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CHAPTER I
INTRODUCTION
Company which is one of the world’s leading suppliers of inductors and the world’s
first axial leaded ceramic capacitors. Electrons Philippines Inc. primarily pioneered
the assembly and mass production of inductors for various companies. It has also
developed the auto strategy technology and learning mode for Digital Video Disc
(DVD) burners. Electrons Philippines Inc. was established in1988 and located at
Every company, has a great role to continue its business operation, and
Electrons Philippines Inc. aimed to maintain and minimize its major problem that
may occur in its operation, it must have immediate disposition. One of these
products produced was inductors which is a small and low profile inductor. It
corresponds to high current, a simple and original magnetic shield structure which
is strong against a shock proof. Its application is for small Direct Current (DC)
Converter – cellular phone, Liquid Crystal Display (LCD), display and in automotive
for navigation and auto mobile. It has a series structure which are wound wire,
terminal electrode, drum core and resin (with ferrite). It has 3 major processes with
such as carrier tape feeder, taping machine, and P-P machine. The Carrier Tape
the carrier tape causing the production process that yields is very low as well as
company financial yield. A stretched carrier tape defect is attributed by tape feeder
should be able to test on its product to see if micro Henry units are within
and Place machine was its continuous operation even though the tape feeder
damaged carrier tape. It is because the carrier tape was loaded on the tape feeder
machine and supplied to the taping machine process, and then it will be endorsed
to Pick and Place (PP) machine to test and program its inductor product.
The current set-up of the tape feeder machine is a separate system from
taping machine process as well as the features such as; PLC (Programmable
Logic Controller), Module, and Controllers. The tape feeder machine is consist of
motors, Programmable Logic Controller, and Stop Start button which is responsible
to supply the carrier tape on the taping machine. Both processes have no
Theoretical Background
sensors are used for go-no-go gauging such as liquid level in reservoirs, where
them to work through a non-conducting window, similar devices (stud sensor) can
find wood studs behind plaster walls. Very high analog accuracy and linearity can
plate geometries can be used with digital circuits to substitute digital precision for
analog precision.
Materials have different values of dielectric constant as well as dielectric loss, and
the values of both properties (particularly dielectric loss, or loss tangent) change
rides, or light fixtures. PLCs (Programmable Logic Controllers) are used in many
digital and analog inputs and outputs, extended temperature ranges, immunity to
life and national defense. More recently, a new era in sensor technology was
properties and behavior, thereby offering possibilities for new sensors with
advanced features, such as greater fidelity, lower cost, and increased reliability.
5
THE PROBLEM
machine using capacitive sensor and modify PLC Programmable Logic Control in
order to reduce stretched carrier tape scrap per day at Electrons Philippines Inc
the following:
1.1 Process;
1.2 Process Yield;
1.2.1 Quantity;
1.2.2 Number of defects; and
1.2.3 Cost?
2.) What is the problem encountered in the present set-up in Kansen-
Taping process?
3.) What electronic system can be proposed to address the problem on the
existing set-up?
The result of this study will define on the systematic auto stop machine
required in the Kansen-Taping process which will be installed in this area that in
turn will eventually reduce the defects. Moreover, it would be beneficial to the
following:
6
The Company
Inc. by increasing the daily output and ensuring manufactured components which
of failure and assistance. Thus, increasing uptime capacity and MTBF (main-time
before failure).
The Customers
products and standard product specification are met. With the expected cost
savings from the proposed project, the customer can also expect a cheaper but of
The Proponent
a very valuable project. It will also result in gaining respect, trust, and confidence
from colleagues and superiors. Through this project study, she can also attain a
college degree as part of the requirements for the degree of Bachelor of Science
The future researchers can use this study as a reference for their
company. This project will also provide the researcher some ideas on problem
DEFINITION OF TERMS
The following are the terms used in the study which are defined for better
Alternating Current (AC). This refers to what occurs when charge carriers in a
Amps. This refers to the measure of energy flow, measured in electrons moving
per second. The number of Amps represents the amount of charge flowing past a point in
Circuit. This refers to an electrical network that has a closed loop giving a return
Charge Controller. This refers to the one that decides to switch on /off charging
and lighting.
nearby objects by their effect on the electrical field created by the sensor.
8
Productivity. This refers to the rate at which the company produces goods
computer which has been ruggedized and adapted for the control of
Switch. This refers to a component which is used for a start, stop, and
Tape Feeder. The term refers to the part of Kansen-Taping machine which
is consist of motors and sensors that are responsible for the automatic supply of
machine.
requirements.
Yield. The term refers to the percentage ratio of output quantity and input
of time).
9
CHAPTER II
THE DATA
This chapter presents, analyzes, and interprets the data collected in the
Kansen-Taping process of the study. The data pertains to the present status of the
SECTION 1
Figure 1 shows the existing Tape Feeder machine at the Kansen taping
Process.
