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In June 2009, the new chief executive officer at the National University Hospital in Singapore had serious concerns about the hospital's prolonged emergency department boarding time-the time between an emergency doctor's decision to admit a patient and the patient's occupation of a hospital bed. He knew that a prolonged boarding time was one of the leading factors contributing to emergency department overcrowding, which in turn hindered the delivery of high-quality medical care and compromised patient outcomes. The chief executive officer needed to decide what strategy the National University Hospital should adopt to reduce the prolonged emergency department boarding time and how the hospital should execute such a strategy.

Spreadsheet to accompany product 8B18D014.

Student Spreadsheet for product 9B18D014.

Kiessling Spedition (Kiessling) was an international operating forwarder in Regenstauf (Eastern Bavaria), Germany, and a member of a large in-night express network. In April 2017, the company faced the problem of losing one of its major consigners. The consigner was a large wholesaler of automotive parts for the utility sector and had been feeding high volumes into Kiessling’s in-night system. This cancellation caused the volume and use of most of Kiessling’s in-night tours to drop significantly, by as much as 40 per cent in volume and 26 per cent in stops. Since the distribution costs were almost fully fixed, the contribution margin of all affected tours decreased. In order to adapt the Kiessling in-night operations to overcome this turmoil, the operations manager and his team needed to choose among several alternatives, and then make a plan to implement the solution quickly.

Kamaths Ourtimes Ice Creams Pvt. Ltd., a company located in Mumbai, India, manufactured and distributed ice cream under the brand Natural Ice Cream. The company specialized in using natural flavours in its products, a fact that helped it carve a niche for itself among health-conscious customers. In April 2017, after witnessing great demand for its ice cream across the country, the company’s board of directors asked the director of operations to draft a plan to expand manufacturing capacity. As his first step towards this expansion, the director wanted to study the current operations and address any inefficiencies. One aspect that caught his attention was the recent delay in product delivery. Based on his experience, he did not see the company’s capacity to fulfill current orders as the reason for delays. Therefore, he decided that the problem was related to the process flow. He would have to find ways to streamline the process to reduce or eliminate all delays in delivery.

In 2017, Equuleus Car Sharing Inc. (ECS) was a relatively new player in the rental car industry, with annual revenues approaching US$100 million. ECS had experienced significant growth since its founding in 2014 due to its focus on low prices and a mix of high-demand vehicle types–specifically, minivans, sport utility vehicles, sedans, and economy cars. ECS management wished to examine the opportunity to purchase new vehicles through financing versus the traditional method of paying cash for dramatically expanding the fleet size. The goal was to develop a fleet purchasing strategy that maximized the present value of net income.

It was July 2017 when the co-founders of Fitpass Business Ventures Private Ltd. (Fitpass), an online platform providing passes to fitness establishments in the Delhi–National Capital Region, were reflecting on the need for continuous innovation to stay relevant to their users. Launched in June 2015, the company intended to satisfy the unmet market need for flexible workout options at an affordable price for fitness-conscious Indian youth. The company’s application, FITPASS, had been downloaded 100,000 times, and the company had gained 60,000 registered users and created a partner network of 1,500 fitness establishments in the region. Generating 100 per cent growth in month-on-month revenue, the company was among the leading platforms in this region. However, the online marketplace was becoming crowded with look-alike competitors, and the founders faced some tough questions: How could the company sustain its position in the current market? Was the company ready to move into other similar markets using the current business model and innovative capabilities?

This case describes the sourcing challenge faced by a firm which is involved in contract manufacturing of a device. The company must decide whether to continue as a contract manufacturer where they are engaged in a wholesale price contract, or they should get into the development of their channel by engaging with the design firm through a revenue sharing contract.

Airvent Fans Co., which manufactures ceiling fans for two OEM customers, Tropical and WindStar, is challenged in fulfilling the demands of its customers. Its plant, currently operating at the full capacity of 0.8 million fans annually (3200 fans/day), is looking at the possibility of improvements within current available resources to increase output in order to handle the immediate future demand, before deciding whether to outsource some of the operations in the long term. This involved thorough studies of the processes, and it was concluded that capacity enhancements were required at various stations. To handle future projected demand that is rapidly growing, the management plans to further increase the planned capacity of the plant to suitable levels. The current layout is incapable of handling such a scale of operations and thus, the concept of lean manufacturing is applied to help restructure the plant's layout and operations. The design and improvements required the determination of various factors. This case study identifies and estimates the various parameters needed to design such a system. Process Flow Analysis and Value Stream Mapping are used as tools to understand and identify the bottlenecks and sources of problem. Immediate demand is met by implementing batch sizes based on Economic Production Quantity (EPQ). For the long term, investments are made in machinery, the factory layout is revised for better material flow, and the assembly line operations are decoupled to achieve higher flow rate. The plant ultimately adopts a Make-to-Stock system from the earlier Made-to-Order system.

This case describes the activities and documents the challenges faced by a small-scale firm in the unorganized sector of textile wet processing industry in India. While the small scale and manual nature of operations allows firms in this industry much flexibility of accepting a wide variety of orders, in terms of size and the type of processing needed by the customers, it also poses quality and delivery related challenges that arise due to the manual nature of operations. The case therefore exposes students to the operational trade-offs between flexibility, cost, quality and delivery time and highlights the tensions between various competitive dimensions in a business scenario. The students are then provided a choice of options to choose from, which will require them to consider the pros and cons of choosing one dimension over the other, in the context a small-scale firm in an unorganized sector of an emerging market, that is constrained for resources.

