Productivity Improvement of an Automated Integrated Thermal Bonding and Head-Forming Machine for Swab Manufacturing at ABC Company

Jaymar Mamauag Salvador

Productivity Improvement of an Automated Integrated Thermal Bonding and Head-Forming Machine for Swab Manufacturing at ABC Company

Author(s)	Mr. Jaymar Mamauag Salvador
Country	Philippines
Abstract	Despite technological advancements, the manufacturing of swabs still demands precision and efficiency, particularly in the two crucial machine processes - the Thermal-Bonding (TB) and Head-Forming (HF) stages. With existing studies primarily focusing on individual machine process development, further enhancement, automation, and integration remain underexplored. This study aimed to evaluate and analyze the efficiency of the existing TB and HF machine processes at ABC Company, specifically addressing bottlenecks, downtime, inefficiencies, and assessing Overall Equipment Effectiveness (OEE) of the current processes. Additionally, it seeks to Develop a Conceptual Design of an Automated Integrated Thermal-Bonding and Head-Forming Machine for Swab Manufacturing, emphasizing system integration to address emerging concerns. Utilizing a quantitative descriptive developmental design, this study statistically analyzed a year-long dataset from the Daily Production Report, providing essential information on production efficiency, swab quality, MUDA, and the necessary data to test the OEE rate. The results indicated significant differences in the current state and efficiency rates of the TB and HF machines. The existing machines are underperforming in production efficiency and swab quality, necessitating enhancements to meet standards and reducing operational costs. Both machines have below-standard OEE scores, highlighting the need for process improvements through automation and integration, supported by significant statistical differences in current issues and efficiency rates. The developed conceptual design focuses on enhancing the efficiency of TB and HF machines through automation and integration, addressing concerns related to production efficiency, swab quality, and MUDA reduction. Future research should explore the implementation and comparison of automated integrated Thermal-Bonding and Head-Forming machines with traditional processes.
Keywords	Thermal Bonding, Head-Forming, Production Efficiency, OEE Improvement
Field	Engineering
Published In	Volume 7, Issue 3, May-June 2025
Published On	2025-05-11

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Productivity Improvement of an Automated Integrated Thermal Bonding and Head-Forming Machine for Swab Manufacturing at ABC Company

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