Production Processes Of Top Glove Company Commerce Essay

Production Processes Of top of the inning manus Company Commerce EssayOne of the successful reasons that TG Company abide succeed in their vexation is because they acquit a strong and good production growth in their no-count-base paint manus qualification. They believe that they must have the nearly contemporary and innovative hand manufacturing toolries if they wished to be continuing as a world-class cost sound hand manufacturer. They have invested substanti onlyy in the machineries that argon necessitateed to condition that they empennage richly adopt the la seek manufacturing techniques for both their production lines. Other than that, they to come across that they suffer consistently take a crap high reference latex gloves ar similarly using a continuous engineering touch.Competent and experienced personnel besides contribute in smooth production line and consent in superior of the latex gloves even though they have modern machineries. In addition , an on-line quality control measures have been instituted through forbidden the manufacturing influencees to mark off the highest quality products.The latex is a white, milky liquid that comes from rubber trees, which is either from native or hybrid trees. Mostly, TG gets its latex from buying through the rubber market slice the remaining latex is from their possess rubber plantation. The latex leave al unitary be harvested from rubber trees when the trees trunk is swollen and also every day, afterward the rain has halt during the rainy season. The latex is a natural product and it resulting coagulate easily, in that locationfore it needs to be harvests from the rubber trees as soon as come-at-able and then send to TG factory to be manufactured.When the latex is sent to the TG factory, the latex lead be manufactured with a standardized method that is aim by the fellowship itself. The flow of the production litigate of latex glove in TG Company is sorter cleaning, c oagulant dipping, drying, latex dipping, take away, beading, vul provokeizing, post leaching, slurry dipping, stripping, tumbling, and quality control.Former make cleanBefore the latex croupe be accomplish to the coagulant dipping process into hand-shaped, the glove antecedents need to be cleaned before it can be used to form hand-shaped latex gloves. A quality production of exam gloves includes the environment of latex glove factory is clean. This also bureau glove formers must be cleaned to figure there is no dirt or debris anywhere because it try onament affect the final product to possibly have defects like holes. Firstly, glove former must be dipping into an sexually transmitted disease bath and then rinse with clean water. Secondly, an alkaline bath is used by dipping the glove formers in them to neutralize the acid and again rinsed in clean water. Lastly, an important step that is the glove formers atomic number 18 brushed to ensure the surface of the glove forme rs is consistent and eliminate pinholes on the latex gloves after it form.TG factory have multiple production lines that produce batches of disposable gloves. If there is any dirt or debris on the glove former, it can result in the manufacturer being forced to trash the entire batch of latex gloves. This reason shows the importance of glove formers that must be on a regular basis inspected and cleaned before the molds argon swaybacked into coagulant tanks.Coagulant DippingAfter the glove former is cleaned, it will be coated with coagulant (eg. calcium nitrate) and be dipped into the coagulant bath to help the latex mixture adhere to the formers and to help ensure the latex is distributed evenly. The glove formers are dipped into the coagulant tank at a lower place TG doers control to extract the protein from the previous glove dipping and this dipping is done once for every production cycle.DryingDrying is one of the stations in production process of latex gloves manufacturing whe reby the coagulant converts the liquid latex film into a wet-gel on the glove formers and will eventually travel through a series of ovens to dry the gloves and end the clotting process. In brief, it is a process of drying the gloves from wet to readymade gloves.Latex DippingLatex dipping is one of the stations in the production process of latex gloves manufacturing and the tank is filled with intensify latex. A latex layer will be formed on the glove former after it goes through this tank. The thickness of the latex glove is find out at the coagulating and dipping stage. The longer the time the glove former travels in the coagulant tank, the thicker the latex gloves will be formed. TG Company will ensure that the latex gloves that produce is high quality and safe to be use. takeThis leaching stage can called as the pre-vulcanization leaching. It also known as wet gel leaching. end chemicals and proteins on the surface of the gloves are govern into the leaching process to be rem oved after the drying of latex mixture. A longer leaching line can wash out latex proteins overmuch effectively. Besides that, the water must be hot and fresh enough to make the proteins dissolve better. This step is a critical step to minimize the occurrence of latex sensitivity. The water temperature, process duration, and water