Company Background. History Established in 1991 with only one factory and three production lines, Top Glove has since grown by leaps and bounds to become the world’s largest rubber glove manufacturer. Top Glove places customer satisfaction at the very heart of its business; hence has put a great deal of emphasis on research and development to ensure continual improvement in its product quality and production efficiency. In order to stay ahead of the curve in product development, it collaborates closely with government agencies and ministries to keep itself abreast of the latest development in rubber research technology.
It has now earned itself a reputation of being a one-stop glove sourcing center offering an extensive and complete range of high-quality, high value-added and cost-effective rubber gloves. It was listed on the Malaysian bourse, Bursa Saham Kuala Lumpur on 27 March 2001. In a short span of slightly more than a year, on 16 May 2002, Top Glove Corporation Berhad’s listing was successfully promoted from the Second Board to the Main Market of the Kuala Lumpur Stock Exchange. Top Glove has a shareholder fund of RM1. 09 billion or USD358 million with an annual turnover of about RM2. 5 billion or USD682 million as at financial year ended 31 August 2011. It is also one of the component stocks of the FTSE Bursa Malaysia (“FBM”) Mid 70 Index, FBM Top 100 Index and FBM Emas Index with a market capitalization of RM3. 01 billion as at 31 August 2011. In line with its objective of capturing a larger share in the world market, the company has undertaken a rapid expansion of its capacity. Its manufacturing facilities which spread across Malaysia, Thailand and China grew from 5 in 2001 to 21 in 2011, and will soon be expanding to 23 by end of 2012.
Top Glove exports to approximately 1000 customers in over 185 countries through its sales and marketing offices in Malaysia, the United States and Germany. Top Glove at a glance: | As at 31st May 2012| 1. | Number of Factories| 22| 2. | Number of Production Lines| 442| 3. | Total production capacity (pieces per year)| 38. 5 billion| 4. | Countries of Export| 185| 5. | Number of Employees| 10,900| 6. | Number of Customers| 1000| | Business Overview Top Glove’s business was established in 1991 by Dato’ Dr Lim Wee Chai and his wife, Tong Siew Bee.
The company has been expanding by leaps and bounds with the establishment of one new factory each year. Top Glove currently has ten (10) factories, of which two plants are in Thailand and one in China. It exports its gloves to about 500 customers in 145 countries. Top Glove produces a diverse range of gloves from powdered/powder free gloves which are smooth or textured, coloured, long length and flavored, to synthetic gloves, surgical gloves and household gloves. Its gloves are sold mainly to the food and healthcare/medical sectors.
Top Glove has been accredited with various quality awards from SIRIM ISO 9001 to ADA (USA). 70% of its products are sold under OEM (Original Equipment Manufacturer) and the rest are marketed under the ‘Top Glove’, ‘TG Medical’ and ‘Great Glove’ brands. Mission To be a world class glove manufacturer providing top quality products with excellent services through continuous improvement and innovation. Vision To strive to be the world’s leading manufacturer with excellent quality glove products and services that enrich and protect human lives. Quality Policy Quality and productivity are our business * Continuous improvement and innovation are our duties * Towards zero defect is our target Corporate Values * Global customer satisfaction * Do it right first time and every time * Integrity and total commitment * Excellence in quality and competitiveness * Environmental friendly and social responsibilities Business Ethics * Honesty * Integrity * Transparency Strategic Plan Top Glove has lined-up the following strategies to spearhead its objective to double its existing global market share in three years’ time : –
I. Robust expansion in production capacity. Top Glove will be embarking on a 3-year rapid expansion in production lines by adding another 55 lines in FY8/05, 66 lines in FY8/06 and 56 lines in FY8/07, in its Phuket, Hatyai, Shanghai and Klang factories. This would require a capex of about RM60m and RM66m in FY8/05 and FY/06 respectively. II. Penetration into new markets. Top Glove targets to have a customer base of 600 by December 2005 from 500 at present by increasing its export destinations to 160 from 145 currently.
