Posted: June 19th, 2022

Production Planning in Juice-Perfect’ Manufacturing:Unplanned Downtime Reduction

(Please provide an excel file)
Company Background
Juice-Perfect, a California-based juice manufacturing company, has 6 manufacturing plants around
the US that produce various sizes and flavor of juices and smoothies. In recent years, management
noticed that Juice-Perfect’s market share has been decreasing due to its inability to sustain the
level of expectations and market demands. A group of internal analysts conducted a thorough
investigation of the root causes of the performance decline and published a report that identified
problems in the production planning of Juice-Perfect’s manufacturing operations as the critical
factors.
In response, leadership at the company decided to contract a team to help identify improvement
areas in the production planning and propose a plan to reform the manufacturing processes across
all plants. Management has decided to pilot the changes on the packaging lines only at one of the
plants (that is the worst performing plant).
• Using internal performance metrics (Appendix A), Juice-Perfect want to identify the worst
performing plant in their network. Hence, analyse this data and identify the worst
performing plant.
• With an aim to boost the day-to-day operations of this plant, analyse the data in Appendix
B to enable Juice-Perfect to uncover specific problems faced within the plant’s
filling/packaging line and recommend improvement strategies that they would be able to
implement nationwide.
APPENDIX:
A. Yearly Performance Overview
B. Inventory Delays
EXPECTED OUTPUT
• A maximum of 20 minutes presentation detailing the comprehensive and systematic analysis of
the case study.
• Slides for the presentation must be detailed and informative. Additionally, excel files used in
the data analysis should be submitted.
• The presentation should highlight the details of the following but not limited to: an
introduction to the analyses, the aims and objectives, the analytical methodology employed,
results and analysis, recommendations and practical implications, conclusions
ATTACHED FILE(S)
Table of Content
Appendix to ISEE.420 Independent Study Case Study
Introduction
The Data Apendices provide clarity on the case study and support on which the solutions should be formed. The data exhibits highlight aspects critical to Production Planning. The data sets in the appendix are distinct and will provide different insights, which may or may not be codependent among each other, into the “current state” of the Juice-manufacturing company.
Table of Content
Appendix A:Yearly Performance Overview This exhibit provides the performance overview of the plants in Juice-Perfect’s network.
Column B: Plant locations
Column C: Total Run Time (hr.)
Column D: Annual Planned Downtime (hr.)
Column E: Annual Unplanned Downtime (hr.)
Column F: MTBF – Mean Time Before Failure (min)
Column G: MTTR – Mean Time to Repair (min)
Column H: Annual Planned Production
Appendix B: Inventory Delays This data set provides information regarding the unmet production plan of ONE production line as a result of inventory issues.
Column B: SKU ID
Column C: Planned Amount
Column D: Bottles available in storage
Column E: Planned production date
Column F: Unmet production reason
Column G: Bottle shipment ID
Column H: Total Amount Shipped
Column I: Amount left in yard
Column J: Arrival Date
Column K: Reasons left in yard
Appendix A
Appendix A
Plant/Metrics Total Annual Run-time (hr.) Annual Planned Downtown (hr.) Annual Unplanned Downtime (hr.) MTBF (min) MTTR (min) Planned Annual Production
Illinois 4,380 100 219 1,421 52 28,000,000
North Carolina 6,570 130 361.35 1,206 55 30,000,000
Texas 8,760 240 525.6 981 54 46,000,000
California 7,665 192.5 536.55 789 56 50,000,000
Georgia 10,950 250 1095 949 55 65,000,000
Florida 4,380 120 657 300 55 36,000,000
Appendix B
Appendix B
SKU ID Planned Amount Bottles Available in Storage Planned Production Date Unmet Production Reason Bottle Shipment ID Total Amount Shipped Amount Left in Yard Arrival Date Reason left in yard
B241APPJ 17000 13000 5-Feb Not enough bottle in production line 44000670 4000 3250 4-Feb Not received in system (Yard)
B76ORGJ 17000 16000 12-Feb Not enough bottle in production line 84661365 1000 850 11-Feb Not received in system (Yard)
B241STWS 15000 11000 13-Feb Not enough bottle in production line 91040117 4000 3500 12-Feb Misplaced in Warehouse
B124KWIJ 13000 10000 28-Feb Not enough bottle in production line 143233333 3000 1300 27-Feb Delay in Staging
B124ORGJ 18000 17000 3-Mar Not enough bottle in production line 162847032 1000 160 2-Mar Misplaced in Warehouse
B241APPS 21000 17000 5-Mar Not enough bottle in production line 166441474 4000 1570 4-Mar Misplaced in Warehouse
