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Production

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Submitted By julietsucalit
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Chapter 1

Introduction

Rationale of the Study

A mosquito coil is mosquito-repelling incense, usually shaped into a spiral, and typically made from a dried paste of pyrethrum powder. The coil is usually held at the center of the spiral, suspending it in the air, or wedged by two pieces of fireproof nettings to allow continuous smoldering. Burning usually begins at the outer end of the spiral and progresses slowly toward the center of the spiral, producing a mosquito-repellent smoke. A typical mosquito coil can measure around 15 cm in diameter and lasts around 8 hours. Mosquito coils are widely used in Asia, Africa, and South America.

Southeast Asian countries, specifically Philippines are eventually tackling problems about diseases carried by the mosquitoes. Mosquitoes are the tiny insects far more nefarious than snakes or any other creature encountered in the wild. The World Health Organization estimates that approximately 20,000 people die per year due to snakebite, but malaria - delivered by mosquitoes -kills more than fifty times that number of people annually. Add other mosquito-borne illnesses to the threat and suddenly humans appear to be losing the battle. (World Health Organization 2006) But with the mosquito coils, mosquito bites are now less problem in our sleep time during at night, it contributes also to the prevention campaign of diseases carried by mosquitoes. In the Philippines there are different manufacturers of quality mosquito coils, and one of them is the Greencoil Industries Inc., only Greencoil’s Lion-Tiger brand and its related brands remain in the market to compete with SC Johnson’s imported Baygon brand. The Lion-Tiger brand has been in the market since 1952.

For more than 50 years of operation Greencoil continued manufactures quality mosquito coils, with a vision “to make this world a much better to live,a nice resting place free from dreaded disease”. They produce different type of mosquito coils, they have regular sizes, junior sizes and king sizes of the coils, they offer also scented coils, and other specification of mosquito coils. (Source:www.lion-tiger.com)

The researchers choose to study the Lion – Tiger Katol brand, regular size, which is commonly manufactured all throughout the seasons. Other products such as scented coils are manufactured when there are some orders from the customers.

This study was conducted to determine the problems of the company, physical and conceptual problems that need an adequate corrective action plans. With the aid of researcher’s analysis and ideas, the management might improve their technical aspects as to production processes and its related aspects. Through the use of different methods and tools, the company could meet their ultimate goal and attain continuous improvement and reduces production waste.

Theoretical/Conceptual Background

Mosquito repellents help reduce or prevent mosquito bites that may lead to not only discomfort but also mosquito-borne diseases such as malaria and West Nile virus illness. Mosquito coils have been and are still the most commonly used mosquito repellents worldwide. Based on our personal communications with a mosquito coil manufacturer, it is estimated that 45 to 50 billion mosquito coils are used annually by approximately 2 billion people worldwide. To be effective, mosquito coils are typically used indoors, primarily at night during sleeping hours.

The following are steps in making a mosquito coil. First is the preparation of material (powder, water, active agent, coloring, etc). Second is tapioca starch powder must be cooked in 95 0C hot water to overcoming the glue. Third is wood powder and coconut shell powder is mixed until uniform. Then, put water into it and mix again. While mixing put solution of active agent, perfume, coloring into mixed powder. After a few minutes put cooked – tapioca starch into mixing and mix it a few minutes to have good pasta. Place it into extruding machine to make it sheet form. Then, pasta sheets will be stamped in the stamping machine and dry wet coil in chamber until moisture content less than 12%. Lastly, coil will be ready to use. http://preventdenguefever.blogspot.com/2009/10/production-flow-chart-of-manufacturing.html

These natural mosquito repellents are derived exclusively from herbal extracts and natural oils, which repel mosquitoes and other household insects. They work by acting as an irritant when mosquitoes come in contact. A mosquito is a two-winged insect whose females suck the blood of humans and animals by piercing their skin. The result is an itchy raised bump, referred to as a mosquito bite. Although the bite itself is not dangerous, mosquitoes can carry and pass along diseases, such as malaria, yellow fever, dengue fever, Rift Valley fever and the West Nile virus, which can have deadly consequences. The herbal mosquito repellents are non-toxic and eco-friendly - a totally safe herbal preparation with pleasing fragrance. Mosquito coils, vaporizer mats and emanators confer protection against mosquito bites through the spatial action of emanated vapor or airborne pyrethroid particles. These products dominate the pest control market; therefore, it is vital to characterize mosquito responses elicited by the chemical actives and their potential for disease prevention.

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.

Dr. Kaoru Ishikawa, a Japanese quality control expert, is credited with inventing the fishbone diagram to help employees avoid solutions that merely address the symptoms of a much larger problem.