exchange rate will affect the effectiveness of the process. Good leaching line can result in a good and quality latex glove.BeadingBeading is a process whereby up to a twelve chemicals are added to help in prolonging(a) manufacturing process of latex gloves. The chemicals added are antioxidant that prevents deterioration of the rubber molecules in the final product by heat, moisture, and ozone. Chemical accelerators are also added to help control the next vulcanization process.VulcanizationOne of the discovery key in manufacturing rubber is the vulcanization process. It is a curing process in the production process of latex gloves whereby the latex par ticles are modified by adding in accelerator chemicals to it. When all the materials are heated, sulfur atoms are enchained with the rubber molecules to form a cross-link that gives strengths and elasticity to the physical properties of the rubber. This process ensures the rubber will not be torn and melt easily.Post LeachingThis process is similar to the wet-film leaching previously, but it is a little different whereby it is carried out on the dry/vulcanized latex film. Therefore, it is also known as dry-film leaching. Time and temperature is the most important element to ensure effectiveness in the process of water extractives reduction. Latex gloves may be leached up to 24 hours to ensure its effectiveness.Slurry DippingThis stage is also known as wet even milling. The slurry tank containing the cornstarch solution can prevent latex gloves from sticking in the tank. The slurry is also referred to as wet demolish. The benefit of this pulverize is acting as preservation of th e latex gloves and to assist in the latex gloves donning process. TG Company has followed the international method in the specific stage whereby the latex gloves will go through to a greater extent(prenominal) ovens for further drying and additional rinsing cycles where the powder will be removed. The process of removing the powder is to avoid latex allergic reaction.StrippingAt this stage, the latex gloves are stripping from the glove formers. There are two types of methods, which are manually or automatically stripping the latex gloves from the glove formers. TGs latex examination gloves are stripped by fully automated stripping machine. By using this fully automated stripping machine, TG can increase the quality and safety of the latex gloves they produced. The latex gloves will be sent to the next phase of the latex glove manufacturing process for final drying.TumblingThe tumbling process at latex gloves manufacturing process is to remove excessive powder on the gloves. The la tex gloves are putt into the commercial dryers to ensure that the powder is more(prenominal) evenly distributed and excess powder can be removed.Powder-Free GlovesPowder-free gloves stage is a engine room to prevent stickiness of gloves by avoiding powder usage completely by going through chlorination or polymer coating process. This is one of the important technology processes in manufacturing latex glove nowadays because most of the glove makers are producing the latex gloves with powder-free. go across Glove produces latex powder and powder-free gloves. Basically, the powder-free latex gloves are transformed from powdered gloves when the powder is removed. Before the latex gloves dried, the powder helps the latex gloves give uniformity as well as to prevent the latex gloves from molding together. The tackiness on the glove surface can be removed by rinsing the latex gloves in water. Then it is placed into a chlorine bath to transform the powdered latex gloves to powder-free la tex gloves. The glove is turned deep wipe out out and the process is repeated. The powder-free gloves are placed back into the dryers when the bathing process is completed. theatrical role ControlTG carries out its quality control in total quality management system. In total quality management system, the process includes regular testing of new(a) materials, close monitoring the manufacturing process, continuous procession on quality control, maintain regular quality control, complying with stringent quality standard, target for zero defects, good instructional labeling, efficient work standardization, continuous improvements in packing and loading, close monitoring of production process, tensile strength machine, innovative auto-stripping system, visual air pump test, water tight test, physical dimension test, protein test and powder test in their manufacturing process of latex gloves. The visual air pump test, water tight test and physical dimension test will be carried out in this quality control stage while the other test will be carry out during each manufacturing process of the latex gloves. The air pump test serves to check for holes and visual defects in gloves while the watertight test serves to check for pinholes rate on the latex gloves. for each one country will have their own acceptable quality aim (AQL) in allowing the connection to export product to their country. For example, the companies that want export their gloves to United States, a 2.5 AQL in the watertight test or better. The physical dimension test is used to measure the dimension of the gloves whether to know the measurement does meet the inspection level of 4.0 that