Countries providing further potential include Russia, Brazil, Portugal, Middle-East and the US. III. Shifting towards more value-added products. In-line with the industry’s trend of favouring powder-free gloves, Top Glove is increasing its powder-free lines resulting in a product mix of 30% by the year 2006 from the current 17%. Apart from that, Top Glove will be producing more higher-margin products such as nitrile and surgical gloves when its future capacity is in place. IV. ‘One Stop Glove Sourcing Centre’.
Top Glove would still maintain its role as a ‘One-Stop Glove Sourcing Centre’ which has altogether a mix of 12 product range although it will be emphasizing on the more value-added range. Compared to other glove manufacturers, Top Glove is the only company in Malaysia that is able to manufacture all the varieties of gloves for healthcare, dental, food packaging, household, industrial, cleanroom as well as operation room. The broad choices has also made it convenient for existing customers as they do not need to approach different suppliers to cater to various needs. V. In-house technical expertise and R&D.
Top Glove’s in-house technical team, which would do the installation, modification and upgrade of production lines, has resulted in significant improvement in plant efficiency as well as savings in maintenance costs and time. In addition, due to the substantial investments in plant technology and product R&D, Top Glove managed to produce new glove variants to meet customers’ requirements (such as the softer feel nitrile glove). Top Glove has also developed production facilities with enhanced leaching systems which extract most of the protein that causes allergy in natural rubber gloves.
VI. Product quality and international accreditations. The advanced production technology and the stringent product quality has earned Top Glove various international accreditation such as US FDA, US ADA, ISO 9001, Australia’s TGA, various European standards and Germany’s TUV. This has strengthened its reputation and facilitated the Group in winning new customers. SWOT SWOT analysis is a useful tool for understanding and decision-making for all sorts of situations in business and organization. SWOT analysis can be classified into internal and external factors affecting a company.
The Strengths and Weaknesses of the SWOT analysis represent the internal factors that influence the viability of the company. While the Opportunities and Threats, on the other hand, are the external factors that may affect the company’s performances. A SWOT analysis provides more understanding of the organization in relation to its internal and external environment so that manager can formulate better strategy in pursuit of its mission. Strengths Top Glove Corporation has a largest market share in glove industry. This company produces a high quality gloves.
Besides that, Top Glove Corporation is a global presence company which they export their product to more than 180 countries worldwide. Top Glove Corporation has established the Top Glove Foundation to empower, employees based on merit, the needy and the less fortunate. Top Glove Foundation provides their funding for charitable purposes, education by giving out scholarship and provides industrial training and also activities in relation to environment preservation. For example, blood donation, Staff Eye Screening Programmed, Star NIE Donation and Bursa Rat Race.
At the same time, they work hard to minimize the impact of their business activities on the environment, whenever possible. As a conclusion, Top Glove Corporation always ensures them giving back to the society and corporate social responsibility. Top Glove Corporation get their award from Frost & Sullivan 2009,Best Brands Manufacturing – Rubber Gloves 2007 – 2008 By The Brand Laureate, Asia Pacific Entrepreneurship Awards (APEA) 2008 Entrepreneur of the Year 2008 By Enterprise Asia, Anugerah Kecemerlangan Industri 2007, SME Platinum Award 2007 By SME Association of Malaysia and many more.
Opportunities ST: Top Glove has a lower cost structure vs. its peers due to its internally engineered production lines and less expenditure on advertising and promotional activities. Oppr: Meanwhile, its ability to transfer increases in latex price (which is the major cost component) to its customers ensures that there is no negative impact on the business due to fluctuations in commodity prices. ‘Wet Latex’ price has stabilized lately, and last traded at RM3. 19/kg against a high of RM3. 64/kg in February 2004.
It is expected to ease further, thanks to the establishment of a tripartite agreement to manage rubber sales and stock between Indonesia, Thailand and Malaysia. On-going replantation exercise of rubber trees is also a boost to stabilizing the price of latex in the long-term. Str: Top Glove is also not directly affected by rising crude oil prices as it utilizes Natural Gas at its Klang factories which are being subsidized 40% by the Malaysian Government for the next 1 ? years while in China its plant is fired by coal.