A fishbone diagram is useful in brainstorming sessions to focus conversation. After the group has brainstormed all the possible causes for a problem, the facilitator helps the group to rate the potential causes according to their level of importance and diagram a hierarchy. The design of the diagram looks much like a skeleton of a fish. Fishbone diagrams are typically worked right to left, with each large "bone" of the fish branching out to include smaller bones containing more detail. This tool is being used by the researchers is to identify all possible reasons in order to discover the root cause that the company may encounter. http://whatis.techtarget.com/definition/fishbone-diagram

Review of Related Literature

Mosquito coil is mosquito-repelling incense, usually shaped into a spiral, and typically made from a dried paste of pyrethrum powder. The coil is usually held at the center of the spiral, suspending it in the air, or wedged by two pieces of fireproof nettings to allow continuous smoldering. Burning usually begins at the outer end of the spiral and progresses slowly toward the center of the spiral, producing a mosquito-repellent smoke. A typical mosquito coil can measure around 6 inches (15 cm) in diameter and lasts up to 8 hours. Mosquito coils are widely used in Asia, Africa, and South America. [Source: J Zhang, School of Public Health and Environmental and Occupational Health Sciences Institute] I recently came across a study published by J. Zhang, School of Public Health and Environmental and Occupational Health Sciences Institute, UMDNJ and Rutgers University. According to the researchers, the smoke that is emitted by these mosquito coils may contain pollutants that can be of serious health concern, posing “significant acute and chronic risks.” In the study, it was discovered that significant amounts of volatile organic compounds in it, including carcinogens (cancer-causing chemicals), were found in the smoke from mosquito coils.

“Burning one mosquito coil released the same amount of particulate matter as burning 75-137 cigarettes would emit. The amount of formaldehyde (an irritating carcinogen that effects many processes inside body) emission from one mosquito coil was as high as that emitted when 51 cigarettes are burnt,” the researchers said.

In another study by UC Riverside scientists, many mosquito coils – most notably those manufactured in Asia – often contain up to one percent BCME (which stands for biscloromethyether, a chemical associated with the breakdown of S-2). BCME has been described as “the most potent lung cancer chemical ever discovered.” And lung cancer is just about the most deadly cancer known. In one Chinese factory where mosquito coils were manufactured, a large fraction of employees were dead within five years of starting their jobs.

The use of mosquito coils as an insect repellent is not only prevalent in Asia, Africa and South America but also readily available and used throughout United States. The dangers of chemical based insect repellents have been well documented and it is evident that mosquito coils smoke poses both acute and chronic health risks and one should avoid their usage. Azizi BHO, Henry RL. 2009. The effects of indoor environmental factors on respiratory illness in primary school children in Kuala Lumpur. Int J Epidemiol 20(1):144–149 Domestic product is produced by Greencoil Industries Inc., a mosquito coil, branded as “Lion-Tiger”, is an insecticidal preparation made up of locally sourced natural combustible materials such as coconut shells, coffee pulps, corn cobs, ipil ipil and cassava starch, blended with chemicals such joss powder, dye stuff, metofluthrin (0.005%) or esbiothrin (0.1%) and sodium benzoate as active ingredients. It is green colored, joss scented and packed in small boxes containing five (5) double coils with a metal holder. The active ingredient is emitted by heat from the slow burning of the coil, thus mixing with air to repel or kill mosquitoes. Local raw materials averaged 26% of the total cost of raw materials used in the production of mosquito coils. The rest are imported chemical ingredients mostly from Indonesia and Thailand. A box of “Lion-Tiger” mosquito coils comes in two sizes: regular and junior. The coil is highly resistant to breakage because it utilizes high quality binding materials and is packed in a sturdy box.

Mosquito coils produced by JHHP and sold in the Philippine market: “Baygon anti-dengue mosquito coil”, which is green, spiral mosquito coil, featuring a mild fragrance and containing 0.20 % d-allethrin as active ingredient: and “Baygon scented coil”, the is a violet, spiral mosquito coil featuring a floral france and containing 0.20% d-allethrin as its active ingredient. Raw materials such as coconut, wood glue and starch powders, dyestuffs, preservatives and fragrance are 100% sourced locally. Both types are used to kill and repel mosquitoes and the active ingredient is emitted to the air by the heat generated by the slow burning of the coil. Each consumer box contains five (5) double coils and each coil last eight (8) hours. Chang J, Lin J. 2008. Aliphatic aldehydes and allethrin in mosquito coil smoke. Chemosphere 36(3):617–624.

THE PROBLEM AND ITS SCOPE

Statement of the Problem

The study seeks to determine what are the problems encountered by the Greencoil Industries Inc. in producing their products and how these problems affect the production process, status of the worker, and its productivity, the study also supply the possible solutions to the problems that the company has encountered. We intend to explore the relationship between the workplace the quality of their product and the working status of the worker. In particular, how better arrangement of the workplace reduces the defects of product and increase their productivity.

Specifically this study would like to answer the following questions: 1. What is the present status of the company in terms of; 1. plant location, 2. building profile, 3. product profile, 4. materials and its sources, 5. facilities and equipment 6. tools, 7. process flow, 8. product costing, 9. production layout, 10. time study, 11. production schedule, and 12. waste disposal? 2. What are the problems perceived by the respondents in terms of the production or technical aspect? 3. What are the proposed solutions to the problems encountered?

