...Case Report: National Cranberry Cooperative Fill in your name in the header. Please read the Assignment Collaboration Guidelines in Course Syllabus: Collaboration between groups is not allowed; however, if you hear something from some other group, please give a reference. Below, write your answers to Questions 1-4 (on BB/Cases). Your analysis should be based on the assumptions listed in the Syllabus. If you need to make additional assumptions to answer a question, clearly state them, logically defend them, and then proceed to answer the question accordingly. The idea is to answer the questions concisely. Double spacing is preferred, 1.5-line spacing is the minimum (consider the reader’s eye strain). 1. Analyze the current process. Using the process flow map (available on CTools) of the current process at Receiving Plant No.1, mark the capacity and utilization of each of the resources. Show the flows of wet and dry berries separately. First we receive 18,000 barrels over a 12 hour period which leads to a 1,500 bbl/ Hr, Then 75% of 1,500 total berries per hour equal 1,125 bbl/Hr and the remaining 25% or 375 bbl/Hr are dry berries. While our Dumper is holding a capacity of 3,000 bbl/Hr and utilizing only the 1,500 bbl/Hr we are receiving. Those berries would then split up in the dry and wet storage bins. Dry bins have a capacity of 4,000 bbl/Hr which is 16 bins holding 250 bbl/Hr each. Whereas the wet bins kept a storage capacity of 3,200 with 8 bins holding 250 bbl/Hr...
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...Case Analysis of National Cranberry Cooperative Team1. Report I. Summary <Process Flow Chart> <Operations> 1) Receiving and Testing ☞ RECEIVING * 243 trucks deliver 75 barrels(=7500 pounds) per truck on average * 75*243 = 18225 barrels (1822500 pounds) * Last truck arrived (1140min) – First truck arrived (411min) = 729min (=1140 - 411) → 729min/60 = 12.15hrs (Total receiving time) ∴ For 12.15hours, 243 trucks delivered 18225 barrels. NCC receives 1500barrels/hr. - Delivering 75 barrels per truck - Capacity at each Dumper = 75 (barrel/truck) * 6 (trucks/hr) = 450 barrels/hr : Total capacity of 5 dumpers = 450 (barrel/hr) * 5 (dupms) = 2250 barrels/hr 2) Dumping and Temporary Holding ☞ Dumping * After berries moving 5 Kiwanee Dumpers, they are dumped into one of five conveyers. ☞Temporary Holding * Berries are stored at one of 27 Temporary Holding Bines at 2nd step operation. Bin 1~24 : 250 barrels / Bin 25~27 : 400 barrels * Trucks require 5~10 minutes to empty the berries and leave, but when Bins are full, trucks should wait for 3hrs max. ☞Bins are emptied by dumping berries on conveyers at 1st step operation. * Bin 1~16 : 16 * 250 = 4000 barrels (Dry) * Bin 17~24 : 8 * 250 = 2000 barrels (wet / dry) * Bin 25~27 : 3 * 400 = 1200 barrels (wet) ∴ Total berries : 7200 barrels (=4000+2000+1200) Wet berries : min.1200 barrels ~ Max.3200 barrels ...
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...National Cranberry Cooperative 1. Analyze the current process. Please see the Excel file. 2. On a busy day, what is RP#1’s current maximum throughput rate? The separator line could process up to 450 bbls/hr. instead of 400 bbls/hr. The other bottleneck for this question is dryer process. So the maximum throughput rate should be: 600+450=1050 bbls/hr. 3. Assuming that processing starts at 7 am on a “busy” day, present the situation during such a day, by constructing an inventory build-up diagram for bins and trucks. Demand rate=18000 bbls/12hr.=1500bbls/hr. 7:00 p.m. trucks stop coming TOTAL INVENTORY = (450*12) bbls =5400 bbls EMPTY=5400/600=9 hr. 9+7:00P.M. =4:00A.M. BIN INVENTORY=3200 bbls (12-7)= 5 (450/75)=6 5*6=30trucks TRUCK INVENTORY=30*75=2250 bbls 4. What are the possible capital investments considered by NCC? One of the possible capital investments considered by NCC was to buy some new equipment. NCC’s overtime costs were out of control and the growers were upset that their trucks and drivers had to spend so much time waiting to unload process fruit into the receiving plant. Will Walliston, the superintendent, thought that the way to avoid these problems was to increase their capacity by buying new equipment. However, in order to buy new equipment it was very important to move quickly since the purchasing and installation lead times are in excess of six months. Another possible capital...
