Littlefield

Emerson Network Power Confidential

LittlefieldLittlefield

Emerson Network Power Confidential 2

AgendaAgendaAgendaAgenda Scope of The Game Current State Process Order Rates


ScopeScopeScopeScope maximizing revenue by in an Dish Manufacturing

Factory optimizing by optimizing batching, raw material, and overcoming bottlenecks through either batching or investment in new equipment.


Game BasicsGame BasicsGame BasicsGame Basics We are to adjust key parameters to optimize throughput

and maximize profit Each Hour reflects an actual day of production

– We can modify each hour if we want

We assume plant responsibility for ordering, acceptance of orders, batch size, investment decisions

We operate 7/24 We will start our management tenure on day 51 and

operate for 266 days. The last 100 days will run based on the last settings

This game will run for 9 days Elapsed time


Current StateCurrent StateCurrent StateCurrent State Labor Cost is not a factor Our manufacturing Process if broken down into 4

distinct processes– Board Stuffing (let’s call it surface mount)

– Initial Test

– Tuning

– Final Test

Waiting Queue Size is not an Issue Initial Material Ordered was for 7,500 kits


Board StuffingBoard StuffingBoard StuffingBoard Stuffing Longest Single step in

process regardless of batch size

No Variability– HERBIE!!!!

– A Surface Mount Machine • Additional Machine costs

$90,000

• No Lead Time noted…

– Scrap $ = $10,000K

– Initial number of Machines• 3


Initial TestInitial TestInitial TestInitial Test Short Cycle No Variability, until we get fully

operational!!!!!! As it shares the same equipment as Step 4 Final Test– Additional Machine costs

$80,000• No Lead Time noted…

– Scrap $ = $10,000K– Initial number of Machines

• 1

9.68


TuningTuningTuningTuning Can be incredibly short Variability Strikes!!!!!!!!!!!!! Equipment

– Additional Machine costs $100,000• No Lead Time noted…

– Scrap $ = $10,000K

– Initial number of Machines• 1

9.68


Final TestFinal TestFinal TestFinal Test Shortest Cycle No Variability, until we get fully

operational!!!!!! – As it shares the resource with

Initial Test Equipment

– A Test Machine • Additional Machine costs

$80,000• No Lead Time noted…

– Scrap $ = $100,000K– Initial number of Machines

• 1• Same Machine as Initial

Test!!!!!!!!!!!!!!!!!!!!!9.68


Order AcceptanceOrder AcceptanceOrder AcceptanceOrder Acceptance We can accept orders but

each batch must be for multiples of 60– If we receive and order for

more than this, we do not have material or capacity, then it will not be accepted can not a

Lead Times– Current Quoted as 7 Days

When accepting Orders– We can accept them at

one of three levels


MaterialMaterialMaterialMaterial Initial on Hand Material

– 7,200 Units

– Material Cost Per unit $10

– All Orders must be placed in Multiples of 60

– Lead time is 4 Days

– Unsure of Initial Inventory when we start game

Holding Period Costs– If not leveraged, 10%

annualized


InvestmentInvestmentInvestmentInvestment AT day 150, we can

obtain financing– 20% annual


Day of Take OverDay of Take OverDay of Take OverDay of Take Over The LT factory began production by investing most of its

cash into capacity and inventory. Specifically, on day 0, the factory began operations with

three stuffers, one tester, and one tuner, and a raw materials inventory of 7200 kits. This left the factory with zero cash on hand.

Management is currently quoting 7-day lead times, but management would like to charge the higher prices that customers would pay for dramatically shorter lead times. In addition, because the factory is essentially bootstrapping itself financially, management is worriedabout running out of cash.


Ordering QueueOrdering QueueOrdering QueueOrdering Queue What is the Current Batch Size What should our contact price be after reviewing other

data


Materials BufferMaterials BufferMaterials BufferMaterials Buffer Current Inventory Levels Reorder point And QTY to order


Key Items to look at while we determine what Key Items to look at while we determine what our Bottlenecks and Variances for Future our Bottlenecks and Variances for Future InvestmentInvestment

Key Items to look at while we determine what Key Items to look at while we determine what our Bottlenecks and Variances for Future our Bottlenecks and Variances for Future InvestmentInvestment Are our bottlenecks where we think they are?


Work/Process CentersWork/Process CentersWork/Process CentersWork/Process Centers Most important short term, if we can’t buy any new

machines is Testing Priority


How are we doing?How are we doing?How are we doing?How are we doing? Should we alter the pricing? Are we confident?


Action PlanAction PlanAction PlanAction Plan Assess Current Position If things are not terrible would recommend batch sizes

of 20 Leave Orders at 7 days for time being EOQ is hard to use as holding

– 2500 Kit at a time

– $26K Cash Needed

Prioritization of the new Assets

Littlefield

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