Significance of the Study

The study aims to help the company in their production process, and it would be benefited the following:

Management. It would be a great help to the company to have basis for the improvement of their production process in making mosquito coils, it could be a great help for their production process plan. This study can also possibly help to increase their productivity.

Workers. It will help them to know the benefits of a better design of the workplace, and how this design contributes to the productivity and would help and uplift its working status.

The community. It may help the community to be aware on the quality of mosquito coils they are using.

Entrepreneur. They may use this study as reliable reference for their future investment on what are the aspects that they need to consider.

Future Researchers. It may help the future researchers to have a basis for their studies.

Scope and Limitations

The study focuses on technical aspect of the company specifically in producing Lion Tiger Katol regular size. It only examined and identified the physical problems that need to improve the production layout and focuses on the processing of making the mosquito coils, and the layout of the production are. The researchers gathered data through direct observation and interviews by the Plant Engineer and the plant tour guide/harvest leadwoman. All financial data were not given by the company due to confidentially, such as the Bill of Materials and other matters.

RESEARCH METHODOLOGY

The method used was a descriptive research focused only on technical aspects at Greencoil Industries Inc., we gather data through interview on the branch manager and conversation with the plant tour guide and workers.

In getting data for the technical aspect, the researchers prepared some questions before conducting the company study. The question being asked to the branch plant engineer and plant tour guide/harvest leadwoman is only focuses on the production process and preparation of the raw materials. Different methodology such as casual interview to the workers, observations to the workplace, picture taking, and conducting time study was also being used. The researchers also used internet as source of data gathering for the company’s product and profile.

Figure No.1. - Flow of Study

The figure shows that the researchers used the following inputs: first is brainstorming, it is where the researchers planned all the actions that need to be done upon conducting the study, it includes the preparation of the letter of permission to allow going on to the company. After the approval of the letter, the manager set schedule for the researchers to conduct the study. During the visit in the production, the researchers are allowed to take pictures on the process and other concerned. The researchers do visual observation in the procedure in making the product from the raw materials, processes and until the product was finished and stored in the finished product area. Another is interview with the plant engineer, conversation with the plant tour guide/harvest lead woman as well as the workers and lastly is the workplace visual observation so that the researchers can gather data about the company. Based from the data gathered, the researchers solve the problems through discussions and analysis by using cause and effect diagram, Gantt chart and time study which leads to recommendations and formulation of the proposed solutions to the problem.

Respondents

The respondents of this study were the plant engineer, plant tour guide/harvest leadwoman and the workers of Greencoil Industries Inc., wherein the researchers ask them some questions about the production and the layout of the company.

Environment

Figure No. 2. – Research Environment

The study was conducted in Greencoil Industries Inc. which is located at Tingub Cor. Pagsabungan, Mandaue City where the researchers gathered the data about the technical aspects such as the workstation and the production processes. It is surrounded of nearby establishments such as Great Ideas Craft International Corporation, it is also located in the place wherein a lot of commercial establishment is present, and it is distant from Dedon Manufacturing Corp., Sendai Motors Manufacturing plant and others.

Instruments

The main tool used in this study is the stopwatch which is used to measure the time in each process, in gathering the data, information in interviews, conversations, and visual observations are also needed. The researchers also surf in the internet for some supporting information, and on unpublished thesis for other information and understanding about the concepts and principles in a production company.

DEFINITION OF TERMS

Biscloromethyether – one of the ingredients used in the mosquito coil production. Also known as the most potent lung cancer chemical ever discovered.

Esbiothrin – one of the chemicals used in making the mosquito coils.

Katol – is the Cebuano term for mosquito coil.

Lingkong – a visayan term which means a deformed mosquito coil, which the company sold at a low price and packed in bulk, into a corrugated box.

Pushcart – is a mean of transportation, use to transport the coils into the different process areas.

Pyrethrins – a chemical used as one of the ingredients, this chemical is an insecticide type of chemical.

Sun dry – an alternative process of drying the stamped mosquito coil.

Chapter 2

PRESENTATION, INTERPRATATION OF DATA, ANALYSIS OF TECHNICAL ASPECT

Company profile

Green Coil is a 100% Filipino owned corporation registered with the Securities and Exchange Commission (SEC) since 21 February 1995. Its business and plant facilities are located at Pagsabungan, Mandaue City, Cebu, Philippines. The company has an authorized capital stock of 500,000 shares, of which 63,755 were issued at PhP100 par value. The company manufactures and distributes mosquito coil under the brand names “Lion-Tiger”, “Lion-Katol” and “Tiger-Katol”. As of 31 December 2009, it has 130 personnel, 121 are directly involved in the production of mosquito coils. Greencoil Industries Inc. operates since 1952, they produce quality mosquito coils, and for more than 50 years of operation, Greencoil Industries Inc. continued manufacturing quality mosquito coils, with a vision, “to make this world a much better to live, a nice resting place free from dreaded disease”. They produce different type of mosquito coils, they have regular sizes, junior sizes and king sizes of the coils, they offer also scented coils, and other specification of mosquito coils. Greencoil Industries Inc. has the total land area of 55, 156 sq.m and its total building area is 16, 854 sq.m.

