Lean warehouse management at Powercoat Manufacturing Company, Inc. / by Denzel C. Blanco, Venus A. Olfato.

Thesis (Bachelor of Science in Industrial Engineering) Cavite State University

College of Engineering and Information Technology (CEIT)

BLANCO, DENZEL C., and OLFATO, VENUS A. Lean Warehouse Management at
Power Coat Manufacturing Co. Inc. Undergraduate Thesis. Bachelor of Science in
Industrial Engineering. Cavite State University, Indang, Cavite. June 2022. Adviser: Ms.
Dina P . Bawag.
This study was conducted to analyze the current warehouse management system of
Power Coat Manufacturing Co. inc. Specifically, this study aimed to: (1) determine the current
warehouse system of Power Coat Manufacturing Company Inc.; (2) identify the problems
encountered by the workers while following the existing warehouse management system; (3)
analyze the root causes of the identified problems that the company encountered; (4)
implement the possible solutions and recommendations that will help to improve the
warehouse of Power Coat Manufacturing Company, Inc.; and (5) determine the improvements
in the warehouse management system of Power Coat Manufacturing Company Inc. after implementing solutions and recommendations. Moreover, the Define-Measure-Analyze-
lmproveControl (DMAIC) approach was used to achieve the stated objectives. The study was conducted at Power Coat Manufacturing Co. Inc., located at Cavite Light
Industrial Park, Maguyam, Silang, Cavite. Due to a small number of populations in PMCI, total
enumeration sampling was used in this study. On the other hand, the researchers were guided
by an interview questionnaire in gathering the data to determine the current warehouse
operation system of PMCI.
Using different industrial engineering tools and techniques, the researchers were able to
identify the problems. Pareto analysis was constructed to identify the problems. These problems
include errors in picking, poor facility layout, and poor sanitation. Upon problem identification, its
root causes were determined using a
fishbone diagram. In addition, a time study was also observed to get the standard time per

process. The flow process chart and operational process chart were used to determine the step-
by-step process of the warehouse at PMCI.

Furthermore, the process was evaluated using value stream mapping and a value-
added flow chart. As a result, waste was discovered, and it was excessive motion and

waiting time.
Lastly, researchers of the study implemented a new warehouse operational process,
flow process, value stream map, 5S system implementation, and solutions based on the
major problems identified in the fishbone diagram. Several process improvements were
developed to increase the process cycle efficiency of Power Coat Manufacturing Co. Inc.
(PMCl's) warehouse processes to 88.9 percent, from 73 percent.

Submitted copy to the University Library. 06/27/2022 T-8891