1

CHAPTER I

THE PROBLEM AND ITS SCOPE

INTRODUCTION

Rationale of the Study

Electrons Philippines Inc. is a Japanese Materials and Electronics

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

the MEPZ 1 industrial hub at Lapu-Lapu City, Cebu.

Every company, has a great role to continue its business operation, and

Electrons Philippines Inc. aimed to maintain and minimize its major problem that

might be encountered in all of its operations in production. Whatever abnormality

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

corresponding sub-processes and purposes. One of the major manufacturing

processes that need to be improved is the Tape Feeder Machine process.

 2

At the Kansen-Taping process which is consist of different sub-processes

such as carrier tape feeder, taping machine, and P-P machine. The Carrier Tape

Feeder machine encountered consistent gross occurrence of a heavy stretched on

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

machine. At Kansen-Taping process where the inductors were processed, one

should be able to test on its product to see if micro Henry units are within

specifications and it is being required by the customer’s.

The main problem at Kansen-Taping process specifically at the (PP) Pick

and Place machine was its continuous operation even though the tape feeder

machine failed to perform its intended function which resulted to stretched or

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

communication device to signal if there is any error manifested during the

production in order to discontinue processing of the product.

Presently, there is no empirical study relating to the defect reduction

undertaken. Hence, this concern was addressed by this project study.

 3

Theoretical Background

This study is anchored on the principle of automation system theory which

is controlled by capacitive sensor.

According to Baxter (1997) who designed the of capacitive sensor, a sensor

technology is in the process of a slow migration from discrete “dumb” instruments,

expensive and inflexible, to smart, self-calibrating, silicon-based units, and the

measurement method of choice for silicon devices as well as for discrete

instruments which is moving from a variety of transducer technologies, such as

magnetic, optical, and piezoelectric, to capacitive.

Capacitive sensors can be used for many different applications. Simple

sensors are used for go-no-go gauging such as liquid level in reservoirs, where

their ability to detect the presence of a dielectric or conductor at a distance allows

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

be achieved with two-or three-plate systems with careful construction, or multiple

plate geometries can be used with digital circuits to substitute digital precision for

analog precision.

Capacitive sensors are also useful for measuring material properties.

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

with temperature and frequency to give material a characteristic signature which

can be measured at a distance.

 4

A programmable logic controller, PLC, or programmable controller is a

digital computer used for automation of typically industrial electromechanical

processes such as the control of machinery on factory assembly lines, amusement

rides, or light fixtures. PLCs (Programmable Logic Controllers) are used in many

machines in most industries. PLCs are designed for multiple arrangements of

digital and analog inputs and outputs, extended temperature ranges, immunity to

electrical noise, and resistance to vibration and impact. Programs to control

machine operation are typically stored in battery-backed-up or non-volatile

memory. A PLC is an example of a "hard" real-time system since output results

must be produced in response to input conditions within a limited time, otherwise

unintended operation will result, (Bryan, 2003).

History has shown that the advancements in materials science and

engineering have been important drivers in the development of sensor

technologies. The high resonance stability of single-crystal quartz, as well as its

piezoelectric properties, has made possible an extraordinarily wide range of high

performance, affordable sensors that have played an important role in everyday

life and national defense. More recently, a new era in sensor technology was

ushered in by the development of large-scale silicon processing, permitting the

exploitation of silicon to create new methods for transducing physical phenomena

into electrical output that can be readily processed by a computer. Ongoing

developments in materials technology will permit better control of material

properties and behavior, thereby offering possibilities for new sensors with

advanced features, such as greater fidelity, lower cost, and increased reliability.
 5

THE PROBLEM

Statement of the Problem

The project aimed to design innovation of transient Kansen-Taping process

machine using capacitive sensor and modify PLC Programmable Logic Control in

order to reduce stretched carrier tape scrap per day at Electrons Philippines Inc

Specifically, it intended to answer the following questions:

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?

4.) What benefits can be generated from the proposal?

SIGNIFICANCE OF THE STUDY

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

In general, the outcome of this project is beneficial to Electrons Philippines

Inc. by increasing the daily output and ensuring manufactured components which

are highly standard.

