American School of Business Week 5 Production Management Paper IMPORTANT NOTE: This assignment should be a continuation of the midterm assignment, using th
American School of Business Week 5 Production Management Paper IMPORTANT NOTE:
This assignment should be a continuation of the midterm assignment, using the same company, product and manufacturing plant, but it should not
include copy pasted sentences or paragraphs from the midterm assignment that could be identified as a match by Turnitin. Previous Assignment is included in the attachments 1. Prepare an MRP following the example explained in class (you can find the excel file under week 5 of our class Moodle site to help you as a guide). The
MRP will need to describe the planning for at least 8 weeks, for the manufacture of your product, whose bill of materials has at least 4 components. The
MRP will need to contain a Materials Master File, and one MRP table for each of the components of the bill of materials, which will contain all the fields
in the following example table:
Element X- …
Week
1
2
3
4
5
6
7
8
Gross Requirement
Scheduled receipt
Projected on hand
Projected net requirement
Planned order release
Define the main quality characteristics of your product following the 9 dimensions of product quality.
Define at least two scenarios of your production process where you would use some of the 7 basic quality tools. Provide and example of how it would
actually work.
Define a predictive maintenance plan for the components of your plant.
Describe the components that will be under the plan (what tools, machines, robots, etc)
Choose two of those components and define a detailed plan of activities for their predictive maintenance.
Prepare a simple plan of future improvements in your plant that you plan to implement in the future using modern technologies such as artificial
intelligence, blockchain, drones, etc… Wordcount: 2000 wordsCover, Table of Contents, References and Appendix are excluded of the total wordcount.
Font: Arial 12,5 pts.
Text alignment: Justified.
The in-text References and the Bibliography have to be in Harvards citation style. This assignment is also based on the previous Midterm assignment that has to be used in order to complete this one Source: F. David de la Peña Esteban, UDIMA
Materials Master file
Element
Availability
A
B
C
D
Lead time
(weeks)
Batch size
Scheduled receipt
Safety
Stock
Batch-to1 batch
50, week 1
1
500
1
150
2
350 200, week 2
75
40
50
110
0
10
0
0
Bill of materials
A
C(2)
B(1)
B(3)
D(2)
MRP
Element A- Avail.: 75 – Lead time: 1 week – Batch-to-batch – SR=50 w1
Week
1
2
3
4
5
Gross Requirement
100
60
50
Scheduled receipt
Projected on hand
Projected net requirement
Planned order release
Element C Avail.: 50 – Lead time: 1 week – Batch=150
Week
1
2
3
Gross Requirement
Scheduled receipt
Projected on hand
Projected net requirement
Planned order release
4
Element B- Avail.: 40 – Lead time: 1 week – Batch=500 – SS=10
Week
1
2
3
4
Gross Requirement
Scheduled receipt
Projected on hand
Projected net requirement
Planned order release
6
7
40
8
55
5
6
7
8
5
6
7
8
6
7
8
Element D- Avail.: 110 – Lead time: 2 weeks – Batch=350 – SR=200 w2
Week
1
2
3
4
5
Gross Requirement
Scheduled receipt
Projected on hand
Projected net requirement
Planned order release
Source: F. David de la Peña Esteban, UDIMA
Materials Master file
Element
Availability
A
B
C
D
Lead time
(weeks)
Batch size
Scheduled receipt
Safety
Stock
Batch-to1 batch
50, week 1
1
500
1
150
2
350 200, week 2
75
40
50
110
0
10
0
0
Bill of materials
A
C(2)
B(1)
B(3)
D(2)
MRP
Element A- Avail.: 75 – Lead time: 1 week – Batch-to-batch – SR=50 w1
Week
1
2
3
4
5
Gross Requirement
100
60
50
Scheduled receipt
50
Projected on hand
75 125
25
25
0
0
Projected net requirement
35
50
Planned order release
35
50
Element C Avail.: 50 – Lead time: 1 week – Batch=150
Week
1
2
3
Gross Requirement
0
0
70
Scheduled receipt
Projected on hand
50
50
50 130
Projected net requirement
20
Planned order release
150
6
7
40
8
55
0
0
55
40
0
40
55
4
100
5
0
6
80
7
110
8
0
30
30
140
10
140
150
100
50
150
5
450
6
490
7
55
8
0
55
65
445
10
10
6
300
7
0
8
0
110
240
110
110
Element B- Avail.: 40 – Lead time: 1 week – Batch=500 – SS=10
Week
1
2
3
4
Gross Requirement
0 450
35
50
Scheduled receipt
Projected on hand
40
40
90
55 505
Projected net requirement
420
5
Planned order release
500
500
500
Element D- Avail.: 110 – Lead time: 2 weeks – Batch=350 – SR=200 w2
Week
1
2
3
4
5
Gross Requirement
0 300
0
0 300
Scheduled receipt
200
Projected on hand
110 110
10
10
10
60