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...Here’s the problem, gang… We now that the bottleneck in the process is the Drying unit. Using the diagram, we can assess: 1. TPT is 19,000*.7 wet barrels/12 work hrs in work day = 1108 wet bbls per day 2. The dryer unit can process 600 bbls wet cranberries per day Looking at the process we know that there is a bottleneck at Drying unit: I. The capacity of the drying unit is 600 bbl /hr which is much lower than the required 1108 wet bbl/day we need. II. On an average day a total of 10,000 bbl is received out of which 7,000 bbl is wet. At an average processing rate of 600 bbl /hr it will take 11.67 hours to process. Assuming normal working day of 8 hours, there is an overtime of 3.67 hours for each member of the crew on each average working day. III. On a peak day a total of 19,000 bbl is received out of which 13,300 bbl is wet. At an average processing rate of 600 bbl /hr it will take 22.17 hours to process. Thus, there is an overtime of 14 hours. Lack of drying capacity is one of the major reasons for the increase in overtime cost. Another reason is the increase in percentage of wet cranberries. * Waiting time for trucks: Inventory build up = arrival rate – processing rate = 1108 bbl – 600 bbl = 508 bbl at this rate the wet bins will be filled in 3500/508 = 6.89 hours. At the end of the day (12 hours) there will be 450*12=5400 bbl in inventory. Out of this 3,500 bbl will be in bins and rest 1,300 bbl will be in trucks. It will take 1,300/600=2.17...
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...National Cranberry Cooperative Case Study 1. How might transport vehicles be utilized more effectively? Should crews be scheduled differently on peak days? More crews should be scheduled in the bagging station during peak days The fourth bagging station should be utilized during peak hours (instead of just three of the four being used at a given time) An additional 2,667 bbls per 12-hour period could be processed with these changes At receiving plant no. 1 (RP1), trucks would arrive randomly throughout the day, with a random amount of berries, anywhere from 20 to 400 bbls. In order to utilize transport vehicles more effectively, there should be crews scheduled differently on peak days. It only takes 5 to 10 minutes to unload a truck into a Kiwanne dumper, but the backup would occur when the holding bins were full, causing drivers to have waits up to 3 hours. The backup is not occurring in receiving, so now additional crews are necessary at that station. All feed conveyors are in use during peak times so no new crews need to be added there. However, there seems to be a backup occurring in the bagging station. Instead of keeping the fourth bagging machine as a spare, they should add another five-member team to operate the fourth bagging machine during peak hours. This would result in an additional 2,667 bbls per 12-hour period, or a total of 10,667 bbls per 12-hour period. The additional crews and adding of a bagging station would reduce the number of berries that...
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...ational Cranberry Cooperative Please read the course pack item “National Cranberry Cooperative”. Consider the following case assumptions: A. All the processes (including Destone, Dechaff, and Dry) start from 7am. B. On an average “busy” day, there are 18,000 bbls delivered over 12-hour period (from 7am to 7pm). C. Wet berries are 70% of all berries. D. Holding bins 17-24 are dedicated to wet berries. E. Capacity of each of five dumpers is 600 bbl/hr. F. When holding bins for wet berries are full, the Kiwanee dumpers are not available to process wet berries, i.e., dumpers cannot temporarily store any wet berries. G. There are 20 peak days in one year, where there is truck waiting happened. H. Truck Drivers are paid by $18/hr Submitted questions: 1. Analyze the current process. [Using the process flow map, available in the Excel file associated with the assignment, of the current process at Receiving Plant #1, mark the capacity of each of the activities. Show the flows of wet and dry berries separately.] 2. On a busy day, what is RP#1’s current maximum throughput rate? 3. Assuming that processing starts at 7 am on a “busy” day, present the situation during such a day, by constructing an inventory build-up diagram for bins and trucks. 4. What are the possible capital investments considered by NCC? 5. Quantify the costs and benefits for NCC’s investment for the fifth Kiwanee dumper in 1980. 6. Quantify the costs and benefits of “converting dry berry holding bins...