The Equipment Engineering Group

On the maintenance side, it will lessen the machine intervention in terms

of failure and assistance. Thus, increasing uptime capacity and MTBF (main-time

before failure).

The Manufacturing Department

The manufacturing department will provide on-time delivery of the products

based on the timeline because of the enhanced tape feeder system.

The Customers

As end user manufactured inductors devices, assurance of high quality

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

high quality of the product in the future.

The Proponent

The self-esteem of the proponent will be boosted especially in completing

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

in Electronics and Communication Engineering and provide additional tools for

higher position in the future.

 7

The Future Researchers

The future researchers can use this study as a reference for their

researches specifically regarding automation improvements in an electronic parts

company. This project will also provide the researcher some ideas on problem

solving and cost savings.

DEFINITION OF TERMS

The following are the terms used in the study which are defined for better

comprehension of the proposed project.

Alternating Current (AC). This refers to what occurs when charge carriers in a

conductor or semiconductor periodically reverse their direction of movement.

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

a particular time period.

Circuit. This refers to an electrical network that has a closed loop giving a return

path for the current.

Charge Controller. This refers to the one that decides to switch on /off charging

and lighting.

Direct Current (DC). This refers to the unidirectional flow or movement of

electric charge carriers (which are usually electrons).

Capacitive Sensors. The term refers to a proximity sensor that detects

nearby objects by their effect on the electrical field created by the sensor.
 8

Electronics. This refers to devices, systems, or circuits that employ

components such as inductor circuits.

Innovation. It means the application of better solutions that meet new

requirements, unarticulated needs, or existing market needs.

Kansen-Taping. The term refers to segregate non-electrical properties and

to pack products in embossed tape.

Productivity. This refers to the rate at which the company produces goods

and services, in relation to amount of materials and number of employees needed.

Programmable Logic Controller (PLC). It means an industrial digital

computer which has been ruggedized and adapted for the control of

manufacturing processes, such as assembly lines, or robotic devices,

Switch. This refers to a component which is used for a start, stop, and

emergency stoppage of the machine.

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

the carrier tape on the taping machine during taping process.

Taping Machine. It means a sub-controlling unit of the Kansen-Taping

machine.

Vacuum Pump. This refers to a main source of machine vacuum

requirements.

Yield. The term refers to the percentage ratio of output quantity and input

quantity. It is an amount of product that is produced (usually within a given period

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

Kansen-Taping process area. This chapter is composed of two sections. Section

1 refers to the existing set-up at Kansen-Taping process; while Section 2 refers to

the problem encountered in the existing set-up.

SECTION 1

The Existing Set-up at Kansen-Taping Process

Figure 1 shows the existing Tape Feeder machine at the Kansen taping

Process.

Figure 1

Tape Feeder Machine

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

taping operation that still continues to do processing.

SECTION 2

Problems Encountered in the Existing Set-up

Figure 2

Stretched/Damaged Carrier Tape

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

fed to the Kansen-Taping machine.

Process Yield

To calculate the Process Yield, the following formula was used:

Where:

Over all Process Yield = (Total Annual Output /Total Annual Input) x 100%

= (7,584,967 / 7,688,000) 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

98.7% 98.7% 98.7%

98.7%
98.7% 98.7% 98.7%
98.6%
98.6% 98.6%
98.6% 98.6%
98.6%
98.6%
98.6%
Aug' Sep Oct Nov Dec Jan Feb Mar Apr May ' Jun Jul
16 '16 '16 '16 '16 '17 '17 '17 '17 17 '17 '17

Figure 3

Current Process Yield at Kansen-Taping Process

Figure 3 shows the process yield at Kansen-Taping Process which is

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

To compute the output quantity, the following formula was used:

Where:

Per Day = 24, 311 units

Per Month = 24,311 X 26 days

= 632,081 units per month

Per Year = per month (632,081) X 12 Months

= 7,584,967 good units

Table 1 shows the current output in terms of quantity of a Kansen

process.

