MT435 Operations Management Toney L Ferguson M.B.A., M.P.M

Albatross Anchor Case Study Albatross Anchor is a small family owned business that began in 1976 with four family members. Albatross anchor has grown exponentially and now employs one hundred and thirty people. Their one location/facility is situated on twelve acres of land located in a rural suburb of Smalltown, USA. The manufacturing plant and the main office are located in the same building with the manufacturing. The administrative offices are in the front of the building and the manufacturing area is in the back of the building. The manufacturing part of the building is antiquated, worn, dirty, technology deprived and it no longer meets all US safety and environmental standards and the administrative offices are shabby and inefficient. The owners of this small business have added on various processes as needed within the limited space provided within the plant. When Albatross Anchor first opened its doors their expertise laid in the manufacture of the bell/mushroom anchor (using a foundry process). Because of international competition in 1989 the owners of Albatross Anchor made the decision to expand their product line to include fabricated snag hook anchors.

Albatross Anchor Case Study Products The bell anchor is used primarily by fresh water marine craft. They are manufactured primarily through a foundry process in which ore is transformed into a liquid state and poured into molds for production. The snag hook anchor is used primarily for small to medium sized saltwater marine craft. The snag hook anchor is fabricated through the bending and welding of iron rods and flat iron into a hook design so that bedrock and seaweed can be snagged to hold the marine craft at anchor. Each anchor is produced in multiple sizes to accommodate the type of craft requiring the anchor.

Albatross Anchor Case Study Manufacturing Each anchor type requires its own unique equipment and manufacturing process. Both manufacturing areas share the same shipping and receiving area, the warehouse area and administration. The manufacturing area of the plant has had to change to accommodate the manufacture of the two separate types of anchors. As each anchor requires its own manufacturing challenges the manufacturing line must be completely changed over each time the anchor type is changed. The time to switch over from one manufacturing process/operation to the other manufacturing process/operation is 36 hours. The plant space is at a premium and warehousing space for raw materials and finished product is limited and located at the far south end of the building. Plant antiquation and safety issues result in small batch production only. As a result lead time for large bulk orders is three to four weeks.

Albatross Anchor Case Study Costs and shipping challenges Current manufacturing costs are $12.00 per pound for mushroom/bell anchors and $6.00 per pound for snag hook anchors. While Albatross Anchor charges the same per unit as their competitors their profit margin is as much as 30% less due to operations inefficiencies. Product size, bulk and weight (either anchor) requires shipment by rail and by specialized ground transportation (large trucks). Domestic orders are shipped by truck and international orders are shipped by rail and then by large freighter. These are the only two methods of shipment of product to customer. Receipt of raw materials is by rail. Prior to the sale of anchors into the international market all shipments of finished product went out completely by truck and therefore all shipping activities were limited to the east side of the building. Now, because of the limitation of shipping product into the international marketplace all product shipments for international delivery go out of the receiving dock for shipment for transportation by rail and then by large freighter. Whereas prior to expansion into the international marketplace shipping had been limited to the shipping department and receiving was limited to the receiving area, now the receiving area must do double duty – shipping of international orders and receipt of all raw materials. Please view the below representation of the current building/facility set up.

Facility Layout

Unit 8 Written Assignment Question One Select three items (as listed below) and explain for each of your three selections how it will help Albatross Anchor to improve job retention, employee morale, and employee dedication. (a) Work design (b) Cross training (c) Gainsharing and profit sharing (d) Job design (e) Task analysis (f) Worker analysis (g) Environmental analysis (h) Ergonomics (i) Technology and automation (j) Job analysis

Unit 8 Written Assignment Question Two Based on the scenario given in unit three and the information given in this case study make recommendations to Albatross Anchor for at least three of the following challenges: (a) Time management (b) Cost management (c) Quality management (d) Performance management (e) Enterprise project management (f) Technology adoption (g) Supply chain management (h) Distribution management

Unit 8 Written Assignment Question Three As the consultant for KU Consulting, you have been authorized to change the existing facility (limited construction budget) and/or refine the process flow of the manufacturing area. All changes must be completed within a 60 day window with the majority of the changes happening at night when the plant is idle. (a) List and detail the proposed changes and/or alterations. Please explain why you chose what you chose, give the rationale behind your choices and finally, substantiate your work. (b) List and detail two implications and two complications that may occur as a result of the recommended changes. Remember activities in one area of the facility may have an impact on other areas of the facility. (c) Create a Gantt chart showing a timeline for when the different changes proposed should be made, detailing which changes may overlap and showing how long each change will take to institute. Provide information to support your decisions and to explain your choices as shown in the Gantt chart.

Gantt chart