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Volvo - Sunwind Volvo is a Swedish multinational which manufactures cars and trucks. Sunwind is one of its suppliers, which supplies door panels for the station wagon models of Volvo’s 240 and 740 series of cars to Volvo’s Torslanda plant in Sweden. Sunwind is a company of some 200 employees, and its product range consists of different interior fittings for the automobile and aeroplane industries. Sunwind has been one of Volvo’s main suppliers since the start. At Sunwind’s Save plant, some 100 Km from Torslanda, the production rate is 2,000 door panels per week for the 740 series and 1,000 for the 240 series. The assembly of panels is done in two assembly lines, one for each model. The panels are produced in eight different variants per line (two different covering materials in four colours). The role of Sunwind was like a subcontractor, as Volvo developed the prototypes and supplied the tools and raw materials to Sunwind. The completed doors with fittings were delivered to Volvo in different containers, each part in its own container. The product being bulky and colour-dependent, a large storage space, both adjacent to the assembly line at Volvo as well as in Sunwind’s own operations, was required. Volvo bought and collected the goods from the Save factory twice a week. Volvo anticipated that the market demand would increase by twice the current production and instructed Sunwind to plan for meeting the demands. Sundwind is now facing the task of planning for anticipated demands and simultaneously address the existing issues of work in progress, shortages, missing parts, congestion and misplacement. Each product has parts processed in the 11 departments which begin at raw material store and end at Dock yard. Each subassembly is produced in batches independently. Figure 1 shows the current layout of the factory. The interaction between facilities can be determined

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