TABLE 1

Current Output in Terms of Quantity of a Kansen Process

Quantity
Kansen Process
Per Day Per Month Per Year

Total Output
24,311 632,081 7,584,967
 13

The output quantity detail of Kansen-Taping process produces 24,311 units

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

To compute the Yield Percentage, the following formula was used:

Yield Percentage = (Good Outputs / Total Outputs) x 100%

= (7,584,967 / 7,688,000) x 100%

= 98.66%

Defective Output Percentage = (Defective Output / Total Output) x 100%

= (103,033 / 7,688,000) x 100%

= 1.34%

Over- all Yield Percentage = Percentage Yield + Defective Output Percentage

= 98.66% + 1.34%

= 100%

Table 2 shows the current output at Kansen process.

 14

TABLE 2

Current Output at Kansen Process

Output Quantity Percentage

Good 7,584,967 98.66%

Defects 103,033 1.34%

Total 7,688,000 100.00%

The present total number of defects produced per year in Kansen-Taping

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-

Taping process yield is running around 98.66%.

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

= $ 41,213.20 X Php 52.06 = Php 2,145,559.19

It shows the computation above that the company total annual scrap cost

is $ 41,213.20 or Php 2,145,559.19.

Table 3 shows the current scrap cost defect per year.

 15

TABLE 3

Current Scrap Cost Defect per Year

Unit Cost Per Piece Total Scrap Cost

No. of Defects
($) ($)

103,033 $ 0.40 $ 41,213.20

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

This chapter shows the proposed innovation of transient Kansen-Taping

process machine using capacitive sensor and modification of PLC (Programmable

Logic Controller) at the Tape Feeder machine. The main purpose of the proposal

is to reduce if not eliminate stretched or damaged carrier tape caused by a machine

which cannot stop the taping machine even though the tape feeder is down.

The Proposed Innovation of Transient Kansen-Taping Process Machine

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

machine as well as changed to stepper motor and modification of (PLC)

Programmable Logic Control. The main purpose of capacitive sensor is to detect

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,

any of both machines will automatically stop.

The actual Tape feeder machine with the installed sensor and modification

of the existing (PLC) Programmable Logic Controller is shown in Figure 4.

 17

Figure 4

Installed Sensor and Stepper Motor in the Tape Feeder Machine

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

required a precise and accurate processing to avoid a constant variation of the

process. The newly-installed stepper motor and sensor in the Taping machine

were connected to proper communication whichever encountered an error, and it

will automatically stop the operation.

The Programmable Logic Controller (PLC) schematic diagram of the

installed devices can be shown in Figure 5.

 18

Figure 5

PLC Ladder Diagram for Sensors which is Installed

at the Tape Feeder Machine

The (PLC) Programmable Logic Controller consists of the stepper motor

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.

The schematic diagram of the industrial stepper motor can be shown in

Figure 6.
 19

Figure 6

Schematic Diagram for Stepper Motor with Translator Circuits

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

when the sensor cannot detect the presence of material.

Table 4 shows the output quantity in the Kansen-Taping process. It shows

the comparison between the current and the proposed innovation of transient

Kansen-Taping process machine using capacitive sensor and modification of the

PLC at Taping process and Taper Feeder machine.

TABLE 4

Comparison of Output Quantity between the Current Set-up Process and

the Proposed Innovation of Transient Kansen-Taping Process Machine

Using Capacitive Sensor

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

To compute the output difference, the following formula was used:

Where:

Difference = Proposed - Present

= 8,818,056 - 7,584,967

= 1,233,089 units

Table 4 shows the output quantity in the Kansen-Taping process. It shows

the comparison between the current and the proposed innovation of transient

Kansen-Taping process machine using capacitive sensor and modification of the

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

Comparison of No. of Defects between the Current Process and the

Proposed Installation of Sensor and Modification of PLC

Output Quantity Percentage

Present Method Good 7,584,967 98.66%
(No Install Sensor Defective 103,033 1.34%
and modification of
PLC) Total 7,688,000 100.00%
PROPOSED Install Good 8,818,056 99.93%
of Sensor and Defective 6,214 0.07%
Modification of
PLC Total 8,824,270 100.00%
Difference (Good
Output) 1,233,089
Difference (Number of
Defects) (96,819)
 22

To compute the comparison the number of defects present and

proposed we use the formula below:

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

innovation, the following formula was used:

Where:

Diff. Good Output = Good Output (Proposed) – Good Output (Present)

= 8,818,056 - 7,584,967

= 1,233,089 Good Output units

Table 5 shows the comparison in terms of good and defective output

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

other hand, the proposed innovation of transient Kansen-Taping process machine

using capacitive sensor output projection is almost 100% good units or 8,818,056

good units and 0.07% defectives units or 6,214.

