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CHAPTER 4

Present System

Greenshine Management Enterprise manufactures both brand new and second

hand boxes to their different distributers. The company has no required number of 

orders unless their buyers or clients declare so. The process required to finish a product

of the second hand boxes has only one difference from the process required to finish

brand new boxes. Generally, the second hand boxes involves the process of unloading

raw materials, carton packaging sie, machine cuxtting !, machine cutting ", slitting,

gluing and then finishing and after that, it will be ready for shipment. #owever, the

process of the brand new boxes consist of the same process of the second hand except

for the inspection which is needed to be done after the unloading of raw materials. The

efficient use of raw materials and high$tech product protection has made flexible

packaging one of the fastest growing segment of the packaging industry not only in the

Greenshine Management Enterprise but also to the different %arton packaging

industries.

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Raw Material Carton PackagingSize

Machine Cutting1

Machine Cutting2

Slitting Gluing

PackagingFinish

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&low %hart '(rand )ew (oxes*

Figure 2 - Flow Chart for Brand ew Bo!es

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Raw Material Inspection

Carton PackagingSizeCutting 1

Cutting 2 Slitting

GluingPackaging

Finish

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&low %hart '+econd #and (oxes*

Figure " - Flow Chart for Se#ond Hand Bo!es

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RA$ %ATER&A'S

nloading delivery bay is the first process in the Greenshine company

where the raw materials including carton boards or used boxes are ready for storage.

There are usually five types of carton boards used for manufacturing brand new boxes.

These are- )on$Tested, !" lbs. /rop +trength, "0 lbs. /rop +trength, 100 lbs. /rop

+trength, and 10 lbs. /rop +trength. &or the company, they uses !" lbs. /rop

+trength carton which costs !.203hp4+q. &t. and 100 lbs. /rop +trength carton which

costs ".03hp4+q. &t. #owever, there are two types of second hand boxes processed

by the company which both costs !03hp per kilogram, the single layered box and the

double layered box. The #onda Motors %orporation supplies the second hand boxes to

the company. +ingle layered boxes are the easiest second hand boxes as they are very

easy to pack. 5ith single layered boxes, the single layer of corrugated boards

strengthens the box. 6n the other hand, the /ouble layered boxes are usually consists

of two layers of corrugated board which are suitable for heavier items.

&SPECT&( )for Brand ew Bo!es only*

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1!

&or the brand new boxes, workers are inspecting the carton boards to check if 

there are any inconsistencies upon receiving the raw materials. +ince brand new boxes

are much expensive than second hand boxes, they are manually checking the carton

boards and carefully making a decision if they should include it on the brand new boxes

or should transfer to the second hand boxes. They also remove the sticker$like brand

name attached on the carton boards. 7uality is very important to the company since

they are aiming for a longer partner relationship to their customer.

CART( PAC+A,&, S&E

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1"

The next step is the processing of raw materials where the carton

packaging sie is being measured. The properties of the contents of the nature, shape,

sie, weight and display are being observed. To prevent the discomfort among the

workers, the company first asks the specifications of the customer before ordering the

carton boards. (asically, the company offers different sie of the carton as long as the

buyers demand the width, length, height and type of the box they need. #owever for the

brand new boxes, sies are much bigger than the second hand boxes because it does

not involve trimming of the edges.

%ACH&E C.TT&, / A0 C.TT&, 2

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2#

There are three operating machines present in the company. The two cutter 

machines which are operated by four '8* persons, trims the edges of the carton boards

according to the customer9s specifications. The sie and the type of box made on the

previous process were cut by these machines which are also fixed with stamping

fittings, allowing the carton boards to be folded. 6ne operator places the carton boards

on the machine cutter while the other one collects the cut carton boards. The

Greenshine %ompany decided to have two cutter machines to increase their production

in case they need to supply large number of boxes to their suppliers.

S'&TT&,

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The slitter machine which can be operated by one '!* person cuts the top

and bottom ends of the carton boards, allowing the box to be closed. This machine is

also fixed but with a perpendicular stamping fitting which allows folding the aperture of 

the box. :n slitting process, the carton boards are then slotted by one operator on to the

sharp guided machines where the rolls come out in uniform shape. ;ike the machine

cutters, the slotted carton boards are processed based on the desired specifications of 

the buyers and are being collected and put on storage.

,'.&,

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$alk to the position area

$alk an% get the glue &or the 'o(

$alk to the stockroo) o& un*nishe% 'o(es+ an% get

$alk 'ack to the position area

Sprea% the glue on the si%e o& 'o(es

Position the 'o(

Co)'ine% the pair o& 'o(es

Storage

22

The workers use wood glue for brand new boxes and natural cassava glue

mixture for second hand boxes. They are manually produced by five '* workers, each

are working on their own. <ewinding4doctoring is a process of finaliing and checking a

good quality of box before going to packaging area. :t is more likely checking the

strength of the carton boards. Then the finished products whether brand new or second

hand boxes are now put on a storage and ready to ship on the transportation bay.

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Figure 4 1 Flow Pro#ess Chart of ,luing

ST(RA,E SCRAP AREA

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 =fter being processed on the three machines, the excess carton boards

which are usually small are put on storage set aside and later on can be recycled. The

Greenshine company chooses among the excess carton boards whether they should

recycle or they are going to put on the scrap area. Then the scraps are being collected

and delivered to another company once a week to improve the working environment of 

the workers and have an additional revenue. 6n the other side, the cut and slotted

carton boards which are also on the storage area are now ready for finishing where they

are placed on the gluing and packaging area.

F&&SH&,

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&inishing area is divided into two, the brand new box storage area and the

second hand box storage area where the process of gluing and packaging takes place.

F&&SHE0 ,((0S3 PR&C&,

The following is the fixed pricing formula for Greenshine Management Enterprise %arton

products-

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&or +econd #and (oxes-

3 >

&or (rand )ew (oxes-

3 >

;egend-

3 > 3rice per box

l > length 'inches*

w > width 'inches*

h > height 'inches*

x > !.?0 for single layer4!" lb drop strength

x > ".10 for double layer4100 lb drop strength