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Case Assignment

HWMR Manufacturing is undergoing a strategic overhaul of its production process to address challenges such as bottlenecks, underutilized resources, and excessive waste. The management team is considering adopting new process types and workflow analysis techniques, as well as optimizing resource utilization through capacity planning models. Additionally, the company aims to effectively implement lean principles to reduce waste without overburdening employees and is exploring options to improve throughput at critical bottlenecks.

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Krystele Mae Lauron
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6 views4 pages

Case Assignment

HWMR Manufacturing is undergoing a strategic overhaul of its production process to address challenges such as bottlenecks, underutilized resources, and excessive waste. The management team is considering adopting new process types and workflow analysis techniques, as well as optimizing resource utilization through capacity planning models. Additionally, the company aims to effectively implement lean principles to reduce waste without overburdening employees and is exploring options to improve throughput at critical bottlenecks.

Uploaded by

Krystele Mae Lauron
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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BA 24 – Operations Management

Case # 2 Assignment

Instructions:
- Deadline (February 07, 2025. 12NN)
- By Group
- Sent it to my xu-mail.

Case Problem Scenario: Process Design and Analysis

Scenario:

HWMR Manufacturing is a mid-sized company that produces customized auto parts. Due to
rising demand and competitive pressure, the company is undergoing a strategic overhaul of its
production process. The management team is analyzing its process types and workflows,
capacity planning, and lean system implementation to improve efficiency and cost-effectiveness.

Recently, the company has faced challenges such as bottlenecks in production, underutilized
resources, excessive waste, and long lead times. The leadership team has hired a process
improvement consultant to evaluate these issues and propose solutions.

Questions:

1. (Process Types & Workflow Analysis)

HWMR Manufacturing currently follows a batch production process, where customized


auto parts are produced in lots before being moved to the next stage. However,
customer demand has become unpredictable, leading to delays and high work-in-
progress inventory.

Which process type should the company consider adopting to improve responsiveness
and minimize delays, and what key workflow analysis techniques should they use to
assess the impact of this transition? Provide a detailed explanation.

Process management is a systematic approach that emphasizes on monitoring, designing,


monitoring, and optimizing business processes to achieve specific organizational goals. It helps
organizations to optimize their operations that inclines with strategic objectives that allow them
to adapt effectively and efficiently to changing conditions effectively. The process type that
should be adopted is to define success metrics to measure the success of the optimized process
including;
 Key Performance Indicators (KPIs) such as cycle time, error rates, or customer
satisfaction scores. In identifying these success metrics, it allows the business for better
tracking of improvements and outcomes that can improve its responsiveness and to
minimize delays.

Workflow analysis is a process of improving and evaluating g the sequence of tasks and
activities, and interactions that constitute a specific business process or function within an
organization. It aims to gain a detailed understanding of how an operation is processed that can
identify areas where processed can be automated or optimized to achieve greater results. The
key workflow analysis techniques that should be applied are;
 Flowchart: simple visual representation that uses standardized symbols to visually
represent the sequence of tasks and decisions in a workflow. This helps the business in
understanding the work structure, identify issues that enables the business for
opportunities of growth.
 Process Mining: This technique is based on data that uses event logs like start date or
due date to analyze, track, and improve business processes. It will help the business to
discover misstatements, errors, identify problems that can optimize process
performance.

Kashyap, S. (2025, January 22). Workflow analysis: A complete guide to optimizing your business
processes. ProofHub.
Hartshorne, D. (2024, December 15). 15 Process Management Strategies to Transform your
business. monday.com Blog.
Kashyap, S. (2025, January 22). Workflow analysis: A complete guide to optimizing your business
processes. ProofHub.

(Capacity Planning & Resource Utilization)

After evaluating production efficiency, the consultant found that machine utilization
rates are inconsistent—some machines operate at 120% capacity, while others are idle
30% of the time. Additionally, the company has identified a critical bottleneck at the
finishing stage that delays order completion.

Using capacity planning models, how should HWMR Manufacturing optimize its
resource utilization and resolve the bottleneck? Justify your answer using relevant
capacity planning techniques.

Capacity Planning Model refers to a strategic plan organizations use to identify and
improve current and future staffing needs. There are various factors that capacity
planning model considers such as human resources, time and skills, and financial
constraints that balances availability with actual demand. It sustains an organizations
day-to-day operation, resource planning, and growth initiatives. Relevant capacity
planning techniques that will help HWMR optimize its resources utilization are;
 Lead Strategy: This consists in anticipating demand and expanding capacity before it’s
needed. This is utilized to maintain a competitive advantage and capitalize on market
opportunities.
 Lag Strategy: When demand is established, only then lag strategy adds capacity. This is a
reactive approach that reduces the risk of excessive investment when it comes to
demand production.
 Match Strategy: This is a strategy that intends to perfectly balance resources with demand
through incremental changes. This is best applied in organizations that has a solid control
over their capacity to produce products and also future demands.

2. (Lean Systems & Waste Reduction)

The company implemented lean principles to reduce waste, but after three months, they
observed no significant cost reductions and increased employee fatigue due to higher
workloads. Management is concerned that the lean system may not be effectively
applied.

Identify potential misapplications of lean principles in HWMR Manufacturing and


recommend a structured approach to ensure waste reduction without overburdening
employees. Use lean tools such as Kaizen, 5S, or Value Stream Mapping in your analysis.

3. (Workflow Bottlenecks & Throughput Improvement)

Data shows that the production line's average lead time is 18 days, but customers are
demanding a 10-day turnaround. The bottleneck occurs at station B, where a specialized
quality inspection takes longer than expected. Management is considering adding more
workers or automating the process.

Compare the two options in terms of cost, impact on throughput, and alignment with
process design principles. Recommend the best approach with a quantitative
justification.

4. (Integration of Lean and Capacity Planning)

The consultant suggests integrating lean principles with capacity planning to maximize
efficiency while maintaining flexibility. However, management is hesitant, fearing that
reducing excess capacity could lead to delays when demand spikes.

Propose a hybrid strategy that combines lean thinking with strategic capacity buffers.
Use real-world examples from industries that successfully balance lean efficiency with
capacity flexibility.

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