B241APPS 24000 21000 12-Mar Not enough bottle in production line 232555599 3000 290 11-Mar Others
B76STWS 17000 13000 13-Mar Not enough bottle in production line 255215557 4000 3980 12-Mar Warehouse is full
B124APPJ 14000 13000 14-Mar Not enough bottle in production line 270699959 1000 850 13-Mar Delay in Staging
B124ORGJ 11000 8000 15-Mar Not enough bottle in production line 276040414 3000 1100 14-Mar Warehouse is full
B76GRPJ 26000 23000 19-Mar Not enough bottle in production line 330312002 3000 2000 18-Mar Not received in system (Yard)
B76KWIS 24000 22000 21-Mar Not enough bottle in production line 333415670 2000 1000 20-Mar Misplaced in Warehouse
B241GRPS 30000 29000 25-Mar Not enough bottle in production line 371493752 1000 300 24-Mar Delay in Staging
B124KWIS 19000 18000 27-Mar Not enough bottle in production line 371695588 1000 250 26-Mar Others
B76ORGS 9000 8000 6-Apr Not enough bottle in production line 439547282 1000 630 5-Apr Delay in Staging
B76ORGJ 11000 8000 8-Apr Not enough bottle in production line 543016700 3000 2250 7-Apr Misplaced in Warehouse
B124APPS 12000 10000 12-Apr Not enough bottle in production line 636927028 2000 1770 11-Apr Misplaced in Warehouse
B124GRPJ 11000 10000 18-Apr Not enough bottle in production line 648775432 1000 280 17-Apr Others
B76ORGJ 20000 18000 19-Apr Not enough bottle in production line 702929209 2000 1220 18-Apr Not received in system (Yard)
B124WMLS 16000 14000 26-Apr Not enough bottle in production line 715158568 2000 90 25-Apr Warehouse is full
B76KWIJ 16000 15000 29-Apr Not enough bottle in production line 769939888 1000 340 28-Apr Delay in Staging
B124GRPJ 10000 6000 1-May Not enough bottle in production line 772429939 4000 1000 30-Apr Misplaced in Warehouse
B124ORGJ 10000 8000 2-May Not enough bottle in production line 789365699 2000 480 1-May Not received in system (Yard)
B241APPJ 16000 13000 6-May Not enough bottle in production line 816375544 3000 1100 5-May Delay in Staging
B76WMLJ 27000 24000 11-May Not enough bottle in production line 829968106 3000 2500 10-May Misplaced in Warehouse
B241GRPJ 17000 16000 17-May Not enough bottle in production line 837545234 1000 450 16-May Misplaced in Warehouse
B124APPS 16000 14000 30-May Not enough bottle in production line 853214184 2000 1040 29-May Misplaced in Warehouse
B76WMLS 28000 26000 3-Jun Not enough bottle in production line 888544595 2000 25 2-Jun Others
B124KWIS 27000 23000 8-Jun Not enough bottle in production line 958295862 4000 3960 7-Jun Misplaced in Warehouse
B76ORGJ 24000 23000 13-Jun Not enough bottle in production line 983749211 1000 440 12-Jun Others
B76ORGS 25000 23000 25-Jun Not enough bottle in production line 1008980093 2000 1060 24-Jun Warehouse is full
B124KWIJ 14000 11000 26-Jun Not enough bottle in production line 1040446071 3000 300 25-Jun Delay in Staging
B124ORGJ 12000 10000 27-Jun Not enough bottle in production line 1067660308 2000 300 26-Jun Delay in Staging
B124APPJ 16000 14000 3-Jul Not enough bottle in production line 1081990792 2000 950 2-Jul Warehouse is full
B241WMLS 15000 13000 7-Jul Not enough bottle in production line 1092498837 2000 1290 6-Jul Others
B76KWIS 18000 16000 11-Jul Not enough bottle in production line 1169339254 2000 2000 10-Jul Not received in system (Yard)
B241WMLJ 30000 26000 12-Jul Not enough bottle in production line 1210704094 4000 900 11-Jul Not received in system (Yard)
B124KWIJ 25000 22000 15-Jul Not enough bottle in production line 1349719711 3000 1480 14-Jul Misplaced in Warehouse
B76ORGJ 23000 22000 24-Jul Not enough bottle in production line 1375164782 1000 930 23-Jul Misplaced in Warehouse
B124STWS 22000 19000 26-Jul Not enough bottle in production line 1381085344 3000 770 25-Jul Delay in Staging
B76KWIJ 18000 16000 28-Jul Not enough bottle in production line 1391282703 2000 1680 27-Jul Misplaced in Warehouse
B241GRPJ 27000 23000 31-Jul Not enough bottle in production line 1391612087 4000 150 30-Jul Not received in system (Yard)
B124GRPS 24000 20000 6-Aug Not enough bottle in production line 1444242099 4000 3600 5-Aug Not received in system (Yard)
B76WMLS 19000 18000 8-Aug Not enough bottle in production line 1508617750 1000 160 7-Aug Warehouse is full
B76ORGS 23000 19000 14-Aug Not enough bottle in production line 1509407174 4000 1200 13-Aug Not received in system (Yard)
B124APPJ 23000 20000 15-Aug Not enough bottle in production line 1509722615 3000 1080 14-Aug Warehouse is full
B76STWJ 12000 11000 20-Aug Not enough bottle in production line 1510204561 1000 380 19-Aug Warehouse is full
B241STWS 29000 28000 22-Aug Not enough bottle in production line 1518107959 1000 650 21-Aug Misplaced in Warehouse
B241STWS 13000 12000 26-Aug Not enough bottle in production line 1557455980 1000 750 25-Aug Not received in system (Yard)

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