Figure No.6- Plant Location

The figure shows the location of Greencoil Industries Inc., it is located at B.Suico St. / Tingub Cor. Pagsabungan Road, Mandaue City. Greencoil Industries Inc. is 5.8 kilometers from Mandaue City proper. It can be reached through PUJ’s, motorcycles and motorized tricycles, the location of Greencoil Industries Inc. is located in the area wherein there are many other manufacturing plant such as Great Ideas Craft International Corp., Dedon Manufacturing Corp., Sendai Motors Manufacturing Plant and others.

Product Profile

Name: Lion Tiger Katol Regular Size

Color: Green

Shape: Double spiral

Size: Regular size (15cm)

Others: last up to 8 – 8.5 hrs.

The product is a mosquito coil use as repellant to malaria and dengue carrying diseases; it is widely used in every household especially here in the Philippines. The product is composed of different raw materials such as coco powder, wood powder, ipil-ipil leaves powder, mahogany leaves powder, mango leaves powder, coffee powder, corn cob, green powder, gum powder, onggok powder, water, and chemical (Esbiothrin). Other product classifications of Greencoil Industries Inc. are as follows:

Lion Tiger Katol Regular Size Modern small box

Now placed in a modern small box, the same effectiveness as the first and customers specially the new generation wants this modern packing. You light one coil and it gives you 8.5 hours of continuous protection against mosquitoes.

Lion Tiger Katol Junior Size

In modern packing, a little bit smaller in coil size than the regular, but still this is formulated to be the same effectiveness as the regular size. When you light one coil, it gives you 8 hours of continuous protection against mosquitoes.

The Greencoil Industries Inc. also produces scented coils, but it depends on the orders from the customers.

Product Price

The company preserved its confidentiality, due to any possible counterfeiting of their product; they decided not to share information about the financial aspect. To determine the product price of a box of Lion Tiger Katol (regular size), the researchers canvassed the price from the groceries, and it was found out that the suggested retail price of the said mosquito coil is Php. 12.50.

Raw Materials

The raw materials are very useful in making the mosquito coils it is from different plants, woods, leaves, and others, it is being pulverized and supplied to the manufacturing plant for the processing. The suppliers of these raw materials are from different part of the country such as Bohol, Leyte, Cagayan and others. Some of the raw materials like wood powder, gum powder and onggok are imported from Indonesia and Vietnam. The suppliers of these raw materials are contractual. For more information about the raw materials, please refer to the table below.

Table No. 1. - The table shows the descriptions of the raw materials that to be use in making the mosquito coils.

|NAME |PICTURE |DESCRIPTION |
|Coco shell powder | |Made from the coconut shell, the shell which is |
| |[pic] |organic in nature. Since it has good durability |
| | |characteristics it is mix with the other raw |
| | |materials to for dough that is used to produce a |
| | |coil. |
|Wood powder | |Is finely pulverized wood that has a consistency |
| | |fairly equal to sand or sawdust, but can vary |
| | |considerably, with particles ranging in size from |
| | |a fine powder to roughly the size of a grain of |
| | |rice. |
| | |Finely pulverize powder from an ipil-ipil tree, it|
|Lead tree powder | |is mix up with the other raw materials to form a |
| | |dough. |
|Mahogany leaves | |A powdered mahogany leaves used as raw material of|
|powder | |the coil dough. |
|Green powder | |A pesticide powder mix up with the other raw |
| | |materials. |
|Gum resin powder | |It acts as a binder in making this Mosquito Coil. |
| | |Mosquito Coil Guar Gum Powder is produced from |
| | |guar seeds or cyamopsis tetragonoloba termed as |
| | |Guar Gum. |
|Corn cob powder | |Is the natural active ingredient in |
| | |a rodenticide (rodent poison) which provides an |
| | |alternative to the more commonly known |
| | |anticoagulants rodenticides. |
|Coffee powder | |A powder from a coffee seed use as an additive to |
| | |thicken up the dough for the coil. |
|Mango leaves powder | |A powder from the mango leaves use as raw |
| | |materials and it functions like the other raw |
| | |material. |
| | | |
|Onggok powder | |A powder that is mix up with the other raw |
| | |materials and it is used as binder. |
| | | |
|Water |[pic] |Mix with the raw materials to thicken and use as |
| | |ingredient to moisten up the mixture of the raw |
| | |materials. |
|Chemicals |[pic] |Use as an additive to the coil to make it as a |
| | |pesticide. |

The table above shows different raw materials being used in producing the mosquito coils. The raw materials needed are the Coco shell powder, Wood powder, Lead tree powder, Mahogany leaves powder, Green powder, Gum resin powder, Corn cob powder, Coffee powder, Mango leaves powder and the Onggok powder.

