Design for Supply Chain

Instructions

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 Candidates will complete an exercise on design for supply, which examines supply

chain requirements during the product and process design of a consumer product. The

learning objectives for this exercise are as follows:

Enhance understanding of the potential benefits of product and process design and

changes for supply chain competitive priorities (e.g., cycle time reduction).

Answer: Following table is showing the current process of Duro product manufacturing

and cycle time calculation. By using unitary method, I have calculated the cycle time for

1 unit and cycle time for 10 units. Currently the manufacturing has been divided into 2

plants, between Main plant and finishing plant.

Note: Transit times are same for 1 unit and 10 units.

Completion
Completion Time for 10
Current method cycle time Time for 1 units
Main Plant

Calculation Capacity unit (Minutes) (Minutes)

Mold 20 hr 3 30
Attach foot pad 38 hr 1.6 15.8
Add trim 28 hr 2.1 21.4
Stack and load 36 hr 1.7 16.7
Trip to Swift finish plant 90 mints 90 90
Unload truck 42 hr 1.4 14.3
plantFinishing

Glue decorative top on

backing 22 hr 2.7 27.3
Glue backing to table top 30 hr 2.0 20
Box and label 36 hr 1.7 16.7
Stack and load 34 hr 1.8 17.6
Trip to WH 90 mints 90 90
Cycle Time in minutes 198.0 359.8

Recommendation:

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 After analyzing, the process I have noticed that majority of manufacturing process is

taking place in main plant. Swift company is wasting a lot of time in loading from main

plant, traveling to finishing plant and unloading.

In order to reduce cycle time and improve the production, I have redesigned the process

as follows:

 Moving operation from Finishing plant to Main plant

 Dividing the manufacturing in to 2 stations, where operations can run parallel

 “Molding operation” and “Glue decorative top on backing” can run parallel on

station A and B respectively. 1 table requires 3 minutes to mold, and 1 Glue

decorative top on backing required 2.7 minutes. In original process this total time

for both operations were 5.7 minutes. Now both can be done parallel in 3

minutes.

See below table for new process.

New Method Station A and B running parallel in Main Plant

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 Completion
Station A Station B Completion Time for 10
Station A time per Station B time per Time for 1 unit units
operations unit operations unit (Minutes) (Minutes)
Glue
Main Plant

decorative top
Mold 3 on backing 2.7 3.0 30.0
Attach foot pad 1.6 1.6 15.8
Add trim 2.1 2.1 21.4
Glue backing to
table top 2.0 2.0 20.0
Box and label 1.7 1.7 16.7
Stack and load 1.8 1.8 17.6
Trip to WH 90 90.0 90.0

Cycle Time in minutes 102 211.5

By moving the finishing operation to main plant, we are able to cut the cycle time for 1
unit by 95.8 minutes and for 10 units, we have reduced the cycle time by 148 minutes.

Per unit Per 10 units

Glue decorative top on
backing 2.7 27
Stack and load 1.7 17
Trip to Swift finish plant 90 90
Unload truck 1.4 14
Time in minutes 95.8 148

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