1.

Scheduling System
Master Tiles produce tiles in large volumes. The product of Master Tiles is therefore
standardized throughout the plant. The entire production process in Master Tiles is ‘line
flow.’ All product lines in the plant are single paced. Inventory is not accumulated between
the processes, except in rare situations. Also, there is no central scheduling system through
a computer. Production at each stage is stimulated by the demand of the next stage. Since
there is no inventory accumulation between the process, we can conclude that the
scheduling system is dependent on each other and the processes are adequately paced.

2. Use of space, movement of material and production line

Master Tiles uses the space very efficiently. The whole process is already automated, and
there is no or very little human interaction in the process. But in a few cases, for example,
when tiles are being taken for polish, Master Tiles have employed multiple line-followed
robots. Forklifts are available only at the end of the entire process where finished tiles are
loaded into trucks through forklifts.

3. Level of inventory and WIP

Inventory can be counted at three stages in the Master Tiles plant. Initially, there is raw
material inventory at the beginning of the plant. At this stage, silica, clay, feldspar, and talc
is stored which are to be mixed in the correct proportion. Second place where inventory can
be observed is when raw materials are converted into liquid form and stored in an
underground tank. The third stage where inventory builds up is where tiles are taken out
from Kiln. At the end of plant there is no inventory for the finished product since all the
finished tiles are loaded into trucks in real-time.

4. Condition and maintenance of equipment and tools.

Almost all the equipment and tools found at the Master Tiles plant were clean and well
maintained. Although the plant operates 24/7, there is one weekly downtime maintenance.
Master tiles supervisors also utilize the fault time for maintenance of equipment. Usually,
when there is an order of new tile design, engineers must change the mold of the Press
Machine. When the mold of the press machine is being changed, the whole line is idle.
Supervisors utilize that crucial time for equipment maintenance. When we asked Shabir, an
employee of Master Tiles, about the preservation of the plant, he replied that the
management takes the maintenance pretty seriously. We get all the required spare parts
and tools for proper maintenance.