Lean: From Theory to Practice — One City’s (and Library’s) Lean Story… Abridged
RJ Spring Rubber and Metal Parts Mfg Corp Company Profile
1. RJ SPRING RUBBER AND METAL
PARTS MFG. CORP.
Company Profile Presentation
2. Page 2
CONTENTS
COMPANY PROFILE
PRODUCTS
PRODUCT APPLICATION
STRATEGIES, MACHINES &
EQUIPMENT
FUTURE PLANS
COMPANY PROFILE
3. Page 3
BUSINESS PROFILE
Business Trade Name : RJ Spring Rubber and Metalparts Mfg. Corp.
Business Address :
Nature of Business :
Plant and Office Area :
Date Established :
Kind of Ownership :
Contact Numbers :
Email :
Website :
171 Nat’l Road, Ortigas Ave. Ext. Brgy. Delapaz, Antipolo City
Manufacturer
Plant : 900 sq.m / Office : 100 sq.m
September 1994
Corporation
(02) 658-19-87 ; (02) 658-19-51 ; (02) 473-04-33 ; (02) 387-93-15
Fax : (02) 212-05-31
Sales@rjspringrubber.com / rjspringrubber@yahoo.com
www.rjspringrubber.com
4. Page 4
ABOUT US
As RJ SPRING RUBBER & METAL PARTS MFG., CORP., faces the 21st century, the company takes pride in its work
by using the latest and updated technology available.
Since its start of operation (September of 1994) up to this day, RJ SPRING RUBBER & METAL PARTS MFG., CORP.,
(formerly Iris Spring and Rubber Industries) have been providing rubber, metal and spring components/items to various
clients, serving the clients according to their needs.
We believe that we’ll be able to compete globally in the near future since it is the company’s vision to become a highly
respected fabricator and producer of various rubber and metal spring components/items.
The company assures its clients of their satisfaction by addressing their needs and requirements in a timely manner. At
its early stage, RJ was able to capture almost 75% of the total market requirement for Automotive, Appliances,
Electronics, Bottling, Shipping and Mining industries merely because of its COMMITMENT IN TOTAL CUSTOMER
SATISFACTION. In this regard, it is thus projected, that it won’t take too long for RJ to rise into prominence and gain
the stature as one of the most reliable and prestigious player in the manufacturing industry.
The company safety and product quality. An open communication policy is practiced throughout the company wherein
the personnel are encouraged to air their problems and resolve them at the earliest possible time. At the early stage,
RJ’s production is strongly determined to lead in this industry by its new management style and system of operation. Its
simple organized structure, office procedures, and policies reflect a new enterprising industry, but still concerned on
work volume capacity and efficiency already reached a level of about 3 to 4 tons per month with zero accident
reported.
As of Today, the company is already ISO 19001:2000 & ISO 14001:2004 Certified under SGS Philippines.
Company History and its Operation
5. Page 5
MISSION AND VISION
QUALITY AND ENVIRONMENTAL POLICY
We, at RJ SPRING RUBBER & METAL PARTS MFG., CORP., believe that the establishment of an
effective quality and environmental management system will help our company achieve its vision of
becoming a highly respected fabricator and manufacturer of various rubber and metal spring
components/items.
The company is strongly determined to lead in this industry by providing satisfaction to our customers and
complying with all applicable environmental laws and other requirements that we subscribe to. We will
achieve this by:
Addressing the needs and expectations of our customers in a timely manner;
Continually improving our processes and manpower through innovation training
Continually raising quality and environmental awareness within the Company and our customers &
suppliers as well;
Developing sound practices for effective waste management and proper consumption of electricity .
It is imperative that all personnel understand this policy and that all relevant objectives/targets
formulated are for the continual improvement of the quality and environmental management system.
6. Page 6
Purpose, Scope and Applicable Standards
Purpose and Scope
This Integrated Quality and Environmental Management System Manual documents RJ Spring
Rubber & Metal Parts Mfg., Corp., quality and environmental systems as a company engaged in the
manufacturing industry, to demonstrate the company’s commitment to consistently provide products
and services that meet customer and regulatory requirements, prevent pollution, and continual
improvement.
This manual establishes compliance with the standards listed in the Applicable Standards section
of this manual. This Quality and EMS Manual applies to all processes and functions within RJ Spring
Rubber & Metal Parts Mfg., Corp., in its Rizal office/plant – manufacture of spring and rubber.
Applicable Standards
ISO 9001: 2000, Quality Management System
ISO 14001: 2004, Environmental Management Systems
Exclusion:
ISO 9001:2000 Section 7.3 –Design and/or Development, including all subsections within these clauses.
ISO 9001:2000 Section 7.5.2 – Validation of Processes for Production and Service Provision and all
subsections within these clauses.
Justification: RJ Spring Rubber & Metal Parts Mfg., Corp., does not design or develop the products it
produces. All product specifications are defined by customers.