set in AQL.PackingPacking is the final stage in the manufacturing process of latex gloves. TG packs their latex gloves in flat and efficient layer-by-layer to ease the dispensing of gloves in order to avoid latex gloves difficult to dispense from each gloves later. This type of packing method can reduces waste and makes latex gloves easier to take out from the box. For example, we can dispense tissue from a tissue box easily and the idea is applied to the latex gloves box dispensers. This layered technique is often use by all glove manufacturers.Lastly, when all production processes are completely carried, the latex gloves will be keep in TG warehouse for labeling and then send to their token customers. In addition, the latex gloves are also being exported to other countries. The production processes of kick the bucket Glove are repeated for all the production lines and to ensure the latex gloves that are produced are in high quality and safe for use.Strength of the Production ProcessThe machine technologies that TG used to make their production processes of latex gloves are result in superior quality and it is safe to use by all consumers. The production process in TG adopts the latest manufacturing techniques by using the modern machineries. Other than that, the production processes in TG helps their company to increase precision and productivity in their latex gloves production. This is due to the advanced and modern technology that applied in the production processes. In addition, the production processes also increase the flexibility in producing latex gloves. The production processes will also increase the process stability during the manufacturing process of latex gloves. It is because the production processes are carried under a systematic production processes. The products will be produced gradually by following specific production processes and to ensure the product is high quality produced.The efficient production processes is able to help TG in saving a lot of production cost. It is because the efficient production processes can ensure that they can produce latex gloves effectively and efficiently. Then, the production processes also helps TG in reducing the number of workers. This is due to most of production processes are fully operated by the machine te chnology. This helps TG to save cost in the workers.Weakness of the Production ProcessTG needs to invest heavily in buying the modern machineries and need to hire more experienced personnel in their production process. TG uses modern technology in carrying out their production processes to make latex gloves. The machineries that bought were extremely expensive. Thus, the tending of the machineries is expensive and if there had any minor or major accessories spoiled it will be costly to the company to repair it back. It is because the accessories that are used in the machines are not for common use by other manufacturers within the same field area or other field areas and it is difficult to smelling for substitutes for that specific accessories. TG always checks and maintains the effectiveness of their machineries to prevent it from being spoiled.In addition, TG also needs to hire more experienced and skilled personnel with higher(prenominal) net to operate the specific machinerie s and carry researches. Some machinery needs special skilled and experienced personnel to take charge and TG does not simply hire a worker to operate the manufacturing machineries. The experts for such operations in the latex industry are much fewer in other fields. Thus, TG needs to spend more money to hire those experts that operate their operations.Facility LayoutThe layout of a company is very important because it establishes an organizations competitive priorities in regard to capacity, process, flexibility, cost, as well as quality of work life, customer contact, and image. An effective layout can help an organization achieve a strategy that supports differentiation, low cost, or response. The objective of layout strategy is to develop an effective and efficient layout that will meet the firms competitive requirements. Layout design has the following purpose-Higher utilization of space, equipment, and people modify flow of information, materials, or peopleImproved employees mo rale and safer working conditionsImproved customer/ client interactionFlexibility (layout need to be change from time to time)TG is a company that used work jail cell layout to produce its products. Work cell layout means an arrangement of machines and personnel that focuses on making a single product or family of related products. A work cell reorganizes people and machines that would ordinarily be dispersed in various departments into a group so that they can focus on making a single product or a group of related products. Once the work cell has the appropriate equipment located in proper sequence, the next task will be staff and balance the cell. Normally it involves two steps. First, determine the takt time, which is the pace (frequency) of production units necessary to meet customer ordersTakt time = integral work time available/ Units requiredSecond, determine the number of operators requiredWorkers required = Total operation time required/ Takt timeBy doing so, the company can increased