A systems study on the production of battle dress attire of Sewingdale Philippines Incorporated

Executive Summary. Sewingdale Philippines Incorporated is engaged in the manufacturing of military products such as combat clothing and equipment. The study focuses on the Sewing Department particularly on the production of Battle Dress Attire. By means of the different problem analysis techniques, various areas for improvement in the company\u27s everyday operation have been identified. These are the defects, delivery delay of nylon, overdependence of AFP contracts and opportunity to export. After analyzing the problems, it was singled out that the occurrence of defects exceeds the 15% allowable rate by 4.44%. This has caused the company P 106,618.12 in terms of monetary losses from December 1998 to May 1999. In the analysis of the defect problem, it was determined that work-in-process (WIP) defects constitute 89.28% of the total number of defects from December 1998 to May of 1999. Pareto Analysis was used to address the top three defects that contribute to WIP defects. These are stitching, twisted and caught defects. The causes for stitching defects were then identified as incorrect thread tension, unacceptable cloth thickness and blunt needle, and for twisted and caught defects, the cause was incorrect machine speed. The general objective of this study is to lower the monthly defect rate such that it falls within the company\u27s allowable rate of 15%. After a thorough analysis of the results, the proposed systems that have to be adopted are new wage policy, double sampling inspection plan and maintenance schedule of needle replacement. With the proposed systems, the NPV computed using a period of 4 years, resulted to P 79,564.09