Chapter 4

This chapter presents the data gathered about the reduction of out of standard products due to
improper cutting of coco pots at Pilipinas Eco Fiber Corporation as well its analysis and interpretation.
Data were presented in accordance with the objectives of this research study.

Process Flow Chart

A process flowchart is a type of diagram that represents an algorithm, workflow, or process, showing the
steps of various kinds, and their order by connecting them with arrows. Flowcharts are used in
analyzing, designing, documenting, or manging a process or program in various fields.

Ishikawa Diagram

To determine the causes of the defects from the production are, the researchers constructed an
Ishikawa Diagram.

Ishikawa diagram is very helpful tool in problem solving. It is used to figure out the cause and effect and
to breakdown the contributing factors of an issue. An ishikawa diagram can also be referred to as a
cause and effect diagram, a fishbone diagram, named for their shaped which, when completed looks like
a fish’s bones.

Figure 4 presents the ishikawa diagram for scorch rubber. The category for causes are man, machine,
materials, method, management and environment while the effect is scorch rubber. The main problem
or the main product defect is the scorch rubber.

Why-why analysis

After constructing the ishikawa diagram and analyzing the causes, it is further analyzed in the why-why
analysis to come up for the possible root cauases of the problem. Why-why analysis is a tool used to
determine the root cause of a defect or problem by repeating the question “Why?”. It is one of the
common tools used in conducting root cause analysis.

The researchers conducted a Why-why analysis for defects caused by improper rubber mixing.

Control chart for Variables (x and R and x and S)

Control chart for variables plots continuous measurement process data, such as length or pressure, in a
time- ordered sequence. It helps identify causes of variation to investigate, so that it can adjust the
process without over- controlling it

Summary of Findings
1.based on the quantified data of product defects given by the quality assurance department from
January to September 2017, the problems encountered were hole defect, scorch rubber, over volume,.
Scorch rubber accumulated the highest quantity with a total of 1, 513 kg.

3. Based on the Pareto Analysis,

4. For the Ishikawa diagram, the possible causes for the scorch rubber are machine overheat, machine
breakdown, low quality of materials, dusty environment, lack of tag cards and wrong chemicals. The
possible causes for the over volume are machine error, machine breakdown, quality of raw materials,
uneven cutting, and inconsistent thickness.

5. For the why why why analysis, the root causes identified were incomplete work instruction, no
routine schedule, lack of monitoring, and lack of production supervision.

6. to reduce the defects in the milling section, the researchers provided action plan that may be able to
solve the problem. The action plan consists of the root cause, recommended action and the people
involved. The following were the provided solution by the researchers.

a.

b.

Conclusion

1.The problems are encounterd in the milling section since the machine are low

2. uneven cutting affects the quality of the product and

3. Proposed cutting tool

Recommendations

For the operators, the management should provide training for newly hired workers and for existing
workers.