Manufacturing Process and Layout

[pic]

Figure No. 3. - Manufacturing Process with Process Flow

The figure shows the manufacturing process flow in making a batch of mosquito coil. The raw materials are supplied by the contracted suppliers it will undergo to a raw material mixing/storage. The manufacturing process starts in kneading process wherein 20 sacks of mixed raw materials are placed into a kneading machine, it will be mix up with the 6 pales of water and a sufficient volume of chemicals. After the raw materials is completely kneaded it will be poured out to the conveyor of the stamping machine for the stamping process, in the stamping machine the raw materials will be stamped into a 6 double coils for regular size and 7 double coils for junior size, after the stamping process the coils will be place into a screen, a screen can accommodate 2 set of stamps, a total of 12 double coils for regular size and 14 double for junior size, the screen will be put on to a push cart to transport to the next process which is drying, in drying process the company uses two types of drying, the tunnel drying which uses a tunnel dryer supported by a steam broiler and the sun dying which uses the heat of the sun to dry the coils. After the coils are being dried it will be harvested by the workers, from the screens the coils will be place into a box and be delivered to the packing area for the packing process. In the packing process the double coils will be piled by 10 and it will be place into the conveyor of the packing machine, 1 box of Lion – Tiger Katol regular size is composed of 5 double coils and 1 mosquito coil stand. After the product is packed it will be stored into the storage area, and it is ready for shipment.

It shows the plant layout of Greencoil Industries Inc., the production area is composed of five areas namely; the kneading area, stamping area, tunnel drying area, harvesting area, and the packing area. It has also an area for sun drying and raw material mixing area. Other areas such as generator set area, office, carbon coal storage area, canteen, comfort room, maintenance dept. area, guard house, and parking area are also provided.

Analysis:

It also shows that the existing metal plate for the aisles of the production area is limited, only provided in the aisle between the first two stamping and tunnel drying machine. As the researchers observed, the production area has metal plate in order to transport easily the stamped coils into the tunnel drying machine, but the existing metal plate is not sufficient and is only limited in a specific area as shown in the Figure above. Rough floor surface of the production area, is also identified as major problem which may cause defects (breakage and deformation) of the product. The company uses pushcarts as a means of transporting the products into different production areas. As the researchers interviewed some of the workers, the workers said that the rough surface of the production area cause some accidents such as the wheels of the push carts be possibly affected of the rough surface. And this accident will lead to the products defects (breakage and deformities).

Process Flow Chart

Figure No.4. - Process Flow Chart

The figure shows the manufacturing process in making the mosquito coil. The raw materials in making the mosquito coils are coco shells, coffee pulp, sawdust; dried ipil-ipil leaves dried mango leaves, dried mahogany leaves, cassava starch, and gum resin powder. Raw materials are prepared by screening, chopping, and then put to a rotary dryer to reduce moisture content. In mixing, all raw material powder will then be poured in a rotary mixing machine, to mix it thoroughly. In kneading, the mixed powder will be transferred to the kneader, add the actives, cassava starch and coloring matter. Stamping, in this process the coils are formed thru a Stamping Machine. One stamp operation produces seven double coils. Wet coils are put on screen trays, and then placed in the push carts for drying. In drying, push carts are used in carrying the trays with wet coils are engaged in a chain pusher to go inside a Tunnel Dryer; the coils are now ready for the next process. In harvesting, the dried up coils are harvested and will undergo the final quality control. Lastly is packing, the final good coils will be transferred to a packing machine and wrap it by 10 double coils in a plastic pillow pack, put a metal stand aside. Put it in a small box, and then the small box is placed in a corrugated carton. Now it’s ready for shipment.

[pic]Figure No.5. – Production Schedule of 17 batches of mosquito coils

The Figure shows the production schedule of 17 batches of mosquito coils, a batch of mosquito coil is composed of raw materials powder, water, and chemicals. One batch can be completed with a standard time of 429.86 minutes and is equal to 7.1 hours. The production process is being done simultaneously, after the raw material mixing is complete is will pass on to the kneading process to be knead in 15 minutes, after the materials are being knead it will pass on to the stamping process, the operator of the kneading process will be knead another batch of raw materials. As well as in the kneading process, but the second batch of the production process will be completed on the next day, this is due to the reason that the drying process will take a long period of time in order to fully dry the mosquito coil. The researchers propose that the company should reduce three (3) workers in order to eliminate idle time.

