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Manufacturing managers in a broad array of industries agree that achieving low cost and high quality is no longer enough to guarantee success. In the face of fierce, low-cost competition and an army of high-quality suppliers, companies are increasingly concentrating on flexibility as a way to achieve new forms of competitive advantage. Having acknowledged the importance of flexibility, however, managers in industry after industry are finding it frustratingly difficult to improve. In a quest to help manufacturing managers begin to understand why the improvement of flexibility has been so elusive, author David Upton embarked on a study of more than 60 factories in North America that manufacture fine paper. Upton found that, contrary to conventional wisdom, the flexibility of the plants depended much more on the people in the operation than on any technical factor.

A high-technology manufacturing company was recently given profit-and-loss "stand-alone" status by its parent. No longer a captive supplier, it must seek new markets for its technology and products on the outside world. Describes a benchmarking study by a group of consultants to determine future operations improvement.

Describes distribution operations in Polaroid Europe. In the late 1980s, Polaroid senior management in the United States proposed moving from a system of 12 decentralized warehouses to a centralized distribution system in which all inventory for European retailers would be held in Polaroid's Dutch distribution center. Most subsidiary general managers opposed the proposal, as did Polaroid's European marketing organization. Describes several distribution alternatives Polaroid considered in 1990 including: 1) direct distribution to retailers through Europe from the Dutch distribution center, 2) hiring a third-party logistics organization to take over all of Polaroid's European distribution activities, and 3) establishing regional satellite distribution centers. Provides an overview of changes in the European retailing and distribution industries at the beginning of the 1990s, with a specific focus on the diverse service expectations of retailers in different European countries and of different retail segments.

Supplement to the (A) case.

Supplements the (A) case.

Supplements the (A) case.

Supplements the (A) case.

About 15 operators work in a simple hybrid batch-flow environment to produce the Earth Buddy novelty product. The case introduces the topic of process analysis. Sufficient information is presented to introduce and discuss the following concepts in an 80-minute class: capacity, throughput time, cycle time, bottleneck identification and resolution, and work-in-process inventory accumulation and draw-down. Issues that can be explored during the discussion include: shift scheduling, the impact of cross-training, batch versus flow production, rush orders, and the impact of defects on capacity. (An Extend simulation file is available for this case, Earth Buddy - Extend Simulation file.)

A manufacturer of cable TV transmission equipment is faced with redesigning its network of international plants that make set-top converters and decoders. One possibility is to have each plant dedicated to manufacturing and engineering support for different product lines. Another is to operate only one "full service" plant, with engineering and ramp-up capability for all product lines and a set of low-overhead, high-volume satellite plants. Depending on what is decided, the company will probably end up closing a different plant. Students must analyze the impact of various sources of market and technological change in order to develop a good manufacturing network strategy for a firm in this fast-changing environment.

The producer of a stage show society needs to use network planning as part of project management to ensure that 10 performances are scheduled well over the next four months. Students will have to construct a network diagram, identify the critical path, and address questions regarding activity crashing. What is particularly unique is that they will have to create a list from the data presented to them at a meeting with the assistant producer. (NOTE: This case has two teaching notes: Number 8A95D15 addresses class discussion and Number 5A95D15 uses a Microsoft Project solution file, which is available with this version of the teaching note, product 7A95D015.)

In the mid-1990s McLeod Motors rationalized a number of motor end shields to reduce manufacturing costs, improve service, and reduce inventories. However, inventories have apparently risen. Students must identify why McLeod has inventory, how large the inventory might have been before the rationalization, how large they might be now, why they are so large, and what could be done to reduce inventory levels. The case can be used in conjunction with a discussion on inventory function.

The Bardolini Division of Mattson Foods, with plants in the northeast and midwest, wants to open up the western market for its pizza. Management must decide whether to build a new plant on the West Coast, and what type of technology to put in the plant if they decide to build it. The case addresses the issue of building a plant for marketing purposes and raises a number of logistical issues, including transportation and warehouse economics. A rewritten version of an earlier case.

Rotron has recently entered the commercial motor market, after many years of servicing government military contracts. Faced with fierce commercial competition, Rotron has attacked its costs and reduced its delivery times and its plants. A new crisis, however, is causing it to rethink its just-in-time production system, and the plant manager must decide whether to re-introduce inventory for key production.

Presents an introduction to methods for understanding user needs in product development. Describes a number of techniques including the use of focus groups, interviews, questionnaires, the Kano method, Lead User analysis, the Product Value matrix, OFD, etc. Provides a "how to" for product developers, and includes theory as well as examples from practice.

Techno Systems, an industry leader in providing electronic kit assemblies for customized commercial applications and government, is currently undergoing a transition from a heavy government orientation to a more commercial customer base. A director of sourcing has been asked to prepare a review of the sourcing function by using benchmarking. She is considering how to effectively implement a benchmarking effort that would contribute to the sourcing review. Based upon her presentation, the upper management will determine the need for strategy development in the sourcing department. In essence, she is determining the hierarchical placement of the sourcing department for the future. This case affords the student an opportunity to examine sourcing in relation to operations strategy and to investigate benchmarking practices. It includes information compiled from benchmark studies conducted by the Center for Advanced Purchasing Studies (CAPS) and provides an insight into gated benchmarking.

Allows students to use an alternative method to analyze the case.

Describes the development and exploitation of a radical new computer-integrated technology in the largely manual meat-processing industry. The technology has been developed by the meat industry's research organization over a period of 15 years and is now ready for commercial exploitation. Unfortunately, it is not clear how the industry can use the technology because its scale demands larger firms than currently exist and its operation requires expertise that the industry does not have. The commercializing firm is also under pressure to break the system into smaller modules, losing some of the benefits of computer integration, but gaining a dissemination path. There is another model for improvement in the industry, relying on incremental improvement, rather than radical technology change, and many have said that the project is doomed, because it might not provide the best path to improvement in the industry.

Increasingly, companies are outsourcing the manufacture of parts for their products. But what should they be looking for in a supply partner and what form should these partnerships take? The authors look to the auto industry for answers.

Describes the predicament of an overworked Western plant manager in a Chinese joint venture. The fourth in a line of such managers, he must deal with the combined problems of an inability to delegate, different customs and practices, and difficulties in information technology and plant control.

Techno Systems, an industry leader in providing electronic kit assemblies for customized commercial applications and government, is currently undergoing a transition from a heavy government orientation to a more commercial customer base. A director of sourcing has been asked to prepare a review of the sourcing function by using benchmarking. She is considering how to effectively implement a benchmarking effort that would contribute to the sourcing review. Based upon her presentation, the upper management will determine the need for strategy development in the sourcing department. In essence, she is determining the hierarchical placement of the sourcing department for the future. This case affords the student an opportunity to examine sourcing in relation to operations strategy and to investigate benchmarking practices. It includes information compiled from benchmark studies conducted by the Center for Advanced Purchasing Studies (CAPS) and provides an insight into gated benchmarking.