However, the Thailand plants are slightly affected as they utilize LPG, but Top Glove is in the process of converting these plants into a biomass-powered system. Oppr: Other than that, Top Glove enjoys the following tax break privileges: – I. Thailand – 8 years tax-free + 5 years 50% tax rate; II. China – 2 years tax-free + 3 years 50% tax rate; and III. Malaysia – Pioneer status for 10 years for Factory 5 due to utilization of biomass energy, investment tax allowance and reinvestment allowances for the Klang factories, tax deduction on roadshows. Industry Outlook
The industry is currently moving towards a consolidation phase, firstly prompted by higher cost of latex and secondly due to technology requirement to produce higher quality gloves. This has resulted in some smaller-scaled players exiting or being acquired by larger players (with economies of scale). Meanwhile, some of the large international players have halted expansion plans and moved to outsourcing due to the need to invest substantially in R&D and upgrade production lines as well as the standard restrictions imposed by international health bodies. Threats and Weaknesses I.
Downtrend in pricing. The selling price of 1000 pcs of powdered latex gloves 15 years ago was USD60 but is now selling at USD16. The trend is inevitable due to advancement in technology, keen competition and expansion in capacities. However, once it reaches a point of saturation, prices will be stable. thr II. Synthetic gloves. Synthetic gloves were innovated due to the latex-protein allergy issues. However, with the advent of leaching processes and other technologies, Top Glove is able to produce polymer-coated, on-line chlorinated and double chlorination gloves that are low in protein content. ppr III. Protein allergy. Although the issue was once much debated, it has subsided invite US as natural rubber latex is still preferred against synthetic latex due to its superior elasticity, strength and barrier protection. thre IV. No long-term contracts. There are no long-term contracts and orders are dependent on regular customers which has relationship ranging from 1 year to over 10 years. thre V. Lack of brand portfolio. Top Glove has only three brand names, i. e. Top Glove’, ‘TG Medical’ and ‘Great Glove’ which accounts for 30% of its production. It may need to invest in a brand-building exercise when the industry reaches a point of saturation in order to defend its market share. weak – r n d, the – competition Strategy to compete Customers’ satisfaction is the focus of Top Glove and it had placed a lot of emphasis in Research and Development to produce a wide and diversified range of high quality and value-added glove products in order to fulfill the expectation of their customers.
The company also collaborates closely with the government agencies and Ministries to keep itself abreast of the latest development in rubber research technology. The company also uses state-of-art high technology and efficient automatic glove manufacturing machine to obtain the most products manufacturing yield and to remain as one of the most cost-effective and highest quality producer in the industry. With all these advantages and strategies, the company is able to compete with the competitors and stand out in the industry.
Production Processes of Top Glove(TG) Company: One of the successful reasons that TG Company can succeed in their business is because they have a strong and good production process in their latex glove making. They believe that they must have the most modern and advanced glove manufacturing machineries if they wished to be continuing as a world-class cost effective glove manufacturer. They have invested substantially in the machineries that are needed to ensure that they can fully adopt the latest manufacturing techniques for all their production lines.
Other than that, they to ensure that they can consistently produce high quality latex gloves are also using a continuous engineering process. Competent and experienced personnel also contribute in smooth production line and consistency in quality of the latex gloves even though they have modern machineries. In addition, an on-line quality control measures have been instituted throughout the manufacturing processes to ensure 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 while the remaining latex is from their own rubber plantation. The latex will be harvested from rubber trees when the tree’s trunk is swollen and also every day, after the rain has stopped during the rainy season. The latex is a natural product and it will coagulate easily, therefore it needs to be harvests from the rubber trees as soon as possible and then send to TG factory to be manufactured. When the latex is sent to the TG factory, the latex will be manufactured with a standardized method that is set by the company itself.