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...1.) Introduction 2 2.) Process Analysis 2 3.) Process Flow at National Cranberry Cooperative 4 4.) Installing a Light Grading System 5 5.) Decreasing the truck waiting time 6 6.) Bag pack or Bulk Pack 8 7.) Conclusions 9 1.) Introduction This case analysis looks at the two primary problems at the receiving plant no. 1 (RP 1) faced by National Cranberry Cooperative during the cranberry harvesting period, viz. 1) too much waiting period for trucks before they unload berries at the RP1 and 2) too much overtime costs. There is also a secondary problem regarding grading of process berries. Half of the berries graded top quality are actually not top quality and do not deserve extra premiums paid on the top quality berries. 2.) Process Analysis We start by making a process flow diagram for the flow of berries at RP1 from the moment berries arrive at the RP1 in trucks to the moment they leave in RP1 after being bag packed, bulk loaded into trucks or loaded into bulk tins. The capacities of the various processes are based on the assumptions or data as shown below: Dumping Capacity Number of Kiwanee Dumpers = 5 Average time taken by truck to load the berries onto Kiwanee Dumpers = 7.5 minutes (Maximum being 10 and minimum being 5 minutes) Average weight of berries in a truck = 75 bbls. Dumping Capacity = 5 * 75 * 60 / 7.5 = 3000 bbls/hr. Holding Bin Capacities Bin No. 1-16 can hold dry berries only up to 250 bbls per bin. Total capacity of bin numbered 1-16 = 250*16...
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...The National Cranberry Cooperative (NCC) is an organization created and owned by cranberry growers to process and market their berries. In the early 1990’s, there was a growing surplus of berries so the growers resorted to the Agriculture Marketing Agreement Act of 1937 to restrict the amount of crop processed. In addition, the cranberry harvesting process was becoming more automated during this period of time. There are two types of berry harvesting: 1) water harvesting which involves flooding bogs, using machines to shake the bushes, and collecting the berries that float to the top; and 2) dry harvesting which requires hand picking. Water harvesting typically results in a yield of 20% more berries than dry harvesting, however, it causes more damage and reduces the time between harvest and long-term storage. Cranberries are processed for one of two purposes: 1) preparing raw berries for sale; and 2) preparing berries for use in juice, canning, freezing, and other processes. The process for preparing berries to be processed at Receiving Plant 1 (RP1) is as follows: 1) Bulk trucks arrive at random with an average delivery of 75 barrels (bbl: which weighs ~100 pounds). 2) The truck is weighed, the full and empty truck weight is recorded and a sample(s) of 30 pounds is taken for initial berry grading (Lowest grade and price 1, 2A, 2B, 3 Highest grade and price). 3) The truck backs into 1 of 5 dumpers 4) A conveyor belt takes the berries to the second level...
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...National Cranberry Cooperative 1. Answer on “Flow Map” (attached Document) 2. Throughput Rate is the rate systems generate product per unit of time or I= R (x) T; R=I/T. Here is, R is for rate, I is for inventory, and T is time. Therefore, I must find I when T=4hr, R=3.25 4hr (x) 3.25bbl = 13bbl per hr 3. If the PP1 opens at 7:00AM and Closes at 7:00PM, then the total bbls of cranberry’s processed for that day will be 18,000 bbls. I come to this conclusion because there are 1500 bbls processed each hours. Multiplying 1500 by (12) for a twelve hour processing day, then 18,000 is derived. Bins 1-16 hold 4000 bbl at a time, and bins 17-27 hold 2950 bbl at a time. There are 5 Kiwanee Dumpers (trucks) and each can ship 75 bbl of berries per delivery. Bins 1-16 hold 250 bbl each, so it takes about 3.33 dumps of a truck to fill one storage bin to capacity. 5 trucks at 75 bbl per trip (375 bbl) could fill bins 1-16 (capacity 4000 bbl per hour) in approximately 10.6 trips. 4. The possible capital investments considered by NCC are buying new equipment to reduce the time that drivers wait to unload picked berries. a. The fifth Kwanee Dumper cost $200,000. This acquisition increased loading capacity, yet accrued further overtime costs for drivers because of a lack of processing capabilities and waiting time to dump these loads. b. Another possible capital investment was $40,000 for a light meter system for color grading. No. 3 (premium) berries were...
