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Graduate School
University of the East
Manila
An Operations Management Audit of
INTRODUCTION
A.
COMPANY PROFILE
History
C.E.M. Allied Industries came into existence in the year 1974. With a small
capital borrowed from rural banks plus a little savings, the company first dealt in
the manufacture of wooden crates and pallet board for batteries and electrolytes
bottles. Along with these, they also engaged in lead smelting with working force
of 10 people. The proprietor work single handedly and going out of town to
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purchase out lumber and coconut charcoal. The company started only with 2
units of second hand blowing machines then with small machine shop as support
for production. These were housed in a makeshift building at the back of the
residence of C.E.M Allieds sole customer was RAMCAR, Inc. the largest battery
manufacturer in the Philippines.
By the late 1970s C.E.M. Allied Industries ventured out in manufacturing
automotive battery accessories. The company core business now is injection of
small plastic accessories for Philippine Batteries, Incorporated (PBI) now one of
the largest automotive battery manufacture in Asia and Mercury Battery
Manufacturing, Inc. a major player in the Philippines automotive battery market.
As continuing commitment to produce quality products and give superior service,
C.E.M. have improved infrastructures by building a new three storey building that
now house the 19 injection machines, 2 blow moulding machines and the small
machine shop use for minor servicing of injection moulds.
C.E.M. stands for Carlos, Elisa and nieces and nephews of the proprietor.
Ownership
The C.E.M. Allied Industries is a single proprietorship owned and
managed by Carlos A. Herrera, a dentist, businessman and an inventor. In 19591965, he first got the interest in business by starting a buy and sell of cars after
serving as a school dentist in Municipal of Bulacan. And stand as his finance
officer was his wife, Elisa J. Herrera, a graduate of Bachelor of Science in
Zoology in University of Sto. Tomas and BS in Elementary Education major in
Home Economics in Philippine Normal University, and now a retired teacher of
Home Economics in a Public School.
Organizational Chart
C.E.M. Allied Services has a total of 30 employees, four (4)
on the
personnels, three (3) Maintenance Technicians, five (5) Internal Quality Auditors,
two (2) Purchasers, and one (1) Warehouseman. The company practices multitasking which means that an employee has varied tasks or works to perform.
President &
Gen
Manager
Assistant
Manager
Production
Production
Head
Production
Operators
B.
Document
Control
Center
Document
Control
Officer
QA
Maintenance
Purchasing
HR
Materials&
Quality
Controller
Maintenance
Technician
Purchaser
HR
Officer
MQC
Operator
Building &
Grounds
Assemblers
INDUSTRY BACKGROUND
CEM is a major supplier battery accessory of Philippine Batteries
Incorporated (PBI). Philippine Batteries Inc is the largest Automotive Battery
Manufacturer in the Philippines with an annual production capacity of 6 Million
Units. PBI's share of the Philippine Automotive and Truck battery market is 80%
and supplies 80% of OEM manufacturers in the Philippines. Main export markets
are North America(US) and Canada, Australia and New Zealand, Japan, Russia,
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1919 The founding of Caro Electrical Service marks the birth of the
automotive lead-acid storage battery industry in the Philippines.
1990 Ramcar, Inc. acquires the assets of Estee Batteries, the biggest
independent automotive battery manufacturer in the US West Coast.
The facility has been operating as Ramcar Batteries, Inc., the
manufacturing and distribution arm of the company in the U.S.
C.
towards the implementation on the different aspect of the company from the
product misconception down to its shipment.
Aside from ISO certification, the company is also involved in the Internal
Quality Audit. They have five employees who are committed to do the work twice
a year since 2006. The companys audit plan includes quality management
system;
management
responsibility;
customer
order
handling;
resource
PRODUCT/SERVICES + DESIGN
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The major product lines of CEM include different types of battery vent
caps for different applications, car battery accessories, and Oriental & Yuasa
Battery Corporation industrial battery accessories (OYBC). CEM provides
services in providing labor, coloring, taping and providing special materials as
required by PBI.
List of Product lines
VENT CAPS
VCCP40
VCCP50
VCCP70
VCCP100
VCMCB
VCSP2
VCMCP
VCSP50R1
VCSP50R1
VCSP50R2
VCSP120 W/ POREX
VCSP120 W/ POREX
VCSP120 W/O POREX
B.
