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Scharffen-Berger Chocolate Maker

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Hechos * Jim Harris jefe operativo de Scharffen Berger con una antigüedad en la empresa de 18 meses. * Empresa fundada en 1996 por Robert steinberg y John Steinberger su objetivo principal era de producir chocolate de la mejor calidad posible a partir de los mejores granos de cacao disponibles. * La industria del chocolate estaba segmentada en 2 categorías: masivos y Premium, el mercado masivo con una valor de 14 mdd, estaba dominado por Hershey y por Nestlé ambos con un 75% del mercado. * Scharffen Berger competía en el segmento Premium del mercado con un valor de 1.2 mdd. * Las ventas Scharffen Berger crecieron de 1.1 mdd en 1999 a 15 mdd en el 2005. * El producto más popular de Scharffen Berger era la barra de chocolate agridulce de 3 oz. * La venta se hacia atraves de 5 tiendas detallistas y 4 mil expendios distribuidos principalmente en áreas urbanas y adineradas. * La planta tenía un área de producción de 1,800 m2, 450 m2 de oficinas y 180 m2 para la venta de tienda directa. * El flujo de producción era el siguiente: Con la maquina limpiadora de grano de cacao la cual limpiaba un promedio de 48,000 kl semanales. * Después de limpiados se pasaban a la maquina tostadora la cual identificaba el sabor, maquina antigua que solo tostaba 10,000 kl a la semana. * Ya tostado el grano se pasaba a una maquina descascaradora la cual separaba la cascara de la pepita de cacao, esta máquina tenía una capacidad ociosa de 200 kg. Por hora. * Pasado el proceso anterior las pepitas de cacao se llevaban a la maquina mezcladora donde se trituraban para liberar la manteca de cacao y convertirlas en pasta de chocolate. * El siguiente paso era refinar las pastas de chocolates en las dos maquinas refinadoras con las que contaba la empresa, en este proceso se incorporaban otros ingredientes como: vainilla, azúcar y lecitina Problemas

Sesión: PRODUCCION Y ENTREGA DE PRODUCTO... Caso: SCHARFFEN-BERGER CHOCOLATE MAKER Equipo: 3 - EQUIPO 3

* Aumentar significativamente la capacidad de producción y mantener simultáneamente la calidad de los productos. * Duplicidad de los pasos de templado y moldeo, ya que lo realizaban en la fábrica y con los empacadores externos. (Como optimizar la producción minimizando tiempos) * No hay programa de producción proyectado.

dependiendo el producto que se quisiera fabricar. * El templado era el proceso en el que el chocolate líquido se llevaba al estado sólido donde * Para mayo del 2005 solo el 35% de la producción se empacaba en la propia fábrica, el 65% restante se enviaba a empacadores independientes. * Por lo menos 2 veces por mes los gerentes y operarios de las maquinas se reunían para evaluar los estándares de calidad mediante pruebas siegas.

Alternativas de Solución * Estudiar y analizar todo el proceso de producción para determinar posibles desviaciones que actualmente puedan ocasionar una calidad no aceptable en los productos terminados, si se mantienen los procesos claves, adquiriendo equipos más modernos y con mayor capacidad de producción, pueden en combinación producir más y no demeritar la calidad de los productos. * Que todo el proceso de empaque se realizara directamente en la fábrica. A1 Introduciendo dos molinos de bola para incrementar capacidad A2 Mandar 100% empaques maquilados externos, estándares de calidad. + Proyectar ventas a 3 meses para programar producción con maquina de bola.

Análisis de alternativas Ventajas * Al crecer la planta productiva se estará en condiciones de comercializar, innovar e incrementar la presencia en el mercado de los productos. * Al crecer e incorporar todo el empaque en la misma planta se puede garantizar que el proceso de producción se lleve a cabo sin ninguna desviación con los más altos estándares de calidad. A1 El tiempo de refinado se reduciría, aumenta caácidad producción, resto de las máquinas trabajan a máxima capacidad A2 Reducir gasto de sueldos y tiempo de este proceso. Desventajas (Riesgos o Requerimientos) * No contar con la maquinaria adecuada para poder lograr los niveles de producción que se requieren, ya que en este momento la demanda está superando la oferta. * La inversión y la adecuación de la planta productiva para incorporar más procesos de los que actualmente no cuentan. A1: Inversión adicional Acciones para reducir los riesgos * Realizar un plan de reingeniería por faces para modificar la planta productiva incorporando maquinaria nueva de manera tal que la operación se afecte lo menos posible. * Levar el proceso de empacado de manera paulatina a mediano plazo para incorporar este nuevo proceso sin afectar las operaciones o los procesos ya establecidos. A1: Negociar financiamiento costo máquinas. A2: Resto de maquinan a total capacidad

Sí yo fuera responsable de tomar la decisión final, ésta sería: * Una vez teniendo los volúmenes proyectados por línea, definir plan para Invertir en la adquisición de maquinaria que me garantizara una capacidad de producción que cumpliera con la demanda actual y los posibles incrementos en la comercialización de los productos, todo esto atraves de un plan de reingeniería muy bien analizado el cual provoque los menores trastornos en las actividad ordinarias de la planta productiva.

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