8/6/2019 IRP my part 23

1/14

Process Selection and Facility Layout

Swim Lane Diagram of the Manufacturing Process

8/6/2019 IRP my part 23

2/14

Process Definition

Mixing Ingredients of Gel coat 1, Gel coat 2 and slurry are mixed.

Molding Forming the slurry into a specific design

Grinding Removing excess part of the molded product

Patching Covering unwanted holes and breaks

Sanding Smoothing the surface and opening of the product

Gel Coating Putting Gel coat inside the product to prevent leakage

Washing Washing the product after gel coating to remove wax

Quality Control AreaFinished products are checked if it is meeting the desired quality

8/6/2019 IRP my part 23

3/14

Existing Plant Layout of DRJ Enterprises

Existing Plant Layout of JRD Enterprises

8/6/2019 IRP my part 23

4/14

Functional Areas

Mixing Area

This area is responsible for mixing of ingredients to make slurry and Gel coat 1 &

2. Slurry is a mixture of Limestone, polycol 130, polycol 113 and water. Gel coat 1 is a

mixture of Polycol 130, polycol 113, water, styrene, cobalt and hardener and Gel coat 2

is a mixture of Polycol 113, caciumine and hardener.

Casting Area

Molding of slurry into a specific design and putting of fiber mat to strengthen the

product is done in this area.

8/6/2019 IRP my part 23

5/14

Grinding Area

After casting, excess part is removed and sharp edges are smoothen in this area.

Patching Area

Fixing small defects and covering small holes in the product is done in this area.

Sanding area

This area is responsible for smoothing the surface and the opening part of the

product. Final sanding after washing and patching is also done in this area.

8/6/2019 IRP my part 23

6/14

Gel Coating Area

This area is responsible for putting gel coat inside the product to prevent leaks.

Washing Area

This area is responsible for washing the product to removed wax after being

coated.

Quality Control Department

This area is responsible for the final inspection of the finished product.

8/6/2019 IRP my part 23

7/14

Safety

Safety rules and regulations

Personal Protective Equipment

Personal protective equipment refers to protective clothing or other garment

designed to protect the wearer's body from injury by blunt impacts, electrical hazards,

heat, chemicals, and infection, for job-related occupational safety and health purposes.

Not wearing gloves Not wearing any t-shirt

Not wearing face mask Not wearing face mask and gloves

The company did not provide any personal protective equipment such as gloves

to protect the hands of the workers and face mask to protect the workers from dust.

8/6/2019 IRP my part 23

8/14

Source of Hazards

y Unwanted stro ng odor from the gel coat i n mixi ng area

y D ust from sa ndi ng and gri ndi ng area

y Noise from gri ndi ng area

Safety Signage and Posters

Fire Prevention Practices

The compa ny does n t have a ny fire fi ghti ng equipme nt such as fire exti ng uisher

and fire exits.

y No Safety Labelsin the Work Area

y No Safety GuidelinesProvided

y No safety Posters

Researchers noticed that the compa ny

lacks safety si gn s a nd labels i n the work area.

Even the fire exit si gn is not available. This

si gn s a nd labels are importa nt to guide the

worker o n what to do.

8/6/2019 IRP my part 23

9/14

Workplace Hazard

Live wires from the electric fa n i n sa ndi ng and gri ndi ng area are exposed.

Uncovered stora ge of chemicals. These chemicals create a n unfriendly odor.

8/6/2019 IRP my part 23

10/14

History of Accident

Department Kind of Accident Frequency Severity Response Mix ing area Mi ld bur n 1 Nonfatal First a id

Record of Accidents

S ince the compa ny does not keep a ny record of acc ide nts occurre nce, the

researchers ask the operat ions ma nager about the acc ide nt occurre nce that happe ned.

D ata show n above shows the k ind of acc ide nt that, its freque ncy, sever ity, a nd the

respo nse made by the compa ny.