Projected net requirement
290
Planned order release
350 350
Production Management
Stanislav Nepomnyashchiy
Production Management
Midterm Assignment
21.06.20
The company that will be discussed is the clothing brand, that
specifies in authentic clothes for both men and women called Vlone. The
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Production Management
Stanislav Nepomnyashchiy
brand primarily specifies on apparel, such as shirts, hoodies, pants etc. In
order for the company to continue expanding, they have to come up with the
brand new products, that the clients may have a demand for.
With the current pandemic situation, that had happened because of
the coronavirus epidemic, it had forced the entire world to adapt to a new
change that had occurred. One of the main changes, that the people have to
start using the face masks. Safety is one of the biggest issues to look after,
and the whole world is recommended to use the face mask, gloves, etc.
There are several different types of materials, which could be used in
order to manufacture the face masks. These materials can vary from
polyester to to cotton. One of the most efficient and quality materials to use
when making a face mask is polyester. To be more particular, the process
start with creating nonwovens. In order to create the most quality and
comfortable face mask, the process begins by composing the thermostatic
polyester elastomer fiber with a regular polyester fiber. By applying a special
manufacturing technology, these two materials can be combined together in
order to produce a nonwoven.
Before applying nonwoven in mask production, it had gone through
several tests in order to test the properties of factors such as: comfort,
mechanical and functional properties. The teste have shown that compared
to the material that had been used to produce face masks before, the
nonwoven showed to have a great air flow and water vaporization systems.
Additionally, the comfort properties like softness have also showed to have a
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Production Management
Stanislav Nepomnyashchiy
greater effect than the previous material, under both conditions, if the mask
is dry or wet.
Mentioning the two big factors, easy production along with a cheap
manufacturing costs, this particular nonwoven masks could be a serious
competitor on the market. With the successful result tests, and higher
comfort, this mask would be a great fit for all ages of customers. The price
may be higher than the surgical masks for example, but again when
comparing the quality to price, the nonwoven masks have one of the best
ration on the market.
Vlone is a brand that is recognized in almost all of the world, between
the people of age 18-25. The brand, is most popular in the United States. It
is best to start a continuous production system, in order to implement the
new product onto the market and give some time to customers to
understand that the product is not being produced. The brand sells its
clothes around the world.
As the product begins to gain the attraction from customers, the
company can start adapting the mass production system, in order to
continue promoting and spreading the brand across the whole world and
globalizing the brand. With globalizing and beginning the mass production,
the brand has to respectively continue growing in numbers and size. As
company employs more workers to help with the tasks, the company can set
higher goals for the future with the profits and total sales.
One of the main plants is located in Shanghai, China, in a region
called Caohejing. This is a region with high productivity, the area for
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Production Management
Stanislav Nepomnyashchiy
manufacturing the masks is cheaper than in other locations. The particular
plant can produce a large amount of masks per day, that are ready to be
shipped to the United States at first, and later potentially distributed to other
parts of the world. The company plans to continue expanding the plant as the
sales begin to rise, if that is the case with the selling of the masks.
The layout for the plant of producing a face mask for Vlone consists of
several objects, some of them include: to minimize material handling,
increase the overall morale of the employees, reduce danger situations that
may occur during the work day. The layout will be designed in order to
minimalize the economical arrangements, regarding the machinery
production, staff, storage space and materials.