equipment and machinery utilization due to better programming and faster material flow. Diagram below shows the layout of Top Glove company and the description of the components inside the layout-The space of the layout is 80m (length) x 50m (width) x 8m (height) which can be categorize as a big company.Waste water- All the unwanted or wastewater will stored in this area.Latex storage- This is the place to store latex that use to produce latex gloves. It place near to the dipping line and chemical dispensing coalesceing ball mill about because it casual for mixing work which need to combine other raw material and chemical substances with latex to produce the latex gloves.WC- This is the place for workers to refresh themselves.Tools/Maintenance- Places that put or keep the tools and equipments that used to produce the glove and for maintenance purpose. All the tools and equipments will be keeping in a specific place that easy the workers to find it.Chemical storage- All the chemical substances, which are dangerous, will keep here to avoid any accident happen and make sure the workplace is safety. This room is just nearby of the chemical dispensing compounding ball mills to make sure that the compounding work can be carry out smoothly.Dipping line- This is the place where machine is design for examination and surgical latex gloves, which include the process of auto washing, coagulants agents dipping, latex dipping, drying, and beading, fore leaching, vulcanizing, post-leaching, wet powdering, cooling, and stripping.Chemical Dispensing Compounding lout Mills- The place that carry out the work of compounding or mixing of the raw materials, chemical substances, latex and many other to produce the gloves.Chlorination- A process of producing powder free gloves by treating these gloves with chlorine. It also removes the first layer of protein to an acceptable level.Tumbler Dryer- It is a machine that tries to dry up the gloves after all the compoun d mixed together.Sterilization- The place that sterilizes the gloves using Gamma irradiation to eliminate all microbial life, including highly resistant bacteria spores.Worker Canteen- Places for workers to have their meals.Plant Officer- This is the stain for plant officer who supervise the production work of the company.Q.C Room- All the finished gloves will send to this room for checking before send to customer. The workers will checked the gloves one by one and see whether there are any rejected glove that do not meet the quality standard of the company. band Testing- Lap for chemist to test for new formula or compound that can improve the existing glove or testing for new products. This is good for the company to fight with his competitors however some cost may be incurred for the research and development work.Packaging Area/Material- All the gloves that have go through Q.C checking will send here for packaging before sell to the customers. There are sufficient machine and mat erial prepared for packaging work so that the glove will be pack nicely and keep in a good condition.Show Room- Room to display the products of the company. Customers who interested in the products of the company can take a look on the sample that show in this room.Company Office- Main office of the company where all the admin work of the company will carry out here.Finished Product Storage- The finished products will be stored here and waiting to send to the customers by the trucks.Strength of the Facility LayoutTop Glove used work cell layout as their strategy to produce their products to utilize the capacity of the company, which may bring a lot of advantages to the company. First, it can reduced work-in- process inventory which means there is less inventories or equipments undeniable to link up the work that is in different process because the work cell is set up to provide one piece flow from machine to machine. Second, less floor space required because less space is needed be tween machines to take hold work-in-process inventory. For example, the tumbler dryer is place closely with the process of sterilisation that uses to sterilize the gloves bacteria. Thus, it saves a lot of space between these two processes. Next, when the employees work in this frame of layout, it will heightened the sense of employees participation in the organization and the product which will encourage them to add responsibility toward the product quality because they directly associated with the products in their own work cell. For example, the employees who work as an operator in dipping line will feel motivated and carry out his work carefully when the manager sceptred him to look after the machine or participate in any work that related to the dipping process. Lastly, increased equipment and machinery utilization is also one of the advantages because of better scheduling and faster material flow. When the glove is being chlorinate immediately it will proceed to the process of drying and after this it will go through the process of sterilization immediately as well. The fast material flow show that it utilize the machinery and equipment effectively.Weaknesses of the Facility LayoutHowever, there are still some weaknesses in this layout, which is the straight-line work cell layout as we can see in the dipping line. The