Housekeeping

Tools and equipment

Keep ing of tools a nd equ ipme nt after work are not co nsiste nt because

some of the workers leave the ir tools u natte nded. Some of the tools are m iss ing

due to th is pract ice.

Raw materials

Unused raw mater ials are left beh ind in the work ing area.

House keeping policies

The compa ny set rules for house keep ing that each workers are respo ns ible in

ma inta in ing clea nliness in there des ignated area before a nd after the operat ion . They

8/6/2019 IRP my part 23

11/14

prov ide these rules to ma inta in pleasa nt a nd hassle free work e nvironme nt. The wastes

obta in from clea ning are placed o n the sacks s ince there are no ava ilable garba ge b ins

in the product ion area but instead, they place the ir waste in sacks. To make use of the

sacks from l imesto ne s they reused as a co nta iner of the garba ge collected.

8/6/2019 IRP my part 23

12/14

Input Process Output Framework

Department /Area Input Process Description Products

Mix ing area

Limesto ne,polycol 130,polycol 113,

water

Mi x ing Limesto ne, polycol 130, polycol113 a nd water are m ixed to makeslurry

Slurry

Polycol 130,polycol 113,

water, styre ne,cobalt,

harde ner

Mi x ing Polycol 130, polycol 113, water,styre ne, cobalt a nd harde ner arem ixed to make Gel coat 1

Gel coat 1

Polycol 113,cac ium ine,harde ner

Mi x ing Polycol 113, cac ium ine a ndharde ner are m ixed to make Gelcoat 2

Gel coat 2

Cast ing Area Slurry,

harde ner,wax,f iber mat

Cast ing andmold ing

Slurry is mold into a spec if icdes ign and putt ing f iber mat a ndgel coat

Unpol ished stcast a nd ur

Grinding

Unpol ished

sto ne cast a ndurns Gr

inding Excess parts are removed a ndsmooth ing sharp object

Grinded sto nand ur n

Patch ing Area Grinded sto ne

cast a nd ur ns patching Cover

ing small holes a nd cracksin the products

patched sto nand ur n

Sanding Area patched sto necast a nd ur ns Sanding

Sanding of ope n ing part a ndsurface of the products to make it smooth

Sanded sto nand ur n

Gel Coat ing area

Sanded sto necast a nd ur ns Coat

ing Coat ing the ins ide of the product

to preve nt leaka ge Coated sto ne

and ur n

Wash ing Area Coated sto necast a nd ur ns Washing Wash

ing the product to removesta ins a nd wax

Washed cast aurns

QualityControl Area Washed cast and ur ns Inspect ing Final inspect ion before sh ipp ing Inspected prod

8/6/2019 IRP my part 23

13/14

Waste Management

Types of Wastes Wastes Generated Disposal Method

Solid Wastes

D ust To be disposed in the

dumps ite

Excess parts of the product To be d isposed in thedumps ite

Used molder To be recycled for futureproduct ion process

Excess slurry To be disposed in the

dumps ite

Excess Gel coat 1 To be disposed in the

dumps ite

Excess Gel coat 2 To be disposed in the

dumps ite

Excess f iber mat To be disposed in the

dumps ite Chem ical drums To be sold

Liqu id Wastes Water Wastes Generated and Disposal Method

The compa ny produces more wastes in the product ion departme nt. Most the ir wastes

are throw n in the dumps ite. The used molders are stored in the vaca nt s ide of the product ion

are for future product ion . D rums are sold for 200-300 pesos each.

Effects of Wastes in the Community

Most of the wastes generated by the compa ny are sol id a nd non biode gradable. If not

properly d ispose it may harm people that is w ith in the v icin ity of the compa ny. Waste l ike dust

is very hazardous to huma n health because it ca n cause irritat ion to the lu ng s a nd could cause

lung disease. Some of the waste l ike the excess gel coat, excess slurry a nd excess parts of the

product are use to f ill the muddy a nd u neve n surfaces of the road.

8/6/2019 IRP my part 23

14/14