To compute the scrap cost difference, the following formula was used:

Where:

Scrap Cost Difference = Present – Proposed

= $ 41,213.20 - $ 2, 485.60

= $ 38,727.60
 23

Cost

TABLE 6

Comparison between Present and Proposed Innovation of Transient

Kansen-Taping Process Machine Using Capacitive Sensor

Output Quantity Scrap Cost ($)

PRESENT METHOD Good 7,584,967

(No Install Sensor and Defective 103,033 41,213.20
modification of PLC) Total 7,688,000
PROPOSED Install of Good 8,818,056
Sensor and Defective 6,214 2,485.60
Modification of PLC Total 8,824,270
Difference Scrap Cost ($) 38,727.60

Table 6 shows the comparison between the present method and proposed

innovation of transient Kansen-Taping process machine using capacitive sensor

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,

Kansen-taping process gained the amount of $ 38,727.60.

 24

TABLE 7

Bill of Materials

Item Description Quantity Price

1 Capacitive sensor 3 PHP 39,000

2 Stepper Motor 1 PHP 16,666
3 Andon Lights 1 PHP 4,000
4 I/O Controller 1 PHP 30,000
3 Cable tray 1 PHP 400
5 Sensor mounted 1 PHP 2,600
Total Cost PHP 92,666.00

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

Description Scrap Cost (USD) Scrap Cost (PHP)

Present (method) $ 41,213 PHP 2,145,548

Proposed (Installation of sensor

$ 2,485.60 PHP 129,400
and modify PLC)

Project Cost $ 1,780.00 PHP 92,666

Difference
(Proposal + Project Cost)- $ (36,948) PHP (1,923,512)
Present)
 25

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

the current set-up and the proposal is around Php 1,923,512.

TABLE 9
Potential Savings

Description USD PHP

Potential Savings (Annual) $ 36,948 PHP 1,923,512

Potential Savings (Daily) $ 118 PHP 6,143

Table 9 shows the annual and daily potential savings computation. The

company saved around Php6, 143 and Php1, 923,512 per year.

Investment Cost and Payback Period

TABLE 10

Payback Period and Investment Cost

Investment Cost PHP 92,666

Payback Period 0.048 year

To compute the payback period the formula is provided below:

𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 𝑐𝑜𝑠𝑡 𝑃ℎ𝑝 92,666.00

Payback Period = = = 0.048 𝑦𝑒𝑎𝑟
𝑆𝑎𝑣𝑖𝑛𝑔𝑠 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟 𝑃ℎ𝑝 1,923,512.00 𝑝𝑒𝑟 𝑦𝑒𝑎𝑟
 26

Table 10 shows the payback period of the investment cost for the proposed

innovation of transient Kansen-Taping process machine using capacitive sensor

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.

Projected Savings in 10 Years

TABLE 11

Projected Savings in 10 years

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:

Year 1 = Total Gained – Investment Cost

= Php 1,923,512– Php 92,666

= Php 1,830,846
 27

CHAPTER IV

SUMMARY, FINDINGS, CONCLUSIONS, AND RECOMMENDATION

This chapter presents the summary, findings, conclusion, and

recommendation of the proposed innovation of transient Kansen-Taping process

machine using capacitive sensor.

SUMMARY

The project aimed to design innovation of transient Kansen-Taping process

machine using capacitive sensor and modify PLC (Programmable Logic

Controller) in order to reduce stretched carrier tape scrap per day at Electrons

Philippines Inc. Specifically, it intended to answer the following questions:

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?