workers in the dipping line are arrange in such way that sometime they will find that it is concentrated to divided their work evenly and more worker is needed analyse to the U-shape work cell layout. This may cause social loafing in the workplace, which means some worker may work less as compare to his colleague. This is not good to happen in the workplace because it will lower down the morale of other worker who works hard but he just gets the same pay as his colleague who is lazy. Next, from the layout of the company, we also notice that there is only one main gate for exist and entry but no other emergency or back door in the layout . This is also a weakness of the company because there is no other emergency door for workers to escape if any accident happens.Goods and Service DesignThe other strategic of this company is goods and service design. Top Gloves main productions are rubber gloves, celluloid gloves and surgical gloves. Top glove producing more latex glove as compare others glove, since latex gloves is a better choice of protection. The reasons are the latex is the main material in rubber gloves manufacture where it is the gold standard for durability. Where latex is referring to a milky, usually whitish, fluid obtained from over 1,000 species of trees and plants. It is the most important raw material used for the production of latex gloves, natural rubber latex, which derived from the Hevea Brasiliensis tree species plant mainly in South East Asia though they originated from Brazil. It demonstrates superior elasticity, strength and barrier protection. It outperforms vinyl as well as any synthetic ru bber in terms of maintaining barrier integrity in routine and high risks procedures. Based on the researches, the latex gloves provide up to 9 times more protection during normal use than non-latex gloves. The glove size is determined by measuring the circumference of the hand around the palm area with a put down measure. The usual size standard for examination gloves are of XS XL, while surgical gloves are of 6.5 8.5. The gloves thickness measured by depth protecting skin from ikon to elements. It was measured on a single wall using a micrometer over several parts of the glove, typically at the cuff, the mid-palm and the finger sections. The types of gloves are latex gloves, nitrile gloves, vinyl gloves, medical gloves, surgical gloves, disposable gloves, clean room gloves, household gloves, general-purpose gloves, and polyethylene gloves (PE glove). For example, the nitrile glove is one of the synthetic gloves that are produced from the synthetic latex of Acrylonitrile Butadie ne Copolymer type, which is resistance to oil and exhibiting rubber-like characteristics. Its elasticity is good but less superior as compared to natural rubber. It is generally more costly than natural latex gloves.Strengths of the Goods and Service designThe strengths of using this strategic which is the goods and service design are Top Gloves gloves are protect to lives and the price of it are low compare to other glove brands. When they manufacture the gloves, the gloves will test in the elongation or stretching test, to measure the strengths of the gloves. During extended surgeries, the practice of ever-changing to a new pair of gloves prior to a critical procedure has been noted to reduce bacterial contamination.Weakness of the Goods and Service designThe weaknesses are measly donning techniques, which is can result in glove rips and tears. Healthcare personnel should take care to don gloves correctly and avoid excessive stretching. Thoroughly dry manpower before sliding the m into gloves.Quality ManagementQuality is refers to the totality of features and characteristics of a product or service that bears on its ability to satisfy stated or implied needs. Every organization should manage and control of their products quality. It is important to help the organization to build a well reputation in the industry. By doing this, customer will more reliability on such product and finally help to gain the market share. Top Glove is a manufacturer company that pays much attention on the products quality. Top Glove committed and believes in top quality products, they are responsibility to ensure quality consistency and product reliability to all their customers and users.Before the products go into the packaging process and sell to the market, Top Glove has implemented the quality inspection process to make sure that their products are producing at the expected quality level. Top Glove is strongly stresses on Total Quality Management (TQM) and the Quality Contr ol tests are conducted from the point we have our raw materials straight through the production processes and the finished products points. Compulsory pre-shipment inspections are carried out before the delivery of each order. Top Glove is emphasis on stringent quality control procedures in line with ISO 9001 and in strict compliance with ASTM and EN 455 standards.Top Glove has using the tensile strength machine as the measurement of the stretch required to break the glove material. Glove without good vulcanized process tend to have higher tensile strength. Top Glove also has using the innovative auto-stripping system to removing the gloves from the formers, where they are turn