Figure 1
Process
10
Figure 1 shows that the Tape feeder machine which is consist of motor and
controller. A drive motor always rotates during operation and the speed of motor
and taping processing both are the same in order to balance the supply and the
output. Unfortunately, the tape feeder machine encountered error or stop which
results that the carrier tape supply will be stretched or damaged because of the
SECTION 2
Figure 2
Figure 2 shows the carrier tapes on the reel. A carrier tape is covered with
top cover tape to protect the products away from damages. A product is placed on
11
the carrier tape cavity. A carrier tape is loaded on the tape feeder machine and is
Process Yield
Where:
Over all Process Yield = (Total Annual Output /Total Annual Input) x 100%
= 98.66%
Process Yield
98.7%
98.7%
98.7% 98.7%
98.7%
98.7%
98.7%
98.7% 98.7%
Process Yield
Figure 3
inclusive from Aug 2016 up to Jun 2017 that has a total of 98.66% process yield.
It will be based on a total input of 7,688,000 units and total output of 7,584,967
12
units. Thus, Kansen-Taping process cannot achieve 99% or more due to non-
conformity of the product. The researcher breaks down the negative 1.34% yield
loss.
Quantity
Where:
process.
TABLE 1
Quantity
Kansen Process
Per Day Per Month Per Year
Total Output
24,311 632,081 7,584,967
13
a day or 7,584,967 per year. It will be based on the actual output of 3,038 per hour.
Based the results of productivity study, the Kansen- Taping process can produce
between 3,000 to 4,000 units per hour. Unfortunately, the study did not consider
all factors such as machine downtime and change of the materials, etc. which can
also contribute to lower output because the researcher is looking into long term
solution.
Number of Defects
= 98.66%
= 1.34%
= 98.66% + 1.34%
= 100%
TABLE 2
Process. There are around 103,033 units or 1.34% defective products per year.
The total good product output is around 7,584,967 units. Currently, the Kansen-
Cost
To compute the total annual scrap cost, the following formula was used:
Where:
Total Annual Scrap Cost = Total number of defects X Cost per Piece
= 103,033 X $ 0.40
= $ 41,213.20
It shows the computation above that the company total annual scrap cost
TABLE 3
The annual total scrap cost of defects is equal to $ 41,213.20. The average
price per unit is $ 0.40 and the number of defects per year is 103,033 units.
16
CHAPTER III
THE PROPOSAL
Logic Controller) at the Tape Feeder machine. The main purpose of the proposal
which cannot stop the taping machine even though the tape feeder is down.
Based on the findings of the current set-up of the Tape feeder and Taping
Machine, the researcher proposed to install capacitive sensor in the tape feeder
the presence of carrier tape supply to the taping process, and the stepper motor
will depend on the sensor. The stepper motor will rotate when the sensor detects
that there is no presence of carrier tape. It also modified PLC program which is
integrated at the taping machine process. By the time there is an error that occurs,
The actual Tape feeder machine with the installed sensor and modification
Figure 4
The tape feeder machine in the Kansen-Taping process which was installed
in the new stepper motor from none industrial motor since the indexing process
process. The newly-installed stepper motor and sensor in the Taping machine
Figure 5
with controlled capacitive sensors. The reel motor will activate when sensor 1 is
not activated until it detects the presence of carrier tape. While Sensor 2 detects
on the pick and place area which triggers when there is the presence of carrier
tape. Sensor 3 dictates to the take up reel motor to avoid sagging the carrier tape.
Figure 6.
19
Figure 6
The stepper motors are DC Motors that move discrete steps. They have multiple
coils that are organized groups called “phases”. By energizing each phase in
sequence, the motor will rotate one step at a time. With a computer-controlled
stepping, one can achieve very precise positioning and/or speed control.
Figure 7
Schematic Diagram Input / Output with Installed Capacitive Sensor
20
Figure 7 shows the schematic diagram of the PLC where the stepper motor
and sensor are both connected. The systems have start and stop buttons and are
supplied with 24VDC connected to the PLC. While the capacitive sensor detecting
the presence of material feed into the next process, a stepper motor is activated
the comparison between the current and the proposed innovation of transient
TABLE 4
Quantity
Kansen-Taping Process
Per Day Per Month Per Year
Present (Method)
24,311 632,081 7,584,967
Proposed install sensor and
modify PLC 28,263 734,838 8,818,056
Difference after improvement
3,952 102,757 1,233,089
21
Where:
= 8,818,056 - 7,584,967
= 1,233,089 units
the comparison between the current and the proposed innovation of transient
PLC at Taping process and Taper Feeder machine. The Kansen-Taping process
current set-up produces 24,311 units per day while the proposed installation of
sensor and modification of PLC produces 28,263 units per day. The company has
a positive output of 3,952 units per day and 1,233,089 per year.