The flow of the production process of latex glove in TG Company is former cleaning, coagulant dipping, drying, latex dipping, leaching, beading, vulcanizing, post leaching, slurry dipping, stripping, tumbling, and quality control. Former Cleaning Before the latex can be process to the coagulant dipping process into hand-shaped, the glove formers 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 means glove formers must be cleaned to ensure there is no dirt or debris anywhere because it will affect the final product to possibly have defects like holes. Firstly, glove former must be dipping into an acid 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 are brushed to ensure the surface of the glove formers 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 regularly inspected and cleaned before the molds are dipped into coagulant tanks. Coagulant Dipping After 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 under TG workers’ control to extract the protein from the previous glove dipping and this dipping is done once for every production cycle. Drying Drying is one of the stations in production process of latex gloves manufacturing whereby 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 coagulation process. In brief, it is a process of drying the gloves from wet to readymade gloves. Latex Dipping
Latex dipping is one of the stations in the production process of latex gloves manufacturing and the tank is filled with compounded latex. A latex layer will be formed on the glove former after it goes through this tank. The thickness of the latex glove is determined 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. Leaching This leaching stage can called as the pre-vulcanization leaching.
It also known as “wet gel leaching”. Residual chemicals and proteins on the surface of the gloves are put into the leaching process to be removed after the drying of latex mixture. A longer leaching line can wash out latex proteins more 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. Beading Beading is a process whereby up to a dozen chemicals are added to help in next 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. Vulcanization One 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 particles are modified by adding in accelerator chemicals to it. When all the materials are heated, sulfur atoms are chained 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 Leaching This 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 Dipping This stage is also known as “wet even powdering”. The slurry tank containing the cornstarch solution can prevent latex gloves from sticking in the tank. The slurry is also referred to as wet powder. The benefit of this powder is acting as preservation of the 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 more 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. Stripping At 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. TG’s 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. Tumbling The tumbling process at latex gloves manufacturing process is to remove excessive powder on the gloves. The latex gloves are putting into the commercial dryers to ensure that the powder is more evenly distributed and excess powder can be removed. Powder-Free Gloves
Powder-free gloves stage is a technology 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. Top 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 latex gloves. The glove is turned inside out and the process is repeated. The powder-free gloves are placed back into the dryers when the bathing process is completed. Quality Control TG carries out its quality control in total quality management system.
In total quality management system, the process includes regular testing of raw materials, close monitoring the manufacturing process, continuous improvement 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 anufacturing 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. Each country will have their own acceptable quality level (AQL) in allowing the company to export product to their country. For example, the companies that want export their gloves to United States, a 2. 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. Packing Packing 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 particular customers. In addition, the latex gloves are also being exported to other countries. The production processes of Top 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 Process: The 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 technology. This helps TG to save cost in the workers. Weakness of the Production Process: TG 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 maintenance 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 look 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 salary to operate the specific machineries 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 Layout: The layout of a company is very important because it establishes an organization’s competitive priorities in regard to capacity, process, lexibility, 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 firm’s competitive requirements. Layout design has the following purpose:- Higher utilization of space, equipment, and people Improved flow of information, materials, or people Improved employees morale and safer working conditions Improved customer/ client interaction
Flexibility (layout need to be change from time to time) TG is a company that used work 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 orders: Takt time = Total work time available/ Units required Second, determine the number of operators required: Workers required = Total operation time required/ Takt time By doing so, the company can increased equipment and machinery utilization due to better scheduling and faster material flow. Diagram below shows the layout of Top Glove company and the description of the components inside the layout:- http://turnkey. aiwantrade. com. tw/En/DB/layout%284%29. jpg 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 compounding ball mills because it easy 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 Ball 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 compound 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 office 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. Lap 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 material 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 Layout:
Top 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 needed 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 between machines to accommodate work-in-process inventory.
