Case Assignment #4

Case Assignment

Analyze the situation in the Plasti-Brack product line. Diagnose the problem and possible solutions to the capacity and order backlog. Determine an appropriate plan for correcting the problem. Justify your plan and make recommendations using your knowledge of productivity, process improvement, inventory, capacity, forecasting, and quality. Write a report to the VP of Operations. Use the Report Template provided.

Assignment Expectations

• Use the information provided in the Background readings from Module 1 through Module 4. It is not necessary to do any additional research.

• Review your backlog notes from your investigation about the Excellent Manufacturing Company and the various opinions, policies and data surrounding this backlog issue for the Plasti-Brack product line.

• Explore the possibilities of spending some of the capital budget on machines and or tools. Also consider improving setup time, improving quality, increasing capacity, and determining EOQs.

• Determine a plan for solving this problem in the Plasti-Brack product line. Consider there may be both a short-term solution and a long-term solution.

• Analyze the capacities including the rates of production, the amount of physical space and needs for equipment and people. At what level of capacity are these processes operating? What are some of the possible bottlenecks?

• What impact does the forecast have on future capacity needs? What are the implications if the forecast is inaccurate (too high or too low?)

• What are some possible ways of increasing capacity and what are the implications for the short term and long term such as costs and investment in capital?

Read and review all of the references and resources on productivity, processes, inventory, quality, and capacity.

Study your notes carefully to obtain all of the important information about this problem. Think through this situation carefully and determine how all of the various operations ideas interact with each other to make this a complex problem.

NOTE: If you use the references provided in the Background, then you do not need to include a References section. If you do decide to use additional references, then you need to cite them and include them in a References section.

The report should be 3–5 pages, and submitted by the module’s due date.

Background Information

Capacity, Part 1: http://www.youtube.com/watch?v=qgUg9UjY3qo

Capacity, Part 2: http://www.youtube.com/watch?v=zujTO5FnmSY

Capacity Planning (2011). Wikipedia, Retrieved from http://en.wikipedia.org/wiki/Capacity_planning

Capacity Utilization (2011). Wikipedia, Retrieved from http://en.wikipedia.org/wiki/Capacity_utilization

Goldman, A. (n.d.). Gaebler Ventures, retrieved from http://www.gaebler.com/Eliminating-Bottlenecks.htm

Inma, R (n.d.) Capacity Planning, retrieved from http://www.referenceforbusiness.com/management/Bun-Comp/Capacity-Planning.html

Walonick, D. (1993). An Overview of Forecasting Methodology, Statpac, retrieved from http://www.statpac.org/research-library/forecasting.htm

Halliday, J. (2010). Buck up,Detroit, there's always Ford, Adweek. New York: Jun 7, 2010. Vol. 51, Iss. 23; p. 11.

Juran, J. (1994). Quality control in service industries. Retrieved from http://www.juran.com/elifeline/elifefiles/2009/11/Quality-Control-in-Service-Industries_JMJuran-94.pdf

iSixSigma. (2009). Statistical Six Sigma Definition. Retrieved from http://www.isixsigma.com/new-to-six-sigma/statistical-six-sigma-definition/

Process Capability (2011). Wikipedia, retrieved from http://en.wikipedia.org/wiki/Process_capability

Pyzdek, T. (2009). The Six Sigma Revolution. iSixSigma. Retrieved from http://www.pyzdek.com/six-sigma-revolution.htm

Quality, Part 1: http://www.youtube.com/watch?v=5JgaMIIEAGQ

Quality, Part 2: http://www.youtube.com/watch?v=hIcV5Q3YyO8

Sharma, S. (n.d.). Services can improve by taking lead from manufacturing, iSixSigma, retrieved from http://www.isixsigma.com/index.php?option=com_k2&view=item&id=717&Itemid=1&Itemid=1

Tague, N. (2004), Excerpted from The Quality Toolbox, Second Edition, ASQ Quality Press, Retrieved from http://asq.org/learn-about-quality/data-collection-analysis-tools/overview/control-chart.html

Total Quality Management (n.d.). American Society for Quality (ASQ), retrieved from http://www.asq.org/learn-about-quality/total-quality-management/overview/overview.html