Number of Defects
TABLE 5
Where:
Diff. No. of Defects = Total Defective (Present) – Total Defective (Proposed)
= 103,033 - 6,214
= (96,819) defective units
To compute the comparison of the present output and the proposed
Where:
= 8,818,056 - 7,584,967
quantity and percentage between the current set-up and the proposed installation
of sensor and modification of PLC. The current set-up produces around 98.66% or
7,584,967 of good units and 1.34% or 103,033 defective units annually. On the
using capacitive sensor output projection is almost 100% good units or 8,818,056
To compute the scrap cost difference, the following formula was used:
Where:
= $ 41,213.20 - $ 2, 485.60
= $ 38,727.60
23
Cost
TABLE 6
Table 6 shows the comparison between the present method and proposed
in the Kansen-Taping process. The proposed method has only 6,214 unit which
is lowered compared to the present method which has 103,033 units. Thus,
TABLE 7
Bill of Materials
Table 7 presents all the parts needed to realize the project proposal. All
components were procured based on the Electrons Philippines Inc. The Purchase
Order System aside from the mechanical part is locally fabricated in the in-house
fabrication center. The Labor cost is dictated solely by the proponent based on the
standard market price.
TABLE 8
Current Set-up and Proposal Installation of Sensor and Modification
of PLC
Table 8 shows the current set-up and proposed installation of sensor and
modification of Programmable Logic Controller. The total scrap cost of the current
set-up is around Php 2,145,548, and the proposal that installed sensor and
modification of PLC cost has a total of Php 129,400. The difference cost between
TABLE 9
Potential Savings
Table 9 shows the annual and daily potential savings computation. The
company saved around Php6, 143 and Php1, 923,512 per year.
TABLE 10
Table 10 shows the payback period of the investment cost for the proposed
in the Kansen-Taping process. The investment cost is Php 92, 666. Payback
period which is computed by dividing the investment cost over annual total savings
(Over-all Difference). That is Php 92, 666 divided by Php 1,923,512 is equal to
0.048 years. The payback period is 0.048 years which is a good outcome for this
project.
TABLE 11
Total Difference
Investment Net Savings
Year (Php) after
Cost (Php) (Php)
Proposed Project
1 year Php 1,923,512 Php 92,666 Php 1,830,846
2 years Php 1,923,512 0.00 Php 1,923,512
3 years Php 1,923,512 0.00 Php 1,923,512
4 years Php 1,923,512 0.00 Php 1,923,512
5 years Php 1,923,512 0.00 Php 1,923,512
6 years Php 1,923,512 0.00 Php 1,923,512
7 years Php 1,923,512 0.00 Php 1,923,512
8 years Php 1,923,512 0.00 Php 1,923,512
9 years Php 1,923,512 0.00 Php 1,923,512
10 years Php 1,923,512 0.00 Php 1,923,512
Total Php 19,142,454
To calculate the Net Savings per year, the following formula was used:
= Php 1,830,846
27
CHAPTER IV
SUMMARY
Controller) in order to reduce stretched carrier tape scrap per day at Electrons
1.) What is the present set-up of the Kansen-Taping machine in terms of the
following:
1.1 Process;
1.2 Process Yield;
1.2.1 Quantity;
1.2.2 Number of defects; and
1.2.3 Cost?
2.) What is the problem encountered in the present set-up in Kansen-
Taping process?
3.) What electronic system can be proposed to address the problem on the
existing set-up?
FINDINGS
In the course of the study, the following findings are gathered from the
analysis of data.
2. The output quantity and quality is affected by the operators physical, mental,
area and a rejection of unit related to stretched carrier tape due to machine
CONCLUSION
In the light of all findings, the current set-up method by installing a sensor
RECOMMENDATION
BIBLIOGRAPHY
A. Books:
Coaching-Blog
Bolton, W. (2001). The book Programmable Logic Controllers The 1st edition in
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Jonathan Love, Process Automation Handbook, A guide theory and practice, 7th
Mims Forrest M. III; (February 2010), Electronics Sensor Circuits & Projects,
Nancy Fitchman Dana & Diane Yendol- Hoppey, The PLC Book, 2nd Edition,
Pavel Ripka and Lois Tipek Modern capacitive Sensors, Great Britain by Ltd,
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33
APPENDICES
34
APPENDIX A
Figure 7
APPENDIX B
APPENDIX C
COMPANY PROFILE
with Sony and Philips in 1988. Founded 60 years ago, currently operates factories
in Japan, Singapore, Korea, China, the Philippines, Taiwan, and Malaysia. They
were well known for their recordable optical media, and were regarded by many to
CURRICULUM VITAE
I. PESONAL DATA
IV. AFFILIATION
V. AWARDS/RECOGNITIONS