Plant Visit Report

Bataan Heroes College
Roman Superhighway 2100 City of Balanga, Bataan

Tel./Fax no. (047)237-2383 Email: bhmc.edu.ph
Mechanical Engineering Department
Manufacturing & Industrial Process with Plant Visit
Plant Visit
in
GIBSON'S SHOE FACTORY INC. MAIN
AND
YANMAR HOLDINGS CO., LTD
_________________________________
A Plant Visit Report

Presented of Mechanical Engineering
_________________________________
Presented by:
De Luna, Romar N.
Madlao, Rolan D.
Reyes, Jofer M.
June 13, 2022

INTRODUCTION
The company was eventually passed down to their daughter, LEONOR C. ANDRES, and
renamed and reorganized as Gibson's Shoe Enterprises in 1974. From its beginnings as a casual
shoe manufacturer, the new firm expanded into military shoe manufacturing and, the following
year in 1975, was approved and accredited by the Philippine Department of National Defense
(DND) as one of its suppliers of Goodyear welted shoes such as dress and combat. Inspired by this
success, the company purchased direct rubber (soling) vulcanizing machines (DRVM) from
Australia and Germany in 1979, as well as upgrading its supplier status with DND to Direct
Molded Soled (DMS) boot-maker, a technology that helped her make a name for herself in the
Philippine military shoe manufacturing industry and win significant contracts with the Armed
Forces of the Philippines (AFP). Because of a large expansion in the capital structure and a much-
expanded activities, the enterprise was turned into a corporation in 1994, titled GIBSON'S Shoe
Factory, Inc as it is known today, and included the inheritor's* family members as investors. In
addition, during this year, the business began producing safety shoes in order to optimize the usage
of its DRVM and capitalize on the DMS safety footwear sector. Gibson Footwear purchased a
polyurethane casting machine (pour type) in 1995, but only used it for 2 years before retiring it in
1997 in exchange for a more modern polyurethane injection system from Desma, Germany.
Gibson's patience was tested further when it came to figuring out how to solve those challenges.
Page 1 of 14
This experience also prompted the business to invest in its own rubber milling and compounding
equipment, as well as open press curing machinery. It cleared the path for direct control over the
quality and properties of rubber soled shoes and boots.
As a result of technical advances in industrial shoe manufacturing, the firm has purchased
a double density PU/Rubber injection machine from Desma, Germany. GIBSON'S Shoe Factory,
Inc is now the most highly sophisticated military and safety footwear manufacturer. It positions
itself as the premier industrial shoe manufacturer of Goodyear welted on PU and/or rubber sole,
DMS on nitrile rubber sole, Single Density PU Shoe Sole, and Double Density PU/Rubber Sole.
The company's name may be found not only in the military, but also in law enforcement, aviation,
security, rescue, coast guard, schools, shipping and logistics, power generation, cement and
mining, and other industries. This can be attributed to her commitment to producing high-quality
industrial shoes, as evidenced by the growing number of her clients and the approvals she has
received from the AFP and the Philippine National Police, as well as certifications from an
internationally recognized footwear accrediting and testing body, OSHC (ANSI).
GIBSON'S Shoe Factory, Inc. will continue her tradition and, with GOD'S guidance and
inspiration, will be able to retain and improve its name in the industrial shoe producing sector; not
only locally, but also worldwide, which she is currently exploring.
Page 2 of 14
REPORT
Products of Gibson's shoe factory inc. main
Pilot boots - feature a unique patent pending Rudder Control Heel Slider. The heel slider is an
injection molded friction-less cleat , which slides effortlessly along the floorboards adding
superior rudder control.
Combat boots - Use is a task-oriented boots that meet the toughest requirements set by the
Philippine Military and the National Police standards. GIBSON'S Shoe Factory, Inc. is a 100%
Filipino-owned shoe manufacturing company from Marikina.
Page 3 of 14
Manufacturing process of shoes product

