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I will need a report on the attached case study
DSGN 53314 – Process Modeling – Individual Case Study – Winter 2024
Due date: Week 9 Class (see course syllabus on SLATE)
Optimizing Inventory Management at Starlite Toys Inc.
Introduction
Starlite Toys (ST) is a renowned manufacturer of a wide range of toys, including action figures, plush toys,
and board games. Founded over two decades ago, the company has built a reputation for producing
high-quality and innovative toys that captivate the hearts of children and collectors alike. With its
commitment to excellence and customer satisfaction, Starlite Toys has established a significant presence
in the competitive toy industry.
Background and Objective
In recent years, as Starlite Toys expanded its product lines and customer base, the company faced an
increasing challenge in maintaining production efficiency. The company’s leadership recognized the need
to optimize its production process to meet growing demand while ensuring the quality and safety of its
products. Speaking to the production facility manager, the primary objective for the consultants is to
analyze Starlite Toys’ production process, identify the root causes of production bottlenecks, and
propose strategies for optimizing production efficiency.
Below is the initial conversion between the manager and the consulting
firm’s sr. consultant:
Interviewer (I): “Good day, Mr. Smith, I’d like to dive deeper into the production process at Starlite Toys.
Can you walk me through the key steps involved?”
Production Manager (PM): “Certainly. Our production process at Starlite Toys involves several critical
steps. We begin with order processing, where our sales and order processing teams receive and confirm
customer orders.”
I: “That sounds like a crucial starting point. Could you tell me who oversees this step?”
PM: “The order processing team handles this step, and they work closely with our sales team. Once
orders are confirmed, the production planning team takes over to schedule production.”
I: “That leads us to the next step, production planning. Who is responsible for this, and what’s their
role?”
PM: “The production planning team, led by our operations manager, plays a pivotal role here. They
analyze the orders and raw material availability to create efficient production schedules.”
DSGN 53314 – Process Modeling – Individual Case Study – Winter 2024
Due date: Week 9 Class (see course syllabus on SLATE)
I: “Great, and what happens after production planning?”
PM: “After that, we move on to material procurement. Our procurement team collaborates with supplier
contacts to ensure we have the necessary raw materials for production.”
I: “Understood. Let’s discuss the production phase. Who’s involved in this step, and how is
communication managed?”
PM: “Our production workers and machine operators are at the forefront of this step. They produce the
toys as per the schedule. Communication flows with daily production updates shared with supervisors
and the quality control team.”
I: “Quality control is certainly critical. Could you elaborate on how it’s managed?”
PM: “Certainly, the quality control team handles this step. They inspect finished products for quality and
safety, and if any issues are detected, they communicate them promptly to production managers.”
I: “That’s important. Moving on to packaging, who’s responsible, and how do they coordinate?”
PM: “Our packaging team, along with assembly line workers, is responsible for this step. Coordination is
maintained through a steady supply of finished products from production to the packaging area.”
I: “Lastly, let’s discuss inventory management. Who oversees this, and how is communication regarding
inventory handled?”
PM: “Inventory management is led by our inventory manager, and they work closely with warehouse
staff. Communication regarding inventory levels and restocking needs is critical. The inventory manager
communicates these details to the procurement team.”
I: “Thank you, Mr. Smith, for providing a comprehensive overview of Starlite Toys’ production process.
It’s evident that effective communication and collaboration among various teams play a crucial role in
ensuring a streamlined production process.”
DSGN 53314 – Process Modeling – Individual Case Study – Winter 2024
Due date: Week 9 Class (see course syllabus on SLATE)
PM: “You’re welcome. Indeed, teamwork and communication are the cornerstones of our production
success at Starlite Toys.”
I: “Thank you for the insights so far. Now, let’s discuss the decision points or gateways within the
production process. Can you highlight some key decision points where choices need to be made?”
PM: “Certainly. We have several decision points that are crucial in our process. One of the significant
decision points is the ‘Order Confirmation Decision’ during order processing. Here, we determine if we
have sufficient materials and production capacity to confirm customer orders.”
I: “That’s an important decision. Are there other key decision points you’d like to mention?”
PM: “Absolutely. Another vital decision point is ‘Quality Control Approval’ during the quality control step.
We decide whether the finished products meet our stringent quality and safety standards before they
move to packaging and shipment.”
I: “Great, having quality control checkpoints is essential. Now, let’s talk about the human resources
involved. Could you provide an overview of who is responsible for overseeing these various steps?”
PM: “Certainly. Here’s a summary of the key human resources involved:
Order Processing: Sales team, order processing team.
Production Planning: Production planning team, led by the operations manager.
Material Procurement: Procurement team, supplier contacts.
Production: Production workers, machine operators, quality control team.
Packaging: Packaging team, assembly line workers.
Quality Control: Quality control team.
Inventory Management: Inventory manager, warehouse staff.”
I: “Thank you for outlining the key team members involved. It’s clear that collaboration is essential.
Lastly, can you describe how communication flows within the production process? How do these teams
coordinate and share information?”
DSGN 53314 – Process Modeling – Individual Case Study – Winter 2024
Due date: Week 9 Class (see course syllabus on SLATE)
PM: “Certainly. Effective communication is vital for our operations. Here’s how we manage
communication flows:
Orders submitted by customers are electronically received and confirmed during order
processing.
Production planning schedules are communicated from the planning team to the production
floor.
Procurement maintains communication with suppliers regarding material orders and delivery
schedules.
Daily production updates are shared with supervisors and the quality control team.
Quality control issues are promptly reported to production managers.
Coordination between production and packaging ensures a steady supply of finished products.
Inventory levels and restocking needs are communicated from inventory management to the
procurement team.
Order statuses and tracking information are communicated to customers.”
I: “Excellent, Mr. Smith. It’s clear that a well-defined process, supported by effective communication and
collaboration, is key to Starlite Toys’ successful production operations. Thank you for sharing these
valuable insights.”
PM: “You’re welcome. It’s been a pleasure discussing our production process with you. We’re always
striving for efficiency and excellence at Starlite Toys.”
Conclusion
Starlite Toys is at a crucial juncture in its growth trajectory. By addressing the production bottlenecks and
optimizing its production process, the company aims to not only meet the demands of its expanding
customer base but also uphold its reputation for delivering high-quality toys. However, due to limited
time with the manager who is now heading to a longterm leave, the Sr. Consultant has asked the Jr.
Consultant to give a complete report with solutions and next steps. He also mentioned that if anything is
missing to perform a evidence based search to fill those gaps, if any.
Good Luck!