and Process ……………………………. 31
E.3. Set Up and Tools …………………………………………………… 31
E.4. Plant Layout ………………………………………………………….32
E.5. Work Design …………………………………………………………. 32
F. Time Study …………………………………………………………………32
G. Work Sampling …………………………………………………………… 32
H. Proposed Two hand Process ……………………………………………………
VIII. CONCLUSION …………………………………………………………………………..
34
IX. REFFERENCES …………………………………………………………………………..
35
X. ATTACHMENT …………………………………………………………………………….
46
 ACKNOWLEDGEMENT

The completion of this research paper could not have been possible without the
participation and assistance of many people whose names may not be all enumerated.
Their contributions are sincerely appreciated and gratefully acknowledged. However, the
group would like to express their deep appreciation and indebtedness particularly to the
following:
Ms. Dina P. Bawag, Professor and adviser; Sir Willie Buclatin , Cvsu IE Chairperson
and advisor ; HCG HR Department ; Sir Niel , HCG Mold development supervisor ;
To Hocheng Philippines corporation (HCG) the company’s participation and
assistance is much appreciated.
To all relatives, friends and others who showed their support financially or
physically, thank you.
Above all, to the God great almighty, the author of knowledge and wisdom, for his
countless love.
We thank you.

Cayetano, John Benedict

Lubigan. Mary Jane
Nicolas, Jomari
 I-Introduction
Production section is the heart of the company so productivity and quality are very
important in the company. If the activities of this section is interrupted, the whole industry
ceases to be productive. This department includes methods engineering, time study
standards, and work design activity. Methods engineering is the analysis and designs of
work methods and systems, including the tooling equipment, technologies, workplace
layout, plant layout, process charts, work environment and human capital
management(www.slideshare.net). This also includes designing, creating, and selecting
the best manufacturing methods, processes, tools, equipment, and skills to manufacture
a product based on the working drawings that have been developed by the product
engineering section.

Methods engineering includes different tools such as problem solving tools,

recording and analysis tools, quantitative tools, operation analysis, work measurement
techniques and motion study. Through these tools and techniques, it helps improve the
productivity of a company, used to identify problems, record and analyze data, establish
time standard, set standards and improve process and calculate production rate,
manpower and increase productivity.

II- Background and Scope of the Study

A. Background of the Study

HCG believes that every bathroom fixture it creates has an 80-year-old story of
excellence and timeless craftsmanship. Since its inception in Taiwan in 1931, the legacy
of Hocheng Chiu has always inspired HCG to innovate products with sophisticated design
and excellent functionality. HCG's unwavering commitment to quality and customer
satisfaction over the years made it a trusted brand of the 21st century.

As the demand for HCG grew exponentially not just in Greater China but across
the globe, Hocheng Philippines Corporation (HPC) was established in 1995. In 1997, a
10-hectare plant was opened in First Cavite Industrial Estate (FCIE) adding to the two
existing state-of-the-art production bases in China. The world-class European technology
admired by millions is now fused with Filipino creativity and ingenuity.
 After just a few years of operation, and with over 55% market share, HCG became
the no. 1 total bathroom solutions provider in the Philippines.

B. Scope of the Study

This study was conducted on the molding production department of the HPC.
Since it’s not possible to study all of the whole company production due to limited time
and company policies and confidentiality, this study focused only on the processes
involved on molding production alone.

Molding department includes the development of prototype of the product. In this

section, the prototype of the product is being develop by the company based on the
drawing/diagram or sample given by the customer. After the prototype has been created
it will be inspected and passed it to the casting section where the mother mold is being
fabricated based on the prototype. The mother mold will be used to create more molding
block. The molding block will be transferred to main production area where the actual
product will be produced. The molding mold will be used to create the actual products
which is delivered to the customer.

III-Literature Review

According to H.A Salaam et al (2012 IOP Conf. Ser.: Mater. Sci. Eng. 36 012006)
Minimizing the number of defects is important to any company since it influence their
outputs and profits. The aim of this paper is to study the implementation of industrial
engineering tools in a manufacturing recycle paper box company. This study starts with
reading the standard operation procedures and analyzing the process flow to get
the whole idea on how to manufacture paper box. At the same time, observations at the
production line were made to identify problem occurs in the production line. By using check
sheet, the defect data from each station were collected and have been analyzed using
Pareto Chart. From the chart, it is found that glue workstation shows the highest number
of defects. Based on observation at the glue workstation, the existing method used to glue
the box was inappropriate because the operator used a lot of glue. Then, by using cause
and effect diagram, the root cause of the problem was identified and solutions to overcome
the problem were proposed. There are three suggestions proposed to overcome this
problem. Cost reduction for each solution was calculated and the best solution is using
three hair driers to dry the sticky glue which produce only 6.4 defects in an hour with cost
of RM 0.0224

IV- Statement of the Problem

Based on the Pareto Analysis, the main problem identified in Hocheng Philippines
Corporation are the transferring of block molds (Finished products of molding production)
from the molding area to the main production area. This method causing the block molds
to have cracks and dents which will lead to defected products and another problem to be
consider is the mixing of the plaster.