The senior director of supply chain management for Colberts Inc. (Colberts) had made tremendous strides. She had been among a select few senior directors chosen to lead an initiative to integrate a new supply chain management system. Although a costly investment, the new information technology infrastructure had helped increase operational efficiency at the store level. While the initiative had initially not received support from everyone at Colberts, the director was now receiving congratulations as the benefits of the new system had become apparent. She was invited to meet with the chief operating officer to discuss a possible promotion to vice-president of Technology Operations. She thought things were going well until the system began to deteriorate that morning. She needed to address the short-term replenishment issue and the longer-term information system issues.

The senior director of supply chain management for Colberts Inc. (Colberts) had made tremendous strides. She had been among a select few senior directors chosen to lead an initiative to integrate a new supply chain management system. Although a costly investment, the new information technology infrastructure had helped increase operational efficiency at the store level. While the initiative had initially not received support from everyone at Colberts, the director was now receiving congratulations as the benefits of the new system had become apparent. She was invited to meet with the chief operating officer to discuss a possible promotion to vice-president of Technology Operations. She thought things were going well until the system began to deteriorate that morning. She needed to address the short-term replenishment issue and the longer-term information system issues.

In September 2017, the managing director of Summit Maritime Pvt. Limited, a marine consulting firm and luxury boat manufacturer in Kochi, India, faced a dilemma. He needed to relocate a production facility and set up a service factory, where boats would be both manufactured and displayed. The managing director needed to decide on the optimal location for the new facility by considering multiple factors. He also needed to design a preliminary layout for the new facility. How should he decide on the optimal facility location and layout to restructure his growing business operations and ensure the company’s future?

In September 2017, the managing director of Summit Maritime Pvt. Limited, a marine consulting firm and luxury boat manufacturer in Kochi, India, faced a dilemma. He needed to relocate a production facility and set up a service factory, where boats would be both manufactured and displayed. The managing director needed to decide on the optimal location for the new facility by considering multiple factors. He also needed to design a preliminary layout for the new facility. How should he decide on the optimal facility location and layout to restructure his growing business operations and ensure the company's future?

This case describes the 2016 market entry in California of an innovative construction system for housing: BONE Structure, developed by the Canadian company of the same name. The choice of this structural system and construction method for a single family home in Palo Alto, California, provides the backdrop for a discussion about process innovations in manufactured housing and environmental sustainability. This case highlights BONE Structure's successful revamping of the supply chain for housing, a design for energy efficiency that has the potential to be even more so (if steel manufacturing could be powered by renewables), and finally, a building system that enables construction and renovation in difficult locations.

The factory manager of John Deere Reman, located in Edmonton, Canada, was preparing for a meeting in September 2017, with the general manager of Global Reman Operations and Marketing at the company's head office in Springfield, Missouri. John Deere's remanufacturing operations had been steadily improving over the last decade. The purpose of the meeting was to discuss opportunities for changes to John Deere's remanufacturing operation that would provide value to the company, improve customer service, and support the company's commitment to environmental sustainability.

In August 2016, the global procurement manager at Hu-Friedy Mfg. Co., LLC, a large U.S. dental equipment manufacturer, realized that materials were being transported between suppliers and production facilities without a consistent strategy-potentially costing the company thousands of dollars each year. To evaluate the company's transportation needs, the manager considered a range of alternatives, including buying or leasing a truck or hiring a third-party logistics (3PL) provider to manage the transportation. To complete his analysis, the manager needed to develop a new set of routes for pickups and deliveries, evaluate the costs associated with owning or leasing a truck, determine the costs of a 3PL provider, and ultimately determine the course of action that would have the most impact on transportation costs with the least impact on daily operations.

When implemented correctly, agile innovation teams almost always result in higher team productivity and morale, faster time to market, better quality, and lower risk than traditional approaches can achieve. What if a company were to launch dozens, hundreds, or even thousands of agile teams? Could whole segments of the business learn to operate in this manner? As enticing as such a prospect is, turning it into a reality can be challenging. Companies often struggle to know which functions should be reorganized into multidisciplinary agile teams and which should not. And it's not unusual to launch dozens of new agile teams only to see them bottlenecked by slow-moving bureaucracies. The authors, who have studied the scaling of agile at hundreds of companies, share what they've learned about how to do it effectively. Leaders should use agile methodologies themselves and create a taxonomy of opportunities to set priorities and break the journey into small steps. Workstreams should be modularized and then seamlessly integrated. Functions not reorganized into agile teams should learn to operate with agile values. And the annual budgeting process should be complemented with a VC-like approach to funding.

Excel spreadsheet for product 8B17D018.

Tony Gascon, general manager for magnetic resonance (MR) value stream operations at GE Healthcare, was preparing for the monthly meeting with the supply chain and inventory management teams, during which they would revise their forecasts for the next quarter. After the meeting, aggregate production schedules based on the forecasts would be locked and pushed to the factories. As Gascon was about to head to the conference room, an e-mail with some startling information came from GE's chief productivity officer. A corporate review revealed that the components of each MR machine traveled more than 260,000 miles before final installation. A full mapping of the supply chain exposed an elaborate logistics structure with myriad technical challenges. Due to this complexity, producing precise forecasts would be more critical than ever, since any uncertainty would be amplified. As the teams met, they explored ways to simplify the structure and reduce the number of miles each machine traveled despite production facilities on three continents, global supply sources, stringent regulatory guidelines, increased competition, and the complexity in the creation and transport of the components. Based on their discussion, Gascon challenged the teams to improve the accuracy of their forecasts, and to better match supply with demand. What steps could they take to simplify/consolidate the logistics structure to make it more efficient? How could they leverage the emerging additive technology to disrupt the supply chain?