Mosquito Coil Utilization Time and Idle Time

Table No. 2. – Utilization time every processes

| | |Time Utilization/ day | |Allotted Time for other product/ | |
| | | | |day | |
|Operators Name |Process Assigned |Time (hrs) |Percentage (%) |Time (hrs) |Percentage (%) |
|Roberto Pasaol |Raw materials mixing |2.83 |37.73 |4.67 |62.27 |
|Richard Tapilot |Kneading |4.25 |56.67 |3.25 |43.33 |
|Dinnnes Gean |Stamping |0.28 |3.73 |7.22 |96.27 |
|Jerry Dela Pena |Drying |6 |80 |1.5 |20 |
|Lyndon Mantunjao |Harvesting |4.82 |64.27 |2.68 |35.73 |
|Melien Beliot |Packing |0.28 |3.73 |7.22 |96.27 |

The table shows the utilization time per day and allotted time per day for each worker. Worker 1 got 37.73% of his utilization time per day and 62.27% of his allotted time per day. Higher idle time doesn’t always mean that he is not efficient because ten minutes is just a part of his overall activity in one day. Worker 2 got 56.67% of his utilization time per day and 43.33% of his allotted time per day. Idle time for worker 3 doesn’t mean that he is not doing his job efficiently because the researchers only timed the stamping of only one mosquito coil screen but overall he is very productive because he can finish hundreds of mosquito coil screen in a day. Worker 4 got 80% of his utilization time per day and 20% of his allotted time per day. Worker 5 got 64.27% of his utilization time per day and 35.73% of his allotted time per day. Idle time for worker 6 doesn’t mean that she is not doing his job efficiently because the researchers only timed the packing of only one small box mosquito coil but overall she is very productive because she can finish hundred boxes of mosquito coils in a day.

Machinery

The machines used in mosquito coil production are very rigid and fixed. It undergoes preventive maintenance once a week/ every Sunday. Every machine is fit with the process that being operated and has its own operator to check its speed, performance, and status whether it is already in overheat. The machines that are being used in Greencoil Industries Inc. to produce a quality mosquito coil are stamping machines, kneading machines, rotary dryers, tunnel dryers, rotary mixing machines, and packing machines. For more information about the machines, please refer to the table below.

Table No. 3. - The picture shows the machinery and its descriptions and the use in making the mosquito coils.

|Name |Picture |Description |
|Stamping machine | |Used to stamp the flattened dough into a double |
| | |mosquito coil. A stamping machine composed of 7 |
| | |stamps for junior size and 6 stamps for regular |
| | |size. |
|Kneading machine | |Kneading Machines are used to knead dough and are|
| | |renowned for their high output. In these machines|
| | |20 sacks of raw materials are mixed together and |
| | |added with water to thicken. |
|Rotary dryer | |It is a type of dryer employed to reduce or |
| | |minimize the liquid moisture content of the |
| | |material it is handling by bringing it into |
| | |direct contact with a heated gas. In this machine|
| | |the raw materials are being dried to reduce |
| | |unwanted moist. |
|Tunnel dryer | |It works in a positive air pressure that comes |
| | |from the fan of low speed. This machine uses |
| | |steam broiler as source of heat and also uses |
| | |wind blower to dry up the coils. |
|Rotary mixing machine| |It is used in mixing a variety of raw materials |
| | |such as the coco shell, wood powder, mango leaves|
| | |and others. |
| | |It is used to pack the harvested dried coils, in |
| | |this machine the coils are placed in the conveyor|
|Packing machine | |and it run in one flow until the coil is placed |
| | |into a paper box. Putting in the coils into a |
| | |paper box is done by the packers. |

The table above shows the machines used in making the mosquito coils which were stamping machine, kneading machine, rotary dryer, tunnel dryer, rotary mixing machine and packing machine. The machines will undergo for a preventive maintenance every Sunday.

Table No.4-Time and Motion Study

|Name of Operator|Performance Rating |Process |Total Observed |Average Observed |Allowance Factor |Normal Time(min) |Standard Time(min)/batch |
| | | |Time(min) |Time(min) | | | |
|1. |95% |Raw materials Mixing |10 |10 |0.12 |
|Rob| | | | | |
|ert| | | | | |
|o | | | | | |
|Pas| | | | | |
|aol| | | | | |
| |Direct materials |
| |Materials |Unit |Qty. |Price(Php) |Unit Cost(Php.) |
| |welding rod |Pcs. |50 |25 |1250 |
| |metal sheets (2m x 5.3m x |Pcs. |47 |650 |30550 |
| |10mm) | | | | |
| |portland cement |Sacks |13 |198 |2574 |
| |Peebles |Sacks |26 |45 |1170 |
| | Total | | |Php |35,544 |
| | | | | | |
| | | | | | |

The table shows the needed materials in implementing the proposed design of the workplace aisles.

Table No. 6. - Utilities

| |
|Utilities |
|Machine |Power(watts) |Electricity rate(Php) |Cost(Php.) |
| Welding Machine |11250 |9 | Php 6,328.12 |
| |

The table shows the utility needed in implementing the proposal.