ACCESSORIES
TCR1 (+)
TCR1 (-)
TCR2 (+)
TCR2 (-)
TCR3 (+)
TCR3 (-)
Post Thimble (+)
Post Thimble (-)
Plug HE
G42 Ledge Adaptor
TP12N9
TP12N12
TP12N12
TPYB3L
TP6N
OYBC PRODUCTS
IB STATIONARY SPACES
UPPER HALF SHEATH
LOWER HALF SHEATH
BOTTOM SEAL
CONNECTOR CAP
LEVELING INDICATOR
PLATE HANGER
CELL PROTECTOR
MARKET DEMAND
i)
Assumptions
ii)
Forecast
C.
LOCATIONS PLANS
i)
Current Location
ii)
The major factors considered in the choice of location of CEM are the land
is all ready available, accessibility of the owner to his residence and plant, & the
convenience to product delivery.
The companys future plan is to be relocated in Sta. Maria, Bulacan near
the location of their customer which is PBI.
D.
PROCESS DESIGN
i)
Key processes
ii)
iii)
Employees involved/roles
CEM involves total of Thirty (30) employees, consists of four (4) staffs
Office/Administration employees, twenty one (21) production staffs, Three (3)
Maintenance staffs, and two (2) Quality assurance staffs.
Business Process
Role/Owner
9
Management
E.
CAPACITY PLANNING
i)
Technologies/equipment in use
10
X2
4. Nissei 70
5. Nissei 40
6. Nissei 30
7. Nissei 20
8. Kawaguchi 200
9. Kawaguchi 175
10. Kawaguchi 175
11. Kawaguchi 165
12. Kawaguchi 150
13. Kawaguchi 110
X2
14. Kawaguchi 40
X2
15. JSW 70
ii)
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Pie Charts
VENT CAPS (Max Cap)
At Maximum Capacity
12
At Maximum Capacity
13
At Maximum Capacity
14
15
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F.
FACILITIES LAYOUT
Grinding
Area
Production
Area
Maintenance
/ Machine
Shop
Training
Area
Office
Receiving
Stairs
Area
1st
Floor
Production
Area
17
Stairs
Coloring
PlasticStaff
area
Colorant
House
storage
area
(In
Elevator
QA Area
Process)
2nd Floor
Materials
Inventory Bulletin
Storage Board
Assembly Area
Area
Coloring
Product for Pick Up
Matl
storage
area
Counting Area
Elevator
18
Stairs
3rd
Floor
G.
WORK SYSTEMS
i)
JOB TITLE
ASSISTANT MANAGER
JOB SUMMARY
Gets direction from the president and performs functions regarding the
companys production operations. Plans and implements production strategies to
maximize potential and profitability of the company. Act as the management
representative of the company.
DUTIES AND RESPONSIBILITIES
JOB TITLE
JOB SUMMARY
Responsible for maintenance, repair, fabrication related to building
grounds and accessories.
DUTIES AND RESPONSIBILITIES
Performs maintenance job related to building and grounds.
Repair of facilities
Welding jobs
JOB TITLE
JOB SUMMARY
In case of the absence of the management representative, act as officer in
charge of the Quality Management System of the company. Design, plans,
implement and maintain QMS.
DUTIES AND RESPONSIBILITIES
20
JOB TITLE
JOB SUMMARY
Assist the Document Control Officer in operation and maintenance of
Document Control Center relevant document and records.
21
JOB TITLE
JOB SUMMARY
Gets direction from the president and performs function regarding the
Documents Control Operations. Plans and implements strategies for the effective
control and maintenance of companys document control. Receiving, monitoring,
planning and initiation of products deliveries.
DUTIES AND RESPONSIBILITIES
JOB TITLE
GRINDER OPERATOR
JOB SUMMARY
Operates the grinding machine to produce quality ground materials for
recycling. Maintains the orderliness, cleanliness and good condition of his work
area and the machine and equipments that he is using.
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JOB TITLE
JOB SUMMARY
Maintain, update HR/201 file records, training records and certification
records. Monitor personnel performance and assists the Assistant Manager in
monitoring and implementation of appropriate training programs.
DUTIES AND RESPONSIBILITIES
JOB SUMMARY
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JOB TITLE
IQA AUDITOR
JOB SUMMARY
On top of their existing responsibilities, the IQA auditors performs audit of
the established Quality Management System, prepares documentations relevant
to the conduct of the Internal Quality Audit. Also assist the company in promoting
QMS awareness among the employees.
