Executive Summary. G.E. Lightings Philippines has been existing in the country since 1947. It used to be known as Philippine Electrical Manufacturing Company (PEMCO) until the year 1963. The company manufactures fluorescent lamps and incandescent lamps as well. Some of its products are imported from its other manufacturing plants worldwide.
Among the company\u27s several lines for its fluorescent products, this study focuses on the production of T12 fluorescent lamps. This line is also known as the Badalex group. The group identified the problem of unaccounted endformed tubes, which amounted to Php 776,891.25 for the period of January to December 1999.
Several causes were identified that contributed to this problem. Among these are absence of documentation of endformed tubes from Support to the mainline of Badalex, incorrect amount of endformed tubes received due to inaccurate checking of incoming tubes, and breakages due to material handling. Work sampling was done to know the occurrence of these causes.
From these causes, a proposed system was developed for the T-12 Fluorescent Lamp Production of the Badalex Group. The proposed system includes a documentation system through the use of a Quantity In/Out Form per station and a material handling system that uses polyethylene foam as cushion for the buses.
The proposed system was validated through implementing the Quantity In/Out form for a week in the Badalex group. Further, two buses with polyethylene foam were used for two days to measure its effectiveness in reducing the number of breakages. The proposed system was also justified through the analysis of the costs that would be incurred as well as the benefits that the company would gain. The analysis yielded a Net Present Value of Php, 2,136,915.94. The monthly savings that the company would realize amount to Php 189,656
