Management Engineering - Operations Management

Full exam

Operations Management Exam O PERATIONS M ANAGEMENT E XAM Prof. Alberto Portioli Staudacher, Marco Taisch, Matteo Rossini Exercise 2 (1 3 points) LaGerla produces eco - plastic packaging for cosmetics products . The range of the product family related to mascara is composed by 48 standard variants: 3 different models, 4 different colours ( black , green , red and blue ) and 4 different printings . LaGerla produces special packaging too based on customers’ requests. These special packaging are different from standard ones because they are customized accordi ng to client request for printings . Each special cover order includes 4 identical items and each order has different printings from another order . If customer asks a standard item, she requires to have it immediately, if she asks a special one she is willing to wait up to 8 working days. S tandard items demand is variable with an average equal to 480 pieces per day and a variability of +/ - 25% per day . Special items demand is instead stable within one week with an average value of 400 special it ems per working week (5 days) . Production process: The production system is composed by 4 stations: Stamping , Washing , Printing , and Packaging. Stamping : there are 2 operators that work in parallel, performing manual activities . Washing: there is one machine and one operator. The operator role is to load, supervise and unload the machine. Printing : there are 2 operators that work in parallel , performing manual activities. Here starts the customization of products. Packaging : there is one machine and one operator. The machine is automatic, supervised by the operator. Each shift lasts 8 hours and there are two 15 - minutes breaks per shift. All stages are completely dedicated to this product family. Upstream the production system there is a stock of raw material of 3 92 0 pieces. There is no scrap in any process. Stations Cycle Time (min.) Changeover (min.) Availability (%) Number of shifts Inventory (downstream) Stamping 5 (single operat o r ) 5 0 (Setups every time model and colour change) 100 3 1 68 0 Washing 2 6 (setups every time model and colour changes) 100 3 1120 Printing 2 (single operator ) 1 5 (setups every time printing changes) 100 2 5 6 00 P ackaging 0,5 5 (setups every time printing changes) 97 1 2800 The company receives everyday customer orders and send forecast once per month . Every day the production control function organizes the shipping department for many deliveries. The production control function issues a weekly production plan for each stage. The production control function places a raw materials order to the supplier every two weeks. Twice per month it makes a forecast about the consumption of raw - materials and sends it to the supplier. The supplier delivers the day after the order. Q1) ( 3 points) Draw the current state map of the operations system. Q2) ( 10 points) Considering that LaGerla board aims both at having EPE target equal to 1 day for standard products and at producing every day 80 special items with 4 units batch, d raw a future - state map of the system, answering the first six questions of the future state and describing the minimum changes LaGer la has to implement (availability cannot be change d ).