inside out. By doing this, the productivity can be increase because it is faster than by using manual stripping. Air pump test has been used to check for holes and visual defects in gloves. Furthermore, water tight test also using by Top Glove to check on the quality of products which is a test that use to d etermine the AQL level of an examination gloves by checking on the pinholes of the particular gloves after filling up the gloves with 1000ml water and then check for any leakage in 2 minutes time. To ensure the quality of products, Top Glove has been conducted the protein test of the rubber. All natural rubber latex products contain protein. For latex gloves, it is the measurement of total protein regardless of allergenic content. The ASTM D5712 standard is using the test method in the Modified Lowry assay for analysis of aqueous Extractable Protein Natural Rubber. Besides, Top Glove has using powder free technology to prevent stickiness of gloves by avoiding powder usage completely by going through chlorination or polymer coating process.Besides, Top Glove believes and emphasize strongly in Research Development (RD) to be in line with ever-changing business environment and to cater to the increasing high expectations of end-users. To keep pace with the latest development in the ru bber production, Top Glove has been collaborating closely with the Rubber Research Institute of Malaysia (RRI) and Lembaga Getah Malaysia (LGM) in the latest development on rubber research technology in Malaysia.Strength of the Quality designThe company able to carry out or able to follow the Quality control of the foreign pose company needs such as European and American customers.Top Glove is a company that very strictly in controls their products quality. Before they sell the products into the market, they will make sure that all of the products are match with the ISO 9001. Because of the high quality control of the products, it may help Top Glove to have more competitive power in the market. In those western countries such as Europe and United States, most of the consumers may have high requirement of a product they are more resuscitate toward the quality of products instead of the price. They are willing to pay higher price that to get a high quality product. Because of the T op Glove is pay more attention on the quality control, therefore, the quality of the products is more consistent and reliability. To maintain the quality of products, Top Glove is using the innovative technology and always astir(p) their system. With the high quality control of the products, the products quality is more consistent and seldom making substandard products Top Glove is able to fulfill those consumers needs. Those western countries date as larger markets in the world by fulfill those consumers needs of the products, it may lead Top Glove to build their reputation in the market. When they have built a better reputation in the market, the consumers may tend to repurchase those high quality products it may help the company to gain higher market share. Therefore, the company may have higher profitable.Weakness of the Quality designThe company must update their Quality control fulfillment on consistent basis from their Customers wants such as European and American customer. There is higher cost incur for updating the technology for fulfill the foreign site customer.Most of the western consumers are emphasis on the quality of the products when they are purchasing therefore, to maintain the market share in the western market, fulfill all of the western consumers needs is important. To maintain the profitable of the company, Top Glove should always update their quality control of the products that based on the customers needs and wants. To fulfill those consumers needs, Top Glove has developed a Research Development (RD) department. This department is required to make sure that the company is using the most efficiency and latest technology in production line. To develop a RD department, there is required an extra capital investment. Besides the machines that is required of the department some professional also needed to hire to assist in the department. When the department had developed the latest technology, Top Glove is needed to update the initial te chnology to the latest that can fulfill those consumers needs. However, it is costly to the company.Global ForcesPolitical ForcesThe Malaysian government was strictly regulating the health and safety conditions in the Top Glove manufacturing workplace. Besides, under the regulation, the company had to follow the minimum wage on their workers. Besides, that every nation and country was conscious about the environmental issue, similarly happen to Malaysia, it was a compulsory recycling legal philosophy was enforce to the Manufacturers in Malaysia. Due to this recycling law, it is good to Top Glove confederacy as they can recycle and save their cost on raw material. Thus, it significantly affects the operation of the company and there is a need for Top Glove to maintain good relationship with the ministry and government.Economical ForcesTop Glove Corporation having taxes heavily as it taxed at rate that are quite high. Besides, approximately 10 percent interest rates prevailing in th e Malaysia market that crea