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Operations Management Exam – 11/01/2023 OPERATIONS MANAGEMENT EXAM Prof. Alberto Portioli Staudacher, Marco Taisch, Matteo Rossini LEAN (13 points) LEGNUM s.r.l. produces wooden toys, both standard and customised based on customers preferences. The range of the standard family is composed of 50 variants: 5 different sizes, 2 shapes and 5 different surface paintings. The customized toys have peculiar colours chosen by the clients and each request differs from the others. The product customization starts from the painting phase. If the customer demands a standard toy, she requires to have it immediately, if she asks for a customised one, she is willing to wait up to 10 days. The demand for standard toys is stable with an average of 500 standard toys per day. The demand for the customised toys is equal to 20 customized toys per day: daily demand is very variable (+/- 30%) but observing a week it is stable. On average, a special order is composed of 10 items of the same variant. Production process: The production system is composed of 5 stages: Wood leaching, Wood cutting, Assembly, Painting, and Packaging. Wood leaching: there is one operator that uses semi-automatic machines; a setup is necessary when product shape changes; Wood cutting: there are two operators using semi-automatic machines; a setup is necessary when product shape changes; Assembly: there are two operators working in parallel on manual machines; a setup is necessary when product size changes. Painting: 3 operators work in parallel at three tables. Each operator works on a painting working station and he does all the activities necessary to complete a toy: first, he attaches chemical additives to the toy, then he paints it, and then he dries the paints. The three activities take more or less the same…