4.) What benefits can be generated from the proposal?

 28

FINDINGS

In the course of the study, the following findings are gathered from the

analysis of data.

1. The current set-up method is very vulnerable to miscommunication machine

related defect which incurs quality threat and cost of scrap;

2. The output quantity and quality is affected by the operators physical, mental,

and emotional condition in the current set-up method;

3. A proposal is innovated to enhance the current method of tape feeder

machine process in Kansen-Taping process area; and

4. With the enhanced Tape Feeder and Taping process at Kansen-Taping

area and a rejection of unit related to stretched carrier tape due to machine

error, the defect will be reduced.

CONCLUSION

In the light of all findings, the current set-up method by installing a sensor

to communicate both machines which is of tape feeder and taping at Kansen-

Taping Process is very effective to prevent a problem.

RECOMMENDATION

Based on findings and conclusions of the study, the proposed innovation of

transient Kansen-Taping process machine using capacitive sensor and stepper

motor must be implemented.

 29

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 30

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Sabrie Soloman, Sensors handbook, Second Edition, Washington DC, USA

Taiichi Ohno 1982, Workplace management, 1st edition1984, Tokyo Japan

Taiichi Ohno, Toyota Production System Beyond large-Scale production, 1st

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Frederick D. Hackworth, John R. Hackworth (2004). Programmable Logic

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Application

Gary Conner (2001). Lean Manufacturing for the Small Shop. Retrieved from

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Gary Dunning (1998). Introduction to Programmable Logic Controllers. Retrieved

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Controllers
 31

George Michael (24 June 2003). Lean Six Sigma for Service: How to Use Lean

Speed and Six . Retrieved from

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 32

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 33

APPENDICES
 34

APPENDIX A

TECHNICAL DRAWING OF A CAPACITTIVE SENSOR

Figure 7

Technical drawing for Capacitive Sensor

 35

APPENDIX B

CROSS SECTIONAL OF A STEPPER MOTOR

 36

APPENDIX C

COMPANY PROFILE

Electrons Philippines Inc. translated as Sun Dielectric Co., Ltd.) is

a Japanese materials and electronics company, situated in Kyobashi, Chuo,

Tokyo, that helped pioneer recordable CD technology (CD-R) along

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

be the very best in the industry.

 37

CURRICULUM VITAE

I. PESONAL DATA

Name : Irene T. Langbid

Age : 32 years old
Date of Birth : October 16, 1985
Gender : Female
Place of Birth : Balud, San Fernando, Cebu
Nationality : Filipino
Height : 5’3”
Religion : Roman Catholic
Marital Status : Married
Father’s Name : Jose T. Tampon
Mother’s Name : Emma S. Tampon
Language Skills : English

II. EDUCATIONAL ATTAINMENT

Tertiary : B.S. in Electronics Communication Engineering

University of San Jose-Recoletos ETEEAP
Magallanes Street, Cebu City, Philippines
2017-2018
Secondary : Sangat National High School
Sangat, San Fernando, Cebu Philippines
2001-2002

Primary : Balud Elementary School

Balud, San Fernando, Cebu Philippines
1997-1998

III. WORKING EXPERIENCES

Production Operator (New Label Generation Process)

Production Department
Taiyo Yuden (Phil’s.) Inc.
MEPZ 1, Pusok, Lapu-Lapu City Cebu 6015
July 26, 2005 up to Present
 38

Production Inspector Operator

Matluster Corporation
MEPZ 2, Basak, Lapu-Lapu City Cebu 6015
August 2004 to June 2005

IV. AFFILIATION

Member, Josenian ETEEAP Executives Association (JEEA)

Expanded Tertiary Education Equivalency and Accreditation Program
University of San Jose-Recoletos
Magallanes, St. Cebu City Philippines 6000
2017-2018

V. AWARDS/RECOGNITIONS

Perfect Attendance Awardee

January to December 2007
January to December 2011
January to December 2012
January to December 2013
January to December 2014

10 Years’ Service Awardee

Taiyo Yuden (Phil’s.) Inc.
MEPZ 1, Pusok, Lapu-Lapu City