Table 1: Problems encountered in the Molding production

Problems Frequency Percentage (%)
Transferring of molds 25 50
Mixing of plasters 12 24
Inadequate storage 8 16
Unclaimed orders 5 10

TOTAL 50 100

Figure 1 Pareto Analysis

 This chart shows that the transferring of mother mold has the highest number of
rejects with 25 frequencies. Next is the Mixing of plaster with 12 rejects and inadequate
storage and unclaimed orders has 8 and 5 respectively.
Using Pareto analysis, it was identified that the transferring of mother mold and
mixing of plaster fell on the left side of 80% which means both should be consider as the
main problems of the company.

V. Objectives

Generally, this study aims to apply the different tools used in methods
engineering in identifying the problems in the company.
Specifically, it aims to:
 Show the importance of every method in determining the problems
 Determine the problems in the molding area of Hocheng Philippines Corporation
 Provide possible solutions to eliminate or limit the occurrence of the problem
identified

VI- Significance of the Study

The findings of this study will contribute to the benefits of the industries considering
that methods engineering plays an important role in manufacturing industries. The need
for better and most efficient processes and methods proves the necessity for the
improvement of processes and methods. Thus, the companies apply the recommended
methods derived from the results of the study will be able to maximize their resources
and eliminate unnecessary processes and methods. For the researchers and students,
this study will help them understand more about the methods engineering and its uses.
VII-Process Analysis

A. Fish Bone Diagram

A fishbone diagram, also called a cause and effect diagram or Ishikawa diagram, is a
visualization tool for categorizing the potential causes of a problem in order to identify its
root causes. Once all the causes that underlie the problem have been identified,
engineers can start looking for solutions to ensure that the problem doesn’t become a
recurring one.

Figure 2. Fish Bone Diagram

Mixing of Plaster
Machine
Low technology- the current technology is not up to date
Man
Lack of Manpower- The current manpower is not enough for the operation
Unskilled Worker- Inexperienced workers assigned to the job
Money
Limited fund- High cost of material in making the product
Management
Lack of Supervision- Unclear instructions given by superiors and the workers are
not always monitored
Materials
 Cost- The materials brands used in making the mold are expensive and budget is
always considered within the aspect.

B. Operation Process Chart

Figure 3. Present Operation Process Chart

The operation chart is a graphical and symbolic representation of the manufacturing

operations used to produce a product. The operation chart illustrates only the value-adding
activities in the manufacturing process; therefore, material handling and storage are not
illustrated in this chart.
 C. Flow Process Chart

Flow process chart show all the moves storage delays encountered by an item as
it goes through the plant. Therefore, flow process chart need several symbols in addition
to the operation and inspection symbols used in operation process chart

Figure 4 Present Flow Process Chart

 This chart shows the present operation process chart of mixing process. The
process starts with the setting of mixer then filling it with water and plaster. Then, let it mix
for 8 minutes to meet the required mixture and inspect it to ensure that the plasters are
totally dissolved. Lastly, distributing it to the casting process and pouring it to the mother
mold to produce the molding blocks.

D. Flow Diagram

Flow diagram is a graphic representation of the physical route or the layout of floors
and buildings, showing the locations of all activities on the flow process chart materials,
products or vehicles associated with the process or procedure plan.

Figure 5 Present Flow Diagram

This diagram shows the flow of products in the molding production from
development area to the main production area.
 E. Worker and Machine Process Chart

A worker-machine chart illustrates the amount of time a worker and a machine are
working or idle in a job. This type of chart is occasionally used in conjunction with a process
flowchart when the job process includes equipment or machinery. The worker-machine
chart shows if the worker's time and the machine time are being used efficiently--that is, if
the worker or machine is idle an excessive amount of time.
 This chart was excluded in the study because the molding production does
not have process where an operator operates two or more machines.

F. Gang Process Chart

The Gang process chart is used to analyze the activities of the group and then
compose the group so as to reduce to a minimum all waiting time and delays. Gang
process chart is used when several workers operate one machine. The chart helps in
exploring the possibility of reducing both the operator time and idle machine time
 This chart was excluded in the study because the company does not have
machines which is operated by two or more machines.

G. Operation Analysis

Operations Analysis is the study of operational systems with the aim of identifying
opportunities for improvement. It has many guises and is sometimes called Operational
Research or Industrial Engineering.

G.1. Tolerances and Specifications

The tolerance and specifications are very critical in the production. In
molding process, there is no tolerance allowed because the mold must only have
.3mm gap between the mold and the product, in this case, if the standard gap
doesn’t meet, the mold will be needed to have repair again.
 G.2. Manufacture Sequence and Process
In making the molding block. There are three major processes which are the
mixing, casting and finishing. The materials mixed in this process are very fast to
dry and hardened thus, the mixer has to mix the materials and distribute it to the
casting process before it gets hard and if failed to do so, he has to do the process
again and the materials used will be gone to waste.