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...Team 3 National Cranberry Cooperative Analysis and recommendations 1. 2. The resource with least capacity determines the maximum long-term achievable throughput rate. Because wet and dry berries follow different routes at RP#1 there will be a maximum achievable throughput for each. The capacity of the dryers is the bottleneck for the wet berries. The maximum throughput for wet berries is 600 bbls/hr. For dry berries the separation process is the bottleneck. The maximum throughput for dry berries is 1200 bbls/hr. The percentage of wet berries to dry berries would affect the throughput rate. Given the current proportion of berries received the capacity of the dryers would be the maximum throughput of the system. The dryers are the system bottleneck. And as the trend of water harvesting continues, this situation worsens. All the process/resources at RP#1 contribute to the throughput but the limitation is the bottleneck. 3. The trucks wait because the processing capacity is less than the system input. And the temporary holding bins are inadequate to buffer the berries coming in and the plants processing capacity. But by using the Theory of Constraints to identify the system bottle necks we are able to discover the root cause of the waits. The large back log of berries is caused by several factors The plant is not currently equipped to handle the supply of wet berries. This problem has likely been increasing over the years as more cranberries are being...
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...National Cranberry Cooperative -- Key Issues OPMT 405 Summer 2006 Major Operational Problem: Long truck waiting time to dump berries -- customer service Excessive overtime -- operating costs Both “symptoms” of a common ailment -- a bottleneck in the process flow. A minor problem that can be easily solved has to do with the grading of berries. $.75/BBL premium paid for grade 3 berries. Premium paid on 450,000 barrels in 1980. Half were incorrectly labeled as grade 3. Accurate grading could save $169,000 per year. Light meter system would cost $20,000 plus annual operator salary. What does this imply to the growers who are also the owners of the plant? Bottleneck Analysis Some simplifying assumptions: 16,400 BBL are delivered per day (70% wet, 30% dry) over 12 hours. Trucks arrive evenly spaced over 12 hours. Each truck carries 75 BBLs Downstream processing begins at the same time as dumping (7 a.m.). Capacity Dumping = = [pic] = 2250 BBL/Hour Destoning = 3x 1,500 BBL/Hour = 4500 BBL/Hour Dechaffing (dry) = 2x1,500 BBL/Hour = 3,000 BBL/Hour Dechaffing (wet) =1x1,500 BBL/hour = 1,500 BBL/Hour Drying = 3x200 BBL/Hour = 600 BBL/Hour Separating = 3x400 BBL/Hour = 1200 BBL/Hour Bailey Mills = 3x400 BBL/Hour = 1200 BBL/Hour Processing Requirement Total: 16,400 BBLs...
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...Marketing Communications | Syndicate assignment Case 1 Prius Launch: Harmony Installations 2011 Bronze | Media Innovation Case 2 Canon Eos Cameras: Photography beyond the still 2011 Silver | Consumer Electronics Case 3 Southwest Airlines: Grab your bag it’s on/ Bags fly free 2011 Gold | Transportation Case 4 Ocean Spray Cranberries: Straight from the Bog 2008 Gold | Renaissance 2011 Silver | Sustained Success Case 5 Sears: Don’t just go back. Arrive 2010 Gold | Retail¬ Case 1 Prius Launch: Harmony Installations 2011 Bronze | Media Innovation GET: Echo/Tech friendly minded people WHO: Are environmentally and technologically aware and enjoy innovation. TO: Think Prius is the car they should buy versus the car they want to own. See Prius as an Icon of progress. Encourage consumers to put a Prius in the mainstream consideration set. BY: Outlining that hybrid motoring is good for the environment, endorsing the idea of being proud to own a Prius. LIKE THIS: By highlighting the “harmony between man, nature and machine”. Happiness, Optimism, Pride, Imagination SUCCESS: Desired 20% increase in sales of Prius. Increase hybrid vehicle market share. Engage social media metrics. $4.5m in earned media desired through Solar flower installations/social media. Market/Commercial insight The reported market decline in the Automotive Industry for passenger cars has declined by 37% in FY2011. Financial modelling of passenger...