DUTIES AND RESPONSIBILITIES
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MAINTENANCE TECHNICIAN
JOB SUMMARY
Keeps the machines, molds, and other equipments and other accessories
on tip top condition. Implements preventive maintenance program.
DUTIES AND RESPONSIBILITIES
JOB TITLE
MANAGEMENT REPRESENTATIVE
JOB SUMMARY
Overall in-charge of the Quality Management System of the company.
Design, plans, implement and maintain the QMS.
DUTIES AND RESPONSIBILITIES
JOB TITLE
JOB SUMMARY
Preparation of materials for delivery to customers. Maintains the
orderliness, cleanliness and good condition of his work area and the machine
and equipments that he is using.
DUTIES AND RESPONSIBILITIES
JOB TITLE
MOLD TECHNICIAN/MACHINIST
JOB SUMMARY
Keeps the molds on tip top conditions. Implements preventive
maintenance programs. Performs mold repair and rehabilitation job and
machining of parts when needed.
DUTIES AND RESPONSIBILITIES
JOB TITLE
JOB SUMMARY
In-line inspection of products including visual inspection, dimensional
monitoring and process parameters monitoring. Act also as reliever injection
machine operator.
DUTIES AND RESPONSIBILITIES
1.
2.
3.
4.
5.
1.
2.
JOB TITLE
JOB SUMMARY
Over-all in charge of the companys operations. Sets the overall direction
of the company.
DUTIES AND RESPONSIBILITIES
JOB TITLE
PRODUCT ASSEMBLER
JOB SUMMARY
Assembly of semi-finished products to produce finished products of
acceptable quality to customers. Maintains the orderliness, cleanliness and good
condition of his work area and the machine and equipments that he is using.
DUTIES AND RESPONSIBILITIES
JOB TITLE
PRODUCTION HEAD
JOB SUMMARY
Performs functions regarding actual supervision of the production
operations. Plan production runs and man power schedules.
DUTIES AND RESPONSIBILITIES
Production planning
1. Production planning
2. Handles and process orders from customers
3. Translates customers order to production plans and schedules
ii)
discretion, the owner has the option to hire personnel as it sees applicable and fit
to the established qualifications. HR officer is responsible reviewing the request
to hires information and coordination with the owner to facilitate the hiring of the
required personnel. And when hired, the HR officer also facilitate the entry,
coordinating the actual on the job training (OJT) of new personnel. The Assistant
Manager is responsible for determining the needs to hire additional manpower
based on the demands of the production operations.
Ilocos province is their source of manpower and nearby towns.
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What
Prepare Request to Hire form
How
1. Fill-up Request to Hire form
2. Indicate relevant information
regarding job qualifications
3. Forward to HR Officer for
review and processing
4. As necessary discussed
request to hire form with the
HR Officer
General Manager
1. Complete relevant
form
Genera l Manager
Manager
1. Review details of request to
HR Officer
required documents.
1. Indicate name of hired
TRAINING
All personnel shall undergo training and certification based on the
requirement of their functions or assignments. The following are the required
training for all personnel: On the Job Training specific to their assigned duty;
Quality Management System Orientation; Quality Policy Orientation; Product
Quality Orientation; and Procedural Orientation specific to their assignments.
Aside from the trainings mentioned above, the management also send
personnel to outside or conduct in-house training as it sees it fit or upon
evaluating and analysis, the training is needed to improve or upgrade the skills. A
training plan shall be established based on the basic job skills available for the
manufacture of C.E.M. Allied Industries products. For multi-tasking purposes this
training plan shall be the basis of regular training programs aside from discussed
above.
To measure the effectiveness of the training conducted, a competency
evaluation shall be conducted by the Management for each individual who
undergone training based on their actual on the job performance. The Assistant
Manager is responsible for training and certification of all personnel performing
jobs related to production of products.
The training schedule for On the Job Training is personnel must be trained
and certified on their specific assigned task for duration of one week with close
guidance and supervision before they are allowed to perform the task on a
regular basis. While Quality Management System Orientation, Quality Policy
Orientation and Product Quality Orientation, personnel must be trained on the
over-all flow covering at least the business process and documentation system.
This must be done not later than the one month upon the start of their
employment. Procedural Orientation schedule is every time there are new
approved procedures for implementation that are related to their jobs.
iii)
Performance management
iv)
Work conditions
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