1. First operations in the manufacturing process are the cutting and marking operations.
2. The stitching line will have hundreds of these machines, the amount depending on the
complexity of the shoe design. The style of the machine will also change to fit the specific
operations required to make each shoe design.
3. Once the stitching is finished, it is time to set the shape of the toe box and heel counters. These
machines heat the thermoplastic counters inside the toe and heel, then clamp the shoe to set
the shape.
4. To sew the bottom fabric onto the upper, closing it.
5. The toe-lasting machine is the centerpiece of the lasting equipment. This machine takes hold
of the upper and physically pulls it down around the last. The machine simultaneously pulls
the upper into place while injecting hot glue to fix the uppers into place on the last.
6. Now the lasted uppers and out soles are on the conveyor line together, each receiving two coats
each of primer and cement. After each application, the parts are placed back on the line to
travel through a heat tunnel to dry the parts.
7. The pressing operation compresses the bottom, sides, and heel of the sole and upper together.
To set the bond, the lasted upper with the bottom attached is often placed in a chiller unit. Once
out of the chiller unit, the shoe is die-lasted by hand or by machine.
8. Finally, the shoe may pass through a dryer oven and UV light tunnel to ensure there is no
possibility of mold growth while the shoe is in transit.
Page 4 of 14
Machines and Equipment
Clicker Cutting Machine Embroider Machine Shoe Logo Welding Machine
Juki Ams Automatic Shoe

Strobel sewing machine Toe-Lasting Machine
Upper Sewing Machine
Footwear Primer and Cement Hydraulic Sole Press Machine UV Dryer Machine
Page 5 of 14
Mission And Vision of Gibson's Shoe Factory Inc. Main
Mission
“To supply high performance footwear for the Armed Forces of the Philippines,
Philippine National Police and industries using cutting-edge technology and state of the art
construction for customer satisfaction.”
Vision
“To achieve public recognition on superior customer and service for excellence in shoe
production, that is durable, dependable and comfortable.”
“To meet the specific foot gear requirement of customers locally and globally.”
Page 6 of 14
INTRODUCTION
Yanmar Co., Ltd. is a Japanese manufacturer of diesel engines, heavy machinery, and agr
icultural machinery that was founded in 1912 in Osaka, Japan. Yanmar designs and distributes en
gines for a variety of purposes, including seagoing vessels, pleasure boats, construction equipme
nt, agricultural equipment, and generator sets. It also produces and distributes temperature control
and aqua-farming equipment, as well as offering a variety of remote monitoring services.
Magokichi Yamaoka created Yanmar in March 1912 in Osaka, Japan. When the firm was founded
in 1912, it produced gasoline-powered motors. The firm began producing a tiny kerosene engine
in 1920. It introduced the world's first viable compact diesel engine, the HB type, in 1933. The
agricultural machinery segment of the company was established in 1961. Yanmar also began
supplying engines to John Deere tractors and some Thermo King Corporation coolers used in
refrigerated trucks and trailers. Yanmar has also established a growing presence in the domestic
unmanned aerial vehicle (UAV) market in Japan and elsewhere, with small helicopter UAVs
primarily used in agricultural spraying and other forms of aerial application. The name “Yanmar”
is a combination of the Yanma Dragonfly (known by names like as Oniyanma and Ginyanma) and
the "Yama" from the name of the firm founder Magokichi Yamaoka, according to the company
website.
Page 7 of 14
Yanmar operates in a variety of industries, including agricultural, pleasure boats, big