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...Reference Books Sr No R-1 R-2 Other Reading Sr No OR-1 OR-2 OR-3 OR-4 OR-5 OR-6 OR-7 OR-8 OR-9 OR-10 OR-11 OR-12 Journals articles as Compulsary reading (specific articles, complete reference) The four things that a service Business must get right HBR Article , Bang & Olufsen Design Driven Innovation : HBR , Smart Product Design : HBR , Mishina, Kazuhiro. Toyota Motor Manufacturing, U.S.A., Inc. HBS Case No. 9-693-019. Harvard Business School Publishing, Boston, 1995. , Hammond, Janice H. Barilla SpA (A). HBS Case No. 9-694-046. Harvard Business School Publishing, Boston, 1994. , Latour, Almar. Nokia Handles Supply Shock with Aplomb as Ericsson of Sweden Gets Burned. The Wall Street Journal. Dow Jones & Company, Inc., 2001. , National Cranberry Cooperative HBS #688122. From Case Map , John Crane UK Ltd Case : The CAD CAM Link . HBS #691021,24p , To Move or not to Move .Case of Cathay Pacific Airways . University of Hong Kong HBS #HKU003,22p , Note on Quality: The Views of Deming, Juran, and Crosby HBS .687011 , Process Control at Polaroid , HBS, #693047 , LL Bean Item Forecasting and Inventory Management HBS, #893003, 5p , Johson Control Automotive Systems , HBS,#69308623p , Title Operations Management Concepts, Techniques & Applications Operations Management Author Evans & Collier Edition 1st Year Publisher Name Cengage Learning Tata McGraw Hill Author Norman Gaither,Greg Frazier Edition 9th Year Publisher Name Cengage Learning William Stevenson Taylor 8th Relevant Websites...
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...OPNS D30 Operations Management National Cranberry Cooperative 1. Process flow diagram and bottleneck operations For the process flow diagram, see Exhibit 1. The bottleneck operation is Drying (rate: 600 bbls/hr). Let’s consider the wet and dry processing separately: * Wet processing: RP1 can dechaff up to 3,000 bbls/hr, but only dry 600 bbls/hr. Thus, the bottleneck operation of wet processing is drying, and the bottleneck rate is 600 bbls/hr. * Dry processing: RP1 can destone 4,500 bbls/hr, but only dechaff 1,500 bbls/hr. The bottleneck operation is dechaffing, and the bottleneck rate is 1,500 bbls/hr. So taking wet and dry processing together, the maximum capacity of processing (destoning, dechaffing and drying) is 1,500 + 600 = 2,100 bbls/hr. Thus, if the plant was running at maximum capacity for both wet and dry processing, the activity with the lowest throughput rate would be quality grading, with a rate of 1,200 bbls/hr. However, 70% of the berries processed by RP1 are supposedly wet berries. RP1 can store up to 4,000 bbls solely with the bins 1 to 16, which can hold only dry harvested berries; on the other hand, it can store a maximum of 1,200 bbls with the bins that are designed only for wet harvested berries (25 to 27). Thus, all the hybrid bins will have to be used to store wet harvested berries in order to cope with the rate of wet berries being received. All in all, RP1 will be able to store up to 3,200 bbls of wet harvested berries; this is less...
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...Harvard Business School 9-898-171 Rev. December 11, 2000 Nantucket Nectars Well, we knew we were in an interesting position. We had five companies express interest in acquiring a portion of the company. Sometimes you have to laugh about how things occur. Tropicana (Seagram) and Ocean Spray became interested in us after reading an article in Brandweek magazine that erroneously reported that Triarc was in negotiations to buy us. (See Exhibit 1 for a copy of this article.) At the time, we hadn’t even met with Triarc, although we knew their senior people from industry conferences. We have no idea how this rumor began. Within weeks Triarc and Pepsi contacted us. We told no one about these on-going negotiations and held all the meetings away from our offices so that no Nectars employee would become concerned. It was quite a frenetic time. The most memorable day was just a few days ago actually. Firsty and I were in an extended meeting with Ocean Spray, making us late for our second round meeting with Pepsi. Ultimately, Tom and I split up: Firsty stayed with Ocean Spray and I met with Pepsi. Ocean Spray never knew about the Pepsi meeting. Tom and I have learned under fire throughout our Nectars experience, but this experience was a new one for us. —Tom Scott, co-founder of Nantucket Nectars Research Associate Jon M. Biotti prepared this case under the supervision of Professors Joseph B. Lassiter III and William A. Sahlman as the basis for class discussion rather...
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