The materials should be used the least amount of times through
minimal distance possible, in order to save on funds and time, while
transporting the goods from one place to another. As well as that, the usage
of space shall be used in most efficient way possible in order to maximize
the potential of the full plant space and have the highest productivity
possible. The plant shall be designed in such way, that the built in principals
should be implemented in the main layout of the plant, in order to provide the
maximum comfort and safety for the workers at the plant.
One of the main principles of the company, is the principle of
flexibility. Meaning that the company continues to adapt to the fact that the
company will be expanding over time, and the company remains open
towards staying flexible, in case certain serious changes will be needed
throughout the process of expanding and perhaps globalization. As well as
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Production Management
Stanislav Nepomnyashchiy
that, some certain technological developments may start to apply to the plant
and the manufacturing process. The process of adapting to a new
technological changes will be able to perhaps speed up the process of
production, which will increase the supply around the world. In many cases,
these technological advances are needed in order for the company to
continue expanding and growing towards larger goals and margins.
Some of the inputs, that are needed in order to successfully complete
the manufacturing have to be brought from abroad. They include the boxes
made out of carton with the brand logo and a specific design, that is being
produced in Indonesia at a cheaper rate than it would be producing in the
closer regions. The company have developed a sheet that shows an
estimate annual usage of the product, the amount ordered per month, and
shipping cost.
The company purchases the finished, designed product, for 8 cents
per box, including the total delivery, calculated single price for a box with the
shipping comes down to 10 cents per box. With the brand still only
implementing the new product from their brand to the market, a large mass
production is not needed yet, what means that at first pace, the amount of
boxes that will be ordered will not exceed two thousand boxes per day. As
the product becomes more recognized, the demand may start to increase,
the production may have to increase to, in order to produce more in order to
satisfy the needs of the clients around the world. The total annual usage, if
the company stays at the same manufacturing rate would be approximately
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Production Management
Stanislav Nepomnyashchiy
seven hundred and twenty thousand units per year. If the company becomes
to expand, the numbers will also rise according to the company growth.
The JIT system, or just in time system is a system that many
companies now a days use in order to increase and maximize the efficiency,
and as well as that to also reduce the amount of wastes produced by a
production by receiving the goods only as they are required for the
production process, and this reduces the inventory costs. This particular
process demands a very accurate and correct prediction about the market
demand of the product of the brand.
In the case of producing the masks, since most of the components are
found locally on the plant, and only some of the products have to be shipped
in for the final production, the JIT system would not fit best to this concept,
simply because the area of production and the materials that are used for
the production of face masks, that include created nonwovens differ and are
not in large need to receive many goods imported from outside and the plant
manufacture can rely on its own local products that are used in order to
manufacture the face masks.
In order for the company to gain the success and recognition, the
company has to provide a correct advertising campaign in order to introduce
the new product from the recognized brand. Once customers start to
understand and see the quality, together with the fact that the world has
been changing due to the epidemic, and people are mandatory to wear
masks inside of a restaurant or bus for example. This mask could also be
used multiple times and does not need replacement like surgical mask does.
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Production Management
Stanislav Nepomnyashchiy
With the good design, correct branding and high quality, the brand Vlone can
achieve large scales and improve and increase the productivity, sales and
total profit which is the goal of a local so far company, to continue growing,
expanding and aiming to globalize and become a global company that
delivers the masks to people around the world.
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Reference:
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Production Management
Stanislav Nepomnyashchiy
Banton, C., 2020. Understanding Just-In-Time (JIT) Inventory
Systems. [online] Investopedia. Available at:
https://www.investopedia.com/terms/j/jit.asp
Sai, S., 2020. Plant Layout: Concept, Objectives, Principles
And Types. [online] Your Article Library. Available at:
https://www.yourarticlelibrary.com/business/plant-layoutbusiness/plant-layout-concept-objectives-principles-andtypes/69514
Globaltimes.cn. 2020. 3M Mask Plant In Shanghai In Full Swing
To Fulfill US Orders – Global Times. [online] Available at:
https://www.globaltimes.cn/content/1185585.shtml
Research Gate. 2020. Fabrication And Characterization Of A
Novel Facial Mask. [online] Available at:
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