G.3. Setup and Tools

In casting the molding block, the caster setting up the mother mold with the
use of hammer for it to be fixed which sometimes causes the mother mold to have
deformity and crack. Thus, the mother mold needed to be repair in the development
unit which causes delay on the process.

G.4. Plant Layout

Since the molds are heavy it is transfer by the use of fork lift through the
outside road. Due to the distance travelled and weight of the product, there are
times that the mold to have crack in it and worst it will be broken which is the main
problem of the molding production that causes delay and additional cost to the
production.

G.5. Work Design

In exchange unit, the transfer of molding block from the molding department
to the production of main product. The mold will be carry by the worker from the
entrance to the line where it will be used. This process sometimes causes the
worker to have muscle pain because of the weight of the mother mold.

H. Time Study
Time study is a structured process of directly observing and measuring human work
using a timing device to establish the time required for completion of the work by a qualified
worker when working at a defined level of performance.
 This chart shows the actual time study on the mixing process. There are 4 elements
included in the process namely filling of water, filling of plaster, mixing and pouring to
casting process. The time study considered ten cycles and used 90% rating and 10%
allowances. Based on the data, the standard time established was 1291.89 sec per cycle.

Figure 6 Time study

I. Work Sampling
Work sampling is the statistical technique for determining the proportion of time
spent by workers in various defined categories of activity. It is as important as all other
statistical techniques because it permits quick analysis, recognition, and enhancement of
job responsibilities, tasks, performance competencies, and organizational work flows.
 In a work sampling study, a large number of observations are made of the workers
over an extended period of time. For statistical accuracy, the observations must be taken
at random times during the period of study, and the period must be representative
of the types of activities performed by the subjects.
 Figure 7 Work Sampling

This chart shows the work sampling recorded on the study. The whole sampling
consisted of 131 cycles based on the computation done by the researchers.
 J. Two hand Process Chart
This chart shows all movements and delays made by the right and left hands, and
the relationship between the basic divisions of accomplishment as performed by hands

Figure 8 Present Two Hand Process Chart

 This chart shows the present two hand process chart of mixing process. The
effective time of right hand was 975.43 sec and 224.57 sec ineffective time while in the left
hand 366.32 sec effective time and 833.68 on ineffective time.

VII-Recommendations
A. Improved Operation Process Chart

Figure 8 Improved Operation Process Chart

 This chart shows the improved process chart. Inspection 1 was added after the
filling of water and plaster to the mixer to ensure the quality of the mixture.

B. Proposed Flow Process Chart

Figure 9 Proposed flow Process Chart

This chart shows the present flow process recommended by the study. The chart
had included the recycling of materials/mother mold rejects to lessen the wastes
accumulated by the company.

C. Proposed Flow Diagram

This is the proposed flow diagram of the study. The revision made was the changes
on company`s layout. The receiving area where the transfer of molding block from molding
department to main production takes place. In this cases, the distance needed to travel by
the molding block will be reduced.

Figure 10 Present Flow Diagram

This diagram shows the revised flow diagram of molding process where the
changes on the layout had considered. The receiving area where the transfer of the
molding blocks from molding area and main production takes place. In this revision, the
distance needed to travel by the molding block was reduced.
 D. Proposed Two-Hand Processed Chart

This chart shows the present two hand process chart. The total effective time of left
hand was 362.32 sec and 623.43 ineffective time while the total effective time for right
hand was 645.21 and 212.22 sec ineffective time
 E. Recommendations on the Approaches to Operation Analysis

E.1 Tolerance and Specification

Based on the observations and data gathered, this study recommended to
use foolproof to avoid unnecessary action or procedure done by the operator in
order to meet the standard gap on the specification of the mold.

E.2.Manufacture Sequence and Process

This study recommended to hire more mixer operator order to make to
process faster. This will help avoid the delay of distribution the mixed plaster and
lessen the risk of wasting the materials.

F.3. Set Up and Tools

This study recommended to used lighter hammer or cover the hammer by
rubber to lessen the impact of the hammer to the mother mold and avoid the
deformity or crack on the mother mold.

F.4.Plant Layout
This study recommended to rearrange or improved the layout of the
production to lessen the distance needed to travel in transfer of molding block to
the main production.

F.5.Work Design
This Study recommended to use cart or rack in transferring the molding block
to avoid injuries and make the process easier and safer.

IX. Conclusions
Among the world full of competitors, every company sets a high standard for all of
the workers they’ve hired. Workers must cooperate and meet the expectation of the
manager to gain excellent performance feedback and excel in its chosen work. Using the
different tools applied in this study, the researchers identified the problems in the company
and possible solutions were recommended.
Based on the study conducted, through the use of different tools in methods
engineering this study identified the problems and provide solutions and establish
standards in the company.
According to the study, problems in the molding area of the company were
determined. The most prevalent of the problems were transferring of molding blocks to the
production are and mixing of plaster. Tools were engaged to evaluate, eliminate or reduce
the problems.
Based on the data gathered, this study concluded that transferring of molding block
were recommended to change the plant layout and on mixing process the best way to
improve the output and reduce the chance of plaster drying is to minimize the time on this
process.

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