7. Page 7
Certification, Awards and Recognition
Certified by ISO : 14001:2004 and 9001:2000
2006 Outstanding Local Suppliers – Isuzu Philippines Corporation
Best in Quality Award – Sharp Philippines Corporation
2004 Appreciation Award for Excellence – Sharp Philippines Corporation
2009 ZERO Delay in Delivery – Isuzu Philippines Corporation
8. Page 8
BUSINESS PROCESS CHART
Customer
Order Handling
Manufacturing
Inspection &
Delivery
Customer
Business
Planning
Admin
Subcon Plating &
Testing
Warehousing &
Maintenance
Review and
Improvement
Management Responsibility &
Resource Management Plan
Product/Service Realization (Do)
Monitoring & Measurement (Check-Act)
9. Page 9
PRODUCT SALES CONTRIBUTION
Spring
30%
Rubber
30%
Fabrication
20%
Stamping
Parts
20%
Spring
Rubber
Stamping Parts
Fabrication
34. Page 34
STRATEGIES
Category Potential Risk Containment Plan Preventative Measures
Material
Material shortage due to:
1. Delivery Delay
2. Uncontrollable Reason
Maintain Stock Level Finish Goods
1 month Buffer Stock
1. Give 3 months forecast to suppliers
2. Regular Visits to local suppliers
3. Monitor suppliers performance on a monthly
basis
Machine Machine Breakdown
1. Conduct Trial for alternative machine
2. Keep back up sub con incase
alternative machine is available
1. Strictly follow machine preventive maintenance
program
2. Maintain stock of commonly used spare parts of
machines
Mold Mold Damage
Conduct Immediate mold repair
1. Rj spring has internal mold repair capability
Conduct mold preventative maintenance after
each production
Man
Line Stoppage due to labor
problem
1. Strengthen labor management council activities.
2. Regular LMC meetings (twice a month) to
discuss LMC concerns and to address labor
issue
Power
Outage
Electrical Supply breakdown
Standby Generator is available incase of
power outage
1. Continue conducting substation preventative
maintenance
2. Quarterly check up of electrical circuit breakers
to check for any abnormality
Fire Occurrence of Fire
Implement Emergency Response
Procedure
1. Continue to implement monthly 5’s & safety
patrol to verify that all safety measures are
implemented.
2. Strictly follow external audit advise and
improvement suggestions.
Contingency Plan
35. Page 35
Machines and Equipments
Mechanical Power Press
Brand
Date
Purchased
Tons Type Die Clearance
Die Size
Machine Qty.
Min Max
Japan Jan. 2002 10 Mech. Power Press 8” 6” 8” 2
Japan Jan. 2002 25 Mech. Power Press 14” 11” 14” 2
Japan Nov. 2008 60 Mech. Power Press 29” 15” 17” 1
Japan Nov. 2008 30 Mech. Power Press 16” 12” 14” 1
Taiwan Nov. 2008 80 Mech. Power Press 20” 16” 18” 1
Japan Jan. 2009 150 Mech. Power Press 1
36. Page 36
Machines and Equipments
Brand
Date
Purchased
Capacity Type
Mould Size
Machine Qty.
Min Max
Japan May. 2001 3 HP Hydraulic 8x8 14x14 2
Japan May. 2001 3 HP Hydraulic 8x8 14x14 1
Assembled May. 2001 3 HP Semi -
Hydraulic
6x6 12x12 2
Rubber Press
37. Page 37
Machines and Equipments
Brand
Date
Purchased
Capacity Type/Kind
Die Size
Machine Qty.
Min Max
Germany Nov. 2008 3 HP Wafios 0.8mm 3.0mm 1
Germany Nov. 2008 3 HP Wafios 1.0mm 3.0mm 1
Germany Nov. 2008 3 HP Wafios 1.0mm 5.0mm 1
Germany Nov. 2008 1 HP Hokuyo 0.3mm 1.0mm 1
Automatic Coiling Machines
- It can produce hundred thousands of spring per day.
38. Page 38
Machines and Equipments
Brand
Date
Purchased
Capacity Type/Kind Clearance
Die Size
Machine Qty.
Min Max
Assembled Jan. 2002 1 HP Manual 0.3mm 1.2mm 2
Assembled Jan. 2002 1 HP Manual 1.0mm 3.0mm 4
Assembled Jan. 2002 1 HP Manual 3.0mm 8.0mm 5
Assembled Jan. 2002 3 HP Manual 8.0mm 12.0mm 3
Assembled Jan. 2002 3 HP Manual 12.0mm 50.0mm 1
Manual Coiling Machines
39. Page 39
Machines and Equipments
Brand Date Purchased Size/Capacity Type/Kind Machine Qty.
Japan Nov. 2008 3 FT/3 HP Conventional Lathe Machine 1
Japan Nov. 2008 6 FT/4 HP Conventional Lathe Machine 1
Japan Jan. 2001 3 FT/3 HP Conventional Lathe Machine 1
Japan Jan. 2004 3HP Vertical Milling Machine 1
Japan Nov. 2008 3HP Conventional Lathe Machine 1
Germany May. 2004 3HP Migweld 1
China Nov. 2008 3HP Power Saw 1
Japan Nov. 2009 Surface Grinder 1
Machines for Fabrication (In-House)
40. Page 40
Technical Support Equipments
Digital Caliper
Vernier Height Gauge
Durometer
(Hardness Tester)
Digital Weighing Scale
Micrometer
42. Page 42
Future Plans
ACTIVITY 2010 2011 2012
Allocation of budget for
plant construction at
laguna plant
Start of plant
construction
Transfer of machine &
production line