marine engines, energy, construction machines, and industrial engines. It runs its own operations
for these enterprises, where it manufactures high-quality Yanmar items. Unfortunately, the
company's industry is so diverse that it is impossible to exchange innovations throughout its
portfolio. As a result, various firms solve the same technological difficulties in isolation from one
another. It is critical for Yanmar that all firms collaborate in order to use their collective power.
Looking farther out, the environment in which the industrial business functions is changing
dramatically. Global manufacturing and procurement systems are examples, as are projects such
as Industry 4.0, which strive to improve production efficiency. In this context, R&D divisions are
doomed to lose competitiveness if they continue to produce the needed parts and products in the
same way they have in the past. Yanmar, with majority of its manufacturing facilities in Japan,
will struggle to exist unless it can continue to capitalize on its special traits to produce added value.
Page 8 of 14
REPORT
Production Processes for Diesel and Gas Engines
The castings made at Yanmar are produced by the sand mold casting of iron. The
production process involves pouring molten metal at a temperature of around 1400 °C into molds
made primarily of sand, and then removing the casting from the mold after it has cooled and
solidified. After that will go to Machining. During the machining process, key components of the
engine such as the cylinder block, cylinder liner, crankshaft, camshaft, and connecting rods etc.
are all machined with high precision and efficiency. After machining, will go to assembling. Each
part is properly assembled with the correct torque and sequence as instructed by our work
navigation system. Next is outfitting process, the assembled engines are placed on a base plate and
additional equipment such as generators, pumps, compressors, and clutches are installed, together
with any necessary piping. The engines can also be fitted with an electro-hydraulic system, for
automated and remote operations, according to the customer's specifications. After outfitting, will
go on testing process. Each engine is rigorously tested by a qualified engineer, run under conditions
equivalent to actual operating conditions on-board a vessel. Further inspections are simultaneously
conducted to determine compliance with the Ship Safety Act and the standards of the Fisheries
Agency of Japan and also members of International Association of Classification Society(IACS).
The last is packaging, the engine is coated, treated to prevent rusting, inspected for shipping and
then packaged for shipment to a location either within Japan or overseas.
Page 9 of 14
Products of Yanmar Holdings Co., Ltd
Marine Propulsion Diesel Engine - is the mechanism or system used to generate thrust to move a
ship or boat across water.
Marine Auxiliary Diesel Engine - are manufactured keeping in mind the rigorous environment
they will be installed and operated in, along with maintaining the continuity of operation to provide
uninterrupted power supply to various ship systems. The most important thing for running the
machinery system in its.
Page 10 of 14
Marine Dual Fuel Engine - can be operated on natural gas as well as fuel oil. Change over from
one fuel to the other can be achieved without any interruption in the power output of the engine.
Industrial Diesel Engine - is a type of internal combustion engine; more specifically, it is a

compression ignition engine.
Page 11 of 14
Machines and Equipment
Furnace Metal Bucket Sand Mixer
Master Molding Machine Thermal Sand Reclaim Oven Machining Center
Assembling Center Outfitting Center Testing Center
Page 12 of 14
Safety and Health
Yanmar provides solutions on the land, at sea, and in the city. Whether it is our versatile
construction machinery business, our highly efficient energy generation business, our original
component business, our agricultural business, which is aimed at ensuring that plenty of food can
be produced globally, our engine business, which is the business with which we were founded and
which prides itself on offering high quality and reliability, or our marine products business, which
operates in harmony with the environment, Yanmar is hard at work, providing diverse solutions to
serve customers on land, at sea, and in the city through these six businesses.
Page 13 of 14

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Bataan Heroes College

Roman Superhighway 2100 City of Balanga, Bataan

A Plant Visit Report

June 13, 2022

Manufacturing process of shoes product

Machines and Equipment

Clicker Cutting Machine Embroider Machine Shoe Logo Welding Machine

Juki Ams Automatic Shoe

Yanmar operates in a variety of industries, including agricultural, pleasure boats, big

Products of Yanmar Holdings Co., Ltd

Industrial Diesel Engine - is a type of internal combustion engine; more specifically, it is a

Machines and Equipment

Furnace Metal Bucket Sand Mixer

Master Molding Machine Thermal Sand Reclaim Oven Machining Center

Assembling Center Outfitting Center Testing Center

Safety and Health

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