For example, the tumbler dryer is place closely with the process of sterilization that uses to sterilize the glove’s bacteria. Thus, it saves a lot of space between these two processes. Next, when the employees work in this kind 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 empowered 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 Layout: However, 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 hard to divided their work evenly and more worker is needed compare 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 Design: The other strategic of this company is goods and service design. Top Glove’s main productions are rubber gloves, synthetic 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 found 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 rubber 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 tape measure. The usual size standard for examination gloves are of XS – XL, while surgical gloves are of 6. – 8. 5. The gloves thickness measured by depth protecting skin from exposure 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 ynthetic gloves that are produced from the synthetic latex of Acrylonitrile Butadiene 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 design: The strengths of using this strategic which is the goods and service design are Top Glove’s 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 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 design: The weaknesses are poor 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 hands before sliding them into gloves.
Quality Management: Quality 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 product’s 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 product’s 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 Control tests are conducted from the point we receive our raw materials straight through the production processes and the finished roducts 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 determine 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 (R&D) 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 rubber 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 design: The company able to fulfill or able to follow the Quality control of the foreign site company needs such as European and American customers.
Top Glove is a company that very strictly in controls their product’s 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 concern 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 Top 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 improving their system. With the high quality control of the products, the product’s quality is more consistent and seldom making substandard products; Top Glove is able to fulfill those consumer’s needs.
Those western countries consider as larger markets in the world; by fulfill those consumer’s 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 design: The 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 consumer’s 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 customer’s needs and wants. To fulfill those consumer’s needs, Top Glove has developed a Research & Development (R&D) 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 R&D 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 technology to the latest that can fulfill those consumer’s needs. However, it is costly to the company. Global Forces:
Political Forces The 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 law was enforce to the Manufacturers in Malaysia. Due to this recycling law, it is good to Top Glove Corporation 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 Forces Top Glove Corporation having taxes heavily as it taxed at rate that are quite high. Besides, approximately 10 percent interest rates prevailing in the Malaysia market that create competitive market places. On the other hand, the economical ramifications of huge financial costs will affect the Top Glove’s financial position.
This was due to adopt and relies on the external sources such as fixed charge capital (fixed interest payment) to finance its operation. Description : Rubber, No. 1 Rubber Smoked Sheet, FOB Malaysian/Singapore, US cents per pound Unit : US cents per Pound Furthermore, the currency exposure face by top glove was affecting their majority sales since most transactions using USD to trade while the USD was weaken sharply. Besides, the fluctuation or speculation of crude oil causes inflation and impact on the other raw materials and logistic cost.
Similarly, the fluctuation of latex price affects to increase the cost of the productions. While, this is greatly challenge Top Glove to produce and sells their product with high quality and low in cost by way of using the high operating cost and raw materials in their production. Moreover, Top Glove face formidable competition with China glove manufacturers as the China glove products was flooded the glove market at a cheaper price and instantly available. Thus, economy force significantly affects the operation cost of the company.
Social and Cultural Forces The Malaysian education level increased has become a challenge for Top Glove, as Malaysian was conscious about the Health and safety issues similarly to most of the country around the world. With this, it challenges their production and operation to add-in more features that need to comply with the laws. At the same time, they need to ensure the satisfactory of their production. In addition, the increases of awareness on health and safety bring up some issues on the Latex made hand gloves.
Thus, education and knowledge information will help in the marketing of the Top Glove and will affect their operation process and production. Technological Forces: Previously, many of Top Glove plants machineries have rendered obsolete this are due to the advent of computerization and the great changes on the electronic and computerize trends. Nevertheless, these issues had solved by acquiring more professional and computerizing programs on their operation and the adaptation to the E-commerce trends. Besides that, the patent infringement on the Machinery and technology can be an issue for Top Glove Corporation.
As it was a case found before the patent infringement on technology on producing on Nitrile glove. Eventually, Top Glove and Tillotson agree to dismiss all claims against each other. It shows that, technology and information trends had significant effect on Top Glove operation system, resources and equipments selection. Recommendation: In the production process, Top Glove needs to maintain their operation system including of its production process and their quality control. It is important for Top Glove to maintain it as their core competency.
Lean production can use in production process as it align with the company goal and mission. Top Glove is recommend to continuously enhance their flexibility in their production process including diagnose and plan for better schedule in the production process to save more time, employees efforts and the company money. Besides that, Top Glove needs to ensure all operations from the top to bottom must run efficiently by adopting programmable logic controller that able to the monitoring of the operation automatically and promote continuous production that help in increase production and minimize cost.
