(Last Name, First Name, MI)

(MEM-BME/MEM-MRE)
2nd Year

(ID Number)

Journal of Learning: 114 Plant Visit

Site 1: Vikings Plastic Center

Date & Time of Visit: February 19, 2016, 10:30pm 11:30pm
Address: #99 Venus Street, E&E Compound, Parada Valenzuela City, Metro
Manila
Company Profile:
Vikings Plastic Center is a company which was started in the year 2012
and was re-established in the year 2014. Naturally, the company is
accustomed to working with plastics. They manufacture plastic bags in
variety of colors out of recycled materials. Their products are ensured to be
durable for average use and are affordable for consumers. Aside from plastic
bags, they also have other plants around Valenzuela which manufacture
different plastic products that used in our daily activities.
Process Flow:
The process flow of Vikings Plastic Center starts with refining the
recycled materials theyve obtained. These materials are then separated
according to color and mixed with polyethylene and are dehydrated for
production. Once dry, they are placed in a large container which will start the
machine process; substances such as calcium and additives are also added.
After which, the material mix is poured into a container. To ensure that no
metal may cause machine obstruction and malfunction, large powerful
magnets are placed behind the conveyer transferring the material mix.
These materials will then be melted inside the machine. Then, the melted
mixture is blown up, forming an elongate bubble. During this stage, the
temperature drops and the plastic is solidified. The plastic are then, rolled in
sheets and will be ready for cutting. It should be noted that each variety of
plastic bag, according to color, size, and thickness, has its own separate
processing machine.
For the cutting process, plastics that should be cut to the same size are
grouped together and are placed in a cutting machine which is manned by a

skilled worker. Once cut, they are packed manually and are ready for
delivery.
The company is able to produce an average of seven sacks of plastic
bag per machine in one day. The production rate may increase or decrease
depending on the bag size, thickness, and worker expertise.

From the point of view of lean to green manufacturing systems,

what improvement can you suggest?
(Insert UNIQUE answer here)

Site 2: Unilever Philippines Inc.

Date & Time of Visit: February 19, 2016, 2:30pm 4:30pm
Address: 1351United Nations Ave, Paco, Manila, Metro Manila
Company Profile:
Unilever Philippines, Inc. was established in the year 1927. Known until
1993 as Philippine Refining Company (PRC), Unilever Philippines started as
an oil milling business which at its peak produced nearly 100,000 tons of
coconut oil annually. As of now, they manufacture a wide variety of products
which include detergents and soaps, shampoos and hair conditioners,
toothpastes, deodorants, skin care products, household cleaners, and toilet
soaps. Additionally, they also produce consumable brands such as Knorr,
Lipton, Becel, Selecta, Ben & Jerry's and Breyers. With a total of 400 brands
spanning 14 categories of home, personal care and foods products, they
claim that no other company touches so many people's lives in so many
different ways. They also aim to decrease environmental foot by treating
their waste ensuring it would not cause additional harm to the environment.
Due to their enormous plant, they have the capacity to produce not only for
the local market but also for the international market.
Process Flow:
Since the only plant fully shown to us was Deo Citys, only Deo Citys
Process Flow will be discussed.
The process starts at loading the conveyer belt with deodorant
containers, which are manufactured by the company in another branch. The
containers are then conveyed into a liquid dispensing machine and filled with
a specified amount of deodorant mix, which is produced in their Personal
Care plant. Before exiting the machine, the containers are run through
scanners to determine whether they are filled with the specified amount or
not. Containers that do not meet the production standards are then
automatically dispensed into a trash bin, never to be recycled for safety
purposes. Meanwhile, containers that meet production standards are
conveyed into a roller insertion machine. Inside the machine, rollers are
pushed into the containers, sealing the deodorant mix inside. Subsequently,
they are again examined by sensors whether they have met production
standards or not. After which, they are conveyed into a capping machine and
again run through product testing. They are then conveyed a labelling
machine and run through final product testing. At this point, if a deodorant is
rejected by sensors, it would only mean that labelling is misaligned,
therefore the rejected deodorants are manually relabelled to meet
production standards and are manually returned to the conveyer belt. Finally,

the deodorants are put into trays of 6 and sealed by an automated set of
machines. They are then put into boxes and stacked for storage purposes. It
should be noted that the only process done by hand within the flow is
relabeling deodorants with misaligned labels.
From the point of view of lean to green manufacturing systems,
what improvement can you suggest?
(Insert UNIQUE answer here)