Table No. 7. – Labor

Labor

| | | | | |
|Worker |No. of worker |Rate per day(Php.) |No. of working days |Cost(Php.) |
|Welder |1 |350 |14 |4900 |
|Helper |4 |250 |14 |14000 |
|Total | | | |Php. 18,900 |

The table shows the needed workers in implementing the proposal.

Table no. 8. – Summary of the total cost of proposal

Summary:

|Direct materials |Php. 35544 |
|Utilities |Php. 6328.12 |
|Labor |Php. 18900 |
|Total cost of proposal: |Php. 60,772.12 |

The table shows the total cost of the proposal as to the direct materials, utilities, and labor.

COST OF PROPOSAL (finishing of the aisles’ surface)

Table No.

|Direct Materials |
|Materials |Unit |Qty. |Price(Php.) |Cost(Php.) |
|Sand |pcs |118 |20 |2,360.00 |
|Cement |pcs |59 |195 |11,505.00 |
|Total Direct Materials 13,865.00 |
|Utilities |
|Water 50.00 |
|Labor |
|Worker |No. of Worker |Rate |No. of Working Days |Cost(Php) |
|Construction worker |1 |300 |7 |2,100.00 |
|Helper |3 |250 |7 |5,250.00 |
|Total Labor 7,350.00 |
|Total Cost of Proposal 21,265.00 |

Summary:

|Direct materials |Php. 13,865.00 |
|Utilities |Php. 50.00 |
|Labor |Php. 7,350.00 |
|Total cost of proposal: |Php. 21,265.00 |

CONCLUSION

Based from the observation and data gathered that undergoes thorough analysis, the production layout is well-organized; the problem is the existing situation of the aisles and the floor surface of each processing area. The aisles between the two stamping machines and the two tunnel dryers has metallic surface, but it didn’t reach up to the other aisles in the production area. It would probably affect the products quality, due to the rough surfaces, the pushcart’s wheels may be affected and it would be the cause of product defects and accidents. And it would probably affect its productivity. The researchers, made a costing both the metal plate extension and the finishing of the aisles’ surface, and it was found out that the finishing of the aisles’ surface is feasible compare to the extension of the metal plate, this is due to that the extension of metal plate is more costly (Php.60, 772.12) compare to the finishing of the aisles’ surface which only cost Php. 21, 265.00.

BIBLIOGRAPHY

A. BOOKS

Freivalds, Andris.2009. Niebel’s Methods, Standards, and Work Design, Twelfth Edition. McGraw – Hill Companies Inc.

B. EBOOKS

Azizi BHO, Henry RL. 2009. The effects of indoor environmental factors on respiratory illness in primary school children in Kuala Lumpur. Int J Epidemiol 20(1):144–149. Chang J, Lin J. 2008. Aliphatic aldehydes and allethrin in mosquito coil smoke. Chemosphere 36(3):617–624.

WHO. 2002. World Health Report: Reducing Risks, Promoting

Healthy Life. Geneva:World Health Organization.

J Zhang. 2005, School of Public Health and Environmental and Occupational Health Sciences Institute

C. Unpublished Materials

Barriga, Mark Kevin, et al; “Company Study at Alberto’s Pizza Danao Branch”; Unpublished Project Thesis; Cebu Technological University-Danao City Campus; October 2013

Tigbao, Eva, et al; “Company Study at Jet Hardware and Construction Supply”; Unpublished Project Company Study; Cebu Technological University-Danao City Campus; March 21, 2013

D. Internet Source:

http://www.lion - tiger.com.html (viewed March 1, 2014)

http://www.lion-tiger.com/location.html (viewed March 1, 2014)

https://www.google.com.ph/maps/search/tingub+cor.+pagsabungan/@10.3602755,123.9381015,17z/data=!3m1!4b1 (viewed March 1, 2014)

http://www.lion-tiger.com/products/mosquito_coils/index.html (viewed March 1, 2014)

https://sites.google.com/site/projectethio/home/chemical-products/mosquito-coils-making-plant (viewed March 27, 2014)

http://preventdenguefever.blogspot.com/2009/10/production-flow-chart-of-manufacturing.html (March 27, 2014)

http://whatis.techtarget.com/definition/fishbone-diagram (viewed March 27, 2014)

http://www.google.com.ph/UC +Riverside+ scientists/mosquito coils (viewed March 1, 2014)

http://www. WHO.com/effects=mosquito+coils (viewed March 1, 2014)

https://www.google.com.ph/search?q=kneading&source=lnms&tbm=isch&sa=X&ei=E9cZU7rjGMnliAfM9YHIAQ&ved=0CAcQ_AUoAQ&biw=1366&bih=667#q (viewed March 4, 2014)

https://www.google.com.ph/search?q=kneading+machine&source=lnms&tbm=isch&sa=X&ei=pwYaU7OCIMPOiAfzkYDAAw&ved=0CAcQ_AUoAQ&biw=1366& (viewed March 4, 2014)

APPENDIX
Computations:
Time and Motion Study Formulas Used:

Normal Time = Total Time x Rating Factor

Standard Time = Normal Time x (1+ allowance factor)

% Time Utilization/ day

Worker 1 = [pic]

Worker 2 = [pic]

Worker 3 = [pic]

Worker 4 = [pic] [pic]

Worker 5 = [pic][pic]

Worker 6 = [pic]

% Idle time/day

Worker 1 = 7.5 – 2.83 = 4.67 hr.

