IMPROVEMENT OF THE HEATING SYSTEM OF GTH TREATMENT MACHINE OF YKK PHILIPPINES IN SAN BARTOLOME, STO.

TOMAS, BATANGAS

Nieva, Mark Dave B. Arboleda, Leo Angelo P. Rodriguez, Mark Joseph N. Domingo, Angelo B.

A Case Study Presented to the School of Engineering Colegio de San Juan de Letran-Calamba In Partial Fulfillment Of the Requirements for the Degree of

Bachelor of Science in Mechanical Engineering

Calamba, Laguna March, 2012

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ABSTRACT

Title of the study

Improvement of the Heating System of GTH Treatment Philippines in Machine of YKK San Bartolome,

Sto.Tomas, Batangas. Name of the Researchers : Arboleda, Leo Angelo P. Domingo, Angelo B. Nieva, Mark Dave B. Rodriguez, Mark Joseph N. General : This study aims to improve the current heating system of the GTH treatment machine to reduce the electric cost of the company. Specific : To reduce the electrical production cost of using the GTH treatment machine. To determine the best and economical alternative heating system to be applied in GTH treatment machine. To determine the benefits of converting the electrical heating system of the GTH treatment machine.

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To determine the cost of the investment of the proposed project. Scope and Coverage : This study focus on the imporvement of the heating system of the GTH treatment machine to reduce the

monthly cost of their energy. Methodology : The data and information used in this study were gathered through

interviews, observation, examination, plan visit, library and internet

reaearches. Major Findings : The study showed that the most efficient and economical way of

improving a heating system and reduce the energy cost is by means of using a steam coil. Conclusion : To improve the heating system of the GTH treatment machine and to

maximize the usage of the existing boiler in the company. The

improvement of the heating system of the machine will lessen the energy cost of the company.

Recommendation

The current heating system of the GTH treatment machine is electrical heaters. It is time consuming in heating the fluid and expensive in terms of energy consumption. Utilizing the steam

produced by the boiler that can be further studied to find ways how will it my benifit the company.

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ACKNOWLEDGEMENTS

We would like to express our deepest gratitude to the following persons who have contributed, motivate and made this study a success. To YKK Inc. Philippines, for accepting our request to conduct our case study in their company and give us different topics to choose from. To Engr. Nelson Platon, the man who motivated us and extended his knowledge in giving informations to complete our research paper. He guided us when we conducted plant visit to the company. To Engr. Jun Quimbao, who guided us to the boiler room and provide us information about their boiler. To Kuya Erap, who guided us to the GTH and GKB treatment machine and provide us information that helped to our research paper. To Engr. Ronaldo Pulido, our group adviser, for the motivation , recommendation and suggestions he gave us and for the preserverance to continue and finish this study despite of the struggles we have encountered. To Engr. Ricardo Bobadilla, our moderator, for all the lessons that we tackled and with the lectures that help to us a lot. To Engr. Nestor Liquido, the chairman of Mechanical Engineering, for giving us ideas in our research paper.

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To our dearest parents, loved ones, who inspired us to do our very best to finish this study, for their support and love that molded us to become better persons. Mostly to our God, for giving us knowledge, wisdom, strengths, and preseverance to overcome our struggles and obstacles we encountered during the making of our research paper.

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TABLE OF CONTENTS

Title Page Approval Sheet Abstract Acknowledgements Table of Contents List of Figures List of Tables

Page no. i ii iii vi vii x xi

CHAPTER I. INTRODUCTION Background of the Study Company Profile Statement of the Problem Importance of the Study Objectives of the Study Research Methodology Review of Literature Definition of Terms II. TECHNICAL STUDY Description of the Present Set-Up Focus of the Study Manufacturing Process Equipment Layout Schematic Flow Diagram Plant Layout

2 2 4 6 7 7 9 30

33 34 34 38 40 41

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Presentation of Alternative Solution Alternative No. 1 Description Strengths Weakness Opportunities Alternative No. 2 Description Strengths Weaknesses Opportunities Alternative No. 3 Description Strengths Weaknesses Opportunities III. Organizational/Management Aspect

42 42 42 42 63 63 63 63 106 106 106 106 113

IV. V.

Economic Study Summary, Conclusions and Recommendations Summary Conclusion Recommendation Bibliography

117

129 130 130 131

LIST OF FIGURES

FIGURE 1 1.1 2 3 4 4.1 5 5.1 6 6.1 7 GTH Treatment Machine Layout GTH Treatment Machine Layout Schematic Flow Diagram Plant Layout Piping and Coil Design Lay Out Alternative 1 Piping and Coil Design Lay Out Alternative 1 Piping and Coil Design Lay Out Alternative 2 Piping and Coil Design Lay Out Alternative 2 Piping and Coil Design Lay Out Alternative 3 Piping and Coil Design Lay Out Alternative 3 Organizational management

PAGE 39 38 40 41 43 43 64 64 107 107 113

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LIST OF TABLES

TABLES 1 2 3 4 5 Summary of Specification Alternative 1 Summary of Specification Alternative 2 Summary of Specification Alternative 3 Gantt Chart Financial summary and comparison of the 3 alternatives

PAGE 56 98 109 112 128