LYCEUM OF THE PHILIPPINES UNIVERSITY

CAVITE

A Methods Engineering Study on

Toms Manufacturing Corporation

Submitted by: Matienzo, Pacumio, Santiaguel, Torres

Toms Manufacturing Corporation
Introduction:
TOMS, a member of NANBU plastics INC. is one of the growing plastic
precision company in the Philippines that aims to be the largest manufacturing
company and no. 1 in the country.

Nature of business varies extensively in:

- Manufacturing
- Painting
- Printing and Assembly of precision plastic parts for automotive
- Electronics
- Medical
- Housing
- Others
TOMS also produce medical products.
Objectives:
General Objectives

• To be able to perform a work measurement study conducting a Time

and Motion study for the selected operation.
• To be able to identify the causes of delay in the process of putting the
jigs.
• To be able to propose recommendation that will improve the
production.
Objectives:
Specific Objectives

• To be able to improve the process of Plate 469 Black and

determine the root cause of the problem.

• To be able to eliminate the 22.39 seconds in the process of

putting of jigs that causes the production to slowdown.
Scope:
• Plate 469 BLACK

• Problem-solving tools: Process Flow Diagram, Flow Process

Chart, Fishbone Diagram and Pareto chart.

• Use of Time and Motion Study, Work measurement and

Problem-solving tools
Limitations:

The study covers the four main activity within the production
process of 469 black: the removing of burr, putting of jigs,
painting and cooling; the next other activity in the production
process of 469 black that the researchers did not cover are
beyond the scope of the study.
Background of the Study:
• The data was gathered through time and motion study, flow
process chart, process flow diagram, fishbone diagram and
Pareto chart.
• The movement of the process must be identified in detailed
order from first station until the last process.
• Second step is to record the process using the recording
tools.
• Third is to proceed with alternative solutions.
• Combine all the data that was gathered, eliminate and make
an improvement to the chosen process.
Flow Process Chart:
Flow Process Chart Analysis
Fishbone Diagram
Pareto Chart

The Pareto Chart shows that the top 3 operations that slow down the production are
putting of the jigs, inspection of the item and wiping the item with 70% alcohol.
Analysis of Alternatives:
Alternative Course of Action 1
Reorganize table placement
The location of facilities in the process of putting the jigs is consuming much
time and delays that is avoidable. Since the location of the facility was found to be
ineffective, the researchers recommended a more effective location of manufacturing
facility in order to improve the production. The jigs must be arranged and placed near
the worker so the worker wouldn’t have to walk and search for the specific jigs
needed, ideally the jigs are arranged and easily reachable for the worker.
Advantages:
• Less production time
• High productivity
Disadvantage:
• Decrease in productivity of the worker due to adaptation to the new method
Analysis of Alternatives:
Alternative Course of Action 2
Eliminate ineffective method
Getting jigs from the recycle box, cause to decrease the production, separating
the jig A, B and C will lessen the time from finding them in the bunch of mixed jigs.
Arrange jigs and separate them according to their label.

Advantages:
• Less production time
• High Productivity
• Less hassle when getting the jigs

Disadvantage:
• The worker needs time to adjust to the new system or operation.
Analysis of Alternatives:
Alternative Course of Action 3
• Hiring an employee
To avoid items from falling off the conveyor, the researchers recommended hiring another
employee. It will balance the work time of each worker in the line and will help them do their
work faster to avoid items from falling off the conveyor. This will also help the workers to
produce greater quantity of the product and will meet their target output.
Advantages:
• Less production time
• High productivity
• Minimization of waiting time
• Maximization of production time
Disadvantages:
• Additional of new workers
• The company must provide trainings and seminars.
• Expense for the salary of employees will increase.
Justification of Chosen Alternative:
The researchers recommend ACAS 2, or the elimination of the ineffective
method. Bottleneck occurs in the process of putting of jigs, with the proposed
improvement will lessen the total cycle time of 22.39 seconds. Separating the jigs
according to their label will help to increase the production of Plate 469 BLACK.
Proposed Method:
Conclusion:

The researchers performed Time and Motion Study to collect

data. The researchers used five problem-solving tools in the analysis
of data: Process Flow Diagram, Flow Process Chart, Fishbone
Diagram and Pareto Chart. Throughout the analysis of data, the
researchers encountered a problem in the process of putting the jigs
that slows down the production that is avoidable. The researchers
recommended a solution that will lessen the existing cycle time of
169.16 seconds by 22.39 seconds. The computed cycle time of the
proposed method is 146.77 seconds and therefore, we conclude that
the proposed method is more effective.
End of Presentation, Thank you very much!!!