Lean exam 3 july 2023

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Operations Management Exam – 3 July 2023 – Prof. Portioli, Rossini, Taisch OPERATIONS MANAGEMENT EXAM Prof. Alberto Portioli Staudacher, Marco Taisch, Matteo Rossini July 3rd, 2023 LEAN Exercise (13 points) Leather Lab s.r.l is one of the most important producer in Italy for wallet. The range of this product family is composed of 20 standard variants: 10 different colors and 2 different types of materials. LeatherLab s.r.l produces also customized wallet based on customer requests and the range for this special product is unlimited. Each tailored wallet is different from the other , for this reason every customized wallet are made in a unitary batches with a dedicated setup for every production stage . Customers require all variants of standard products every day. The average demand for the company is 40 units/day. The daily demand is divided in 85% of standard wallet and 15% of special wallet. The demand, both for standard products and special products, is affected by variability (+/- 10% daily base). The costumers send orders for standard wallet ones per day, and they want to receive the order within the same day. On the other hand the orders for customized wallets are collected monthly. The company delivers customized wallet two times per week. The company works on shifts (8 hours per shift with 2 breaks of 15 minutes per shift) 5 days per week. Production process (there are no scraps): The production system is composed by 4 departments decoupled by stocks: Leather tanning phase– In this stage, the leather for the wallet is elaborated. The machine needs to do a setup every time a material is changed. Only one operator supervises the machine. Color phase – In this stage, 2 operators work in parallel performing manual activities. The operators need to make a setup…