INTRODUCTION
I
n this section you will learn the background information that will
prepare you to understand and complete each of the milestones of this
case study. This information includes a history of the business, a
description of the business’s current facilities, and the descriptions
of the problems that triggered the project.
Case Background
GB Manufacturing is a producer of electronic components and testing
equipment. The company is located in multiple plants in the New York
City area. The corporation has over 10,000 full-time employees.
Approximately 200 employees are employed with the company's Maintenance
department, which is responsible for the maintenance of building and
grounds. Maintenance has assigned a group of employees to provide
maintenance for each building or plant. The employees assigned to each
building or plant collectively possess the skills needed to provide
proper upkeep. Such employees include carpenters, electricians,
painters, welders, plumbers, and the like. The Maintenance department
also has a group of employees with special skills to assist with special
projects that may arise.
Organization Structure
The following individuals report directly to Bill Venkman, Director of
Maintenance. Each of the managers has a group of foremen and supervisors
that report directly to him or her, though only the supervisors of the
Equipment Depot are listed below.
GB Manufacturing Maintenance Department
The Problem
In August of 2003 Bill Venkman and his management staff completed a
one-week retreat aimed at assessing the maintenance operations. Several
initiatives resulted from this retreat. It was determined that the most
important initiatives were those that primarily dealt with the equipment
depot operation.
The equipment depot's function is to provide the equipment needed by
maintenance employees to perform their job duties. Employees are
provided with a toolbox containing commonly used, and relatively
inexpensive tools such as hammers, screwdrivers, tape measures, and so
on. Other tools and pieces of equipment that are needed to complete a
job must be checked out through the equipment depot. When the job is
completed, the employee must return the checked-out equipment.
and are therefore never checked back in and made available for others.
The dollar amount of lost and stolen equipment has reached an alarming
total. It has been estimated that more than $50,000 worth of tools are
lost or stolen each year. Bill Venkman has decided that something must
be done to get the losses under control. Thus, he is giving top priority
to the development of a new automated equipment check-out system that
that will track the check-in and check out of equipment.
The Materials Warehouse is responsible for obtaining and storing
supplies that are needed to complete jobs. For example, the Materials
Warehouse makes sure to maintain a supply of screws, nails, plywood,
drywall, and other materials. The Materials Warehouse operates in two
locations. The main Materials Warehouse is a large building located
approximately a mile away from the main campus. For convenience, a
smaller Materials Warehouse is located on near the central office and
stores a small amount of the most commonly used materials. When workers
need materials for a job assignment they are supposed to check both
warehouses to see if the goods are available. Unfortunately, the
employees are often impatient and will simply check the availability of
materials at the smaller, more conveniently located warehouse. If the
goods are not available, they routinely choose to simply move on to the
next job assignment — rather than checking with the main warehouse.
While the main warehouse will provide for the delivery of materials,
employees prefer not to have wait for their delivery. To complicate
things further, even though the materials may be available at the larger
warehouse, employees frequently request that the smaller warehouse order
needed materials that are not in stock there. The net result is
excessive inventory and inventory carrying costs!
While management is not sure of the total dollar amount that can be
attributed to carrying excessive inventory, they are in agreement that
it is likely very substantial. Therefore, a new and improved warehousing
system is another top priority for the Maintenance Department.
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