For the facility layout, Top Glove had to plan well and locate its facilities feasibly depend on it logistic and position design, company capital and its activities, workplace safety and health and so on. Reliability centered maintenance and value driven maintenance can use as improvement methods for TG to utilize its capital on investment and maintenance of its operations such as overcome the operation maintenance risks on resource allocation, assets utilization, cost control and safety and health environment.
Furthermore, the flexible work cell layout must maintain by Top Glove, as it will be able enhancing the flexibility of the operation, utilize the place taken, providing comfortable and safety workplace for workers, and minimize the potential accident and injuries. Besides, Top Glove must always update and maintain the lay out that fixed by ISO or other manufacturing standard. For the Goods and Service Design, Top Glove can focus on the products development and extend their products life cycle.
For example, develop the glove by improving its donning techniques that able to minimize the rips and tears when consumers use the Gloves. Usage and methods of wearing Gloves may provided and show on the packaging. Other than this, Top Glove can be also focus or strengthen more on details product design such as creating innovative glove with functions and amenity features for all type range of gloves use in surgical and clinical practice and operation.
Addition, TG products packaging must provide with its product outlook and description that meet the preferences of their customer across different countries and cultures. Concerning fluctuation price on raw material, Top Glove needs to find the sources of it production raw materials to prevent affecting from high cost markup on raw materials. Therefore, TG need is recommend to invest more rubber plantation, by ensuring the price for the Glove product without affecting the fluctuated rubber price and ensure the product able to sell economically.
For the Quality Design, no matter how difficult to company to obtain the qualification of the quality, the company still needs to be fulfilling it. This shows the capacity of the company to growth further and stay survive in the worldwide market. Therefore, Top Glove had to maintain and enhance it products and operation quality endlessly. Top Glove always needs to audit their operation and the product quality control to ensure low than low defectiveness in their production based on the six sigma and Total Quality Management procedure.
On the other hand, Top Glove needs to review foreign countries’ Acceptable Quality Level to improve in their company’s quality management system. Perhaps, Top Glove needs to adopt total quality management or done R&D on high quality latex to ensure producing high quality products that meet their customer expectation. Conclusion: In conclusion, the key processes of the Top Glove’s manufacturing operation are, its production process flow, facilities layout plan, its operation strategies on products and service design and quality design.
The Strength and Weakness analysis for each key process analyzed in depth based on Top Glove’s internal manufacturing operation and providing some recommendations based on the discussion after the operation and global force analysis. The global forces discussed on global political and more focus in Malaysia political issues; global economy on the raw material price fluctuation, demand and supply analysis of the Glove products; social cultural issues across the global market and technology forces that evolve rapidly on different business aspects including industrial operation.
The recommendations provided with other successful application of theory and concept that help to continuously improving the operation of the manufacturer such as lean manufacturing, total quality management, six sigma, reliability-centered maintenance and value driven maintenance and so on. In brief, these key analysis and discussion on Top Glove manufacturing operation will help in understanding of each key function from each operation processes and makes improvement to Top Glove’s operations based on the studies of latest operation management system.
With this, Top Glove will be able to maintain or strengthen each of its manufacture’s operation and its products positioning in the world market. INTERNAL STRATEGIC FACTORS | WEIGHT| RATING| WEIGHTED SCORE| COMMENTS| STRENGTH:S1: QUALITY MAYING S2 :EXPERIENCED TOP MANAGEMENTS3: VERICAL INTEGRATIONS4:EMPLOYEERELATIONSS5:INTERNATIONAL ORFENTATION| 1. 15-05-. 05-. 101. 15| 5. 04. 23. 93. 02. 8| . 21. 39. 15| | WEAKNESS:W1:PROCESS-ORLENTED R&DW2:DISTRIBUTION CHANNELS| -. 05-. 05| 2. 02. 1| | | TOTAL SCORES| 1. 00| 4. 0| | | | | | | | | | | | |