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Barilla SpA, an Italian manufacturer that sells to its retailers largely through third-party distributors, experienced widely fluctuating demand patterns from its distributors during the late 1980s. This case describes a proposal to address the problem by implementing a continuous replenishment program, under which the responsibility for determining shipment quantities to the distributors would shift from the distributors to Barilla. Describes support and resistance within Barilla's different functional areas and within the distributors Barilla approached with the proposal.

Spreadsheet supplement for case 694-046.

Faced with an unprecedented number and variety of products on the market, managers are finding it more difficult to predict demand and plan production and orders accordingly. As a result, inaccurate forecasts are increasing and, along with them, the costs of those errors. A new approach to the entire forecasting, planning, and production process, accurate response entails first figuring out what forecasters can and cannot predict well. Then supply chains must be made fast and flexible so that managers can postpone decisions about their most unpredictable items until they have some market signals--like early-season sales results--to help correctly match supply with demand. Accurate response enables companies to use the power of flexible manufacturing and shorter cycle time much more effectively.

Describes the highly successful efforts of a management team to turn around the performance of a $30 million Raychem division that manufactures electronic connectors. The original manufacturing system was a batch operation, with a broad product line, high inventories, and slow throughput time. Describes the process of converting the operation to a low-inventory, just-in-time plant, organized by manufacturing cells. Shows how it was done, and the impact it had on different categories of overhead cost.

This business game allows participants to make 12 scheduling decisions under conditions of demand uncertainty. It is played with groups of 3-5 participants and does not require a computer.

In 1993, Eli Lilly is preparing to build manufacturing capacity for three new pharmaceutical products that it expects to launch in 1996. Management wrestles with a decision of whether to add specialized manufacturing capacity or flexible capacity. This question touches off a broad debate within the company about which strategy to follow for future facilities decisions. This case presents two alternatives (flexible and specialized plants) and describes the benefits and costs associated with each.

A medium-sized Canadian packaging firm is facing the potential recall of 90,000 individual products by one of its major pharmaceutical clients. The defects are packaging-related and were traced to a lot of customer-finished boxes that Jones, Box and Label had recently delivered. The immediate issue is to determine the problem causing defective packaging materials and how to solve it. Other business basics include: quality assurance, what type of relationship between buyer and supplier is most effective for problem-solving and whether the anticipated level of uncertainty dictates the nature of buyer-supplier relationships. The case introduces students to Kepner-Tregoe problem solving and offers an opportunity to compare and contrast this problem resolution methodology with Ishikawa (or fishbone) diagrams and other problem-solving techniques.

Supplements the (A) case.

Bose Corp. is evaluating an unusual plan to manage relationships with vendors that supply components for Bose speakers. The company must decide: 1) which planning and ordering activities should be performed by Bose and which can be performed by vendors, 2) how much access vendors should have to Bose computer systems and facilities, and 3) how to adapt vendor relations as the company grows or as markets change. Students are asked to consider both the buyer's and the vendor's perspective on the buyer-seller relationship.

Supplements the (A) case.

Supplements the (A) case.

Supplements the (A) case.

Materials Technology Corp. (MTC) is an MIT-based start-up company that identified an initial product market for its advanced materials-processing technology using conventional market research techniques. While pursuing that market--advanced microelectronic components--customers from very different markets such as steelmaking and electricians' hardware approach MTC, offering to pay MTC substantial money to develop and manufacture products for it. This calls into question MTC's initial market and product strategy.

Supplements Project Ghost Busters (A).

The senior vice president and head of Mutual Life's group division, was trying to decide whether to proceed with a plan to guarantee his division's services as a task force had recommended. If the division decided to proceed, he would have to decide whether to accept the task force's suggestions on the design of the guarantee and answer a number of questions that they have left unanswered. Students have to assess whether Mutual Life would benefit from a guarantee and the performance of the division and the task force so far, as well as address the design issues. A sequel to this case Mutual Life of Canada - The Group Client Service Guarantee (B), describes the guarantee and an issue that has arisen.

The regional group marketing director, was trying to decide what to do about Consolidated, a client who had made a claim for $9,500 under the company's new group client service guarantee. The problem was that, although she believed Consolidated's claim was completely without basis, the guarantee prominently said: If you have a problem, we will pay, no questions asked. Students have to assess Mutual Life's guarantee and decide what to do about both the Consolidated incident and the guarantee. This case can be used either alone, or in conjunction with Mutual Life of Canada - The Group Client Service Guarantee (A), which addresses several issues in the design of the guarantee.

The plant manager of Hammond Manufacturing's Guelph, Ontario transformer plant was concerned about problems with the delivery of enclosures from a sister plant ten kilometres away. These problems reduced the company's ability to compete for business by delaying production and shipments to customers. Both plant managers wanted to reduce not only the frequency of late deliveries, stockouts, and backorders, but also the level of frustration between their two plants. Students have to identify the source of these problems and propose a reasonable course of action to deal with them.

This case examines the design of Apple's first notebook computer in a context of extreme time-to-market pressures that challenge Apple's "time-to-perfection" culture and functional organizational structure. Its focus is on industrial design (ID), user testing, and mechanical design interaction in creating design alternatives, identifying user-centered themes that bring coherence to the design. The examines tensions between diverse concepts of product, competing priorities, and tradeoffs between design perfection and time-to-market. Holistic approach of ID versus incremental approach of other groups is highlighted.

Explores the leveraging of ID resources.

In early 1990, the company is contemplating changes in its European plant network for producing hypodermic products, including the total production capacity to be provided, the number and location of plants over which to spread this capacity, and which products should be allocated to various plants (and countries). After years of having too much capacity, the latest sales forecasts indicate that it will soon be running out of capacity, and the company has to decide how to react. In analyzing this decision, students are invited to review the decision-making processes that the company has followed in the past--and that have resulted in too much capacity and high manufacturing costs--and asked to propose changes in the way it approaches such decisions in the future.