Case Study on Meltdown Process at Esterol Sdn. Bhd.

-, Kavintharan (2012) Case Study on Meltdown Process at Esterol Sdn. Bhd. Final Year Project (Other), Tunku Abdul Rahman University College.

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Abstract

ESTEROL SDN BHD is one of the leading foods processing plant involved in manufacturing food emulsifiers from Palm Oil. ESTEROL's business nature is producing food emulsifiers. During the time of production, some emulsifier product accumulated along the walls of its path of flow. If this situation is left alone over time, the emulsifier will continue to coat the flow path until a block which eventually occurs. Thus, preventing this problem of blockage along the flow lines is important. "Meltdown," refers to the cleaning of the machine equipment where emulsifier products flows through. From the problem, there are three main objectives that are specified to solve the problem. They are "To identify the most delayed changeover meltdown product", "To identify the detailed step of meltdown and its individual time consumption" and "To propose a method or solution of time reduction in meltdown process." To accomplish the first objective, a record of the meltdown process time was obtained and analysed. The data was obtained from the Research and Development Department of the plant. From the data obtained, a bar chart was constructed and its highest value was recorded together with its average value. In the second objective, the step-by-step procedures and its individual time was obtained by observation and interviewing employees on the production line. The data collected was recorded using a "Process Mapping Table." Without these steps, a time study cannot be carried out as there are no time data to analyse.