20240628 Lean Text Active

Page 1

OPERATIONS MANAGEMENT EXAM Prof. Alberto Portioli Staudacher, Marco Taisch, Matteo Rossini LEAN EXERCISE (20 Points) FYD is a European company producing garments (t-shirts, shorts, etc.) for a prominent football team. The range of t- shirts they produce is composed of 30 variants: 5 sizes, 3 colors, and 2 patterns. The average demand for t -shirts is equal to 950 units per week, however, the demand is highly variable. Every day, all variants are requested by customers who want to receive the product on the same day. The company works 5 days per week. Each shift lasts 8 hours and there are two 15 minutes breaks per shift. Production process: ▪ Cutting: An automated cutting machine cuts the fabric to give an output of two identical pieces (one piece is the front side of the t-shirt and the other is the back side of the t-shirt). An operator must supervise the machine throughout the process. ▪ Sewing: There are four stations working in parallel with one operator in each station. Each station receives two sides of the t-shirt coming from the cutting stage, and the operator in the station sews these two sides together using a sewing machine to make a complete t-shirt. Each station performs all the necessary sewing activities to make a complete t-shirt. ▪ Printing: An automated printing machine prints the pattern on the t-shirt. An operator must supervise the machine throughout the process. ▪ Ironing: An automated ironing machine irons the t -shirt. An operator must supervise the machine throughout the process. ▪ Packaging: An automated packaging machine is used to fold and pack the t-shirt. An operator must supervise the machine throughout the process. All stages are dedicated except for the cutting stage which dedicates only 75% of its time to the product family under…