% = [pic]

Worker 2 = 7.5 – 4.25 = 3.25 hr.

% = [pic]

Worker 3 = 7.5 – 0.28 = 7.22 hr.

% = [pic]

Worker 4 = 7.5 – 6 =1.5 hr.

% = [pic]

Worker 5 = 7.5 – 4.82 = 2.68 %

% = [pic]

Worker 6 = 7.5 – 0.28 = 7.22 hr.

% = [pic]

Allowance factor: 12% of 7.5 hr. = 0.9hr/day

DIRECT MATERIALS:

Portland cement: 59 sacks x Php195=Php11,505.00

Pebbles: 118 sacks x Php20=Php2,360

Total: Php. 35,544

UTILITIES:

Water: cost used = Php. 50.00

LABOR:

1 Construction worker: Php. 300 x 7 days = Php. 2,100

3 Helper: Php. 250 x 7 days = Php. 1,750

Total: Php. 21, 265

Letter with approval

[pic]

Pictures

The picture shows the outside and inside vicinity of the company. Inside, you can see the dryer area, packing area, harvest area, and the stamping area.

The picture shows the two process of drying the mosquito coils:the sun dry and the tunnel drying process. It also shows the raw materials of the product. The last two pictures are the finished products but the one at the left side is what they call “Lingkong”.

The picture shows the researchers outside and inside of the company’s vicinity. The researchers were also given a chance to have a picture with the company’s Plant Engineer also with the Harvest Leadwoman.

Curriculum Vitae

Personal Information

Name : Ariel Jay C. Cases

Address : Looc, Danao City

Age : 20

Gender : Male

Birthdate : January 25, 1994

Birthplace : Compostela Cebu

Citizenship : Filipino

Religion : Roman Catholic

Civil Status : Single

Father : Alfredo Cases

Mother : Wenceslawa Cases

Mobile Number: 09322916849

Email Address : ariel.cases@yahoo.com

Personal Information

Name : Jannelyn G. Aring

Address : Taytay, Danao City

Age : 20

Gender : Female

Birthdate : January 19, 1994

Birthplace : Danao City

Citizenship : Filipino

Religion : Roman Catholic

Civil Status : Single

Father : Felixberto Aring

Mother : Lourdes Aring

Mobile Number: 09334058030

Email Address : jannelynaring19@yahoo

Personal Information

Name : Caryn L. Hermoso

Address : Cahumayan, Danao City

Age : 20

Gender : Female

Birthdate : July 28, 1993

Birthplace : Cahumayan, Danao City

Citizenship : Filipino

Religion : Roman Catholic

Civil Status : Single

Father : Julito Hermoso

Mother : Melchora Hermoso

Mobile Number: 09107850568

Email Address : carynhermoso@yahoo.com

Personal Information

Name : Maria Juliet C. Sucalit

Address : Can-ibuang, Catmon Cebu

Age : 20

Gender : Female

Birthdate : March 12, 1993

Birthplace : Catmon, Cebu

Citizenship : Filipino

Religion : Roman Catholic

Civil Status : Single

Father : Allan Sucalit

Mother : Narcisa Sucalit

Mobile Number: 09233921698

Email Address : sucalit_juliet@yahoo.com

-----------------------
OUTPUT

• Recommendations

• Proposed solutions to the existing problem

INPUT

• Brainstorming

• Personal interview, visual observation

• Personal interview and conversation

• Company and product data

• Web surfing

• Visual observation

• Time Study

PROCESS

• Cause and

Effect Diagram

• Gantt Chart

• Brainstorming

• Standard Time

OUTPUT

• Recommendations

• Proposed solutions to the existing problem

INPUT

• Brainstorming

• Personal interview, visual observation

• Personal interview and conversation

• Company and product data

• Web surfing

• Visual observation

• Time Study

PROCESS

• Cause and

Effect Diagram

• Gantt Chart

• Brainstorming

• Standard Time

[pic]

Start

Raw Material Storage

Mixing

Kneading

Stamping

Drying

Harvesting

Packing

End

Production Schedule

Figure No. 10. - Cause and Effect Diagram

The figure shows the Cause and Effect Diagram on what is the main cause of the product defects of Greencoil Industries Inc. , it shows that product defects has a lot of possible cause, in terms of their worker, machine, materials, methods and environments. Through the direct observation method, the researchers analyzed and identified that the main possible cause of the problem is in their environment, specifically the design of the aisles which has metal plate that is insufficient in the whole needed area.

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