February 4, 2013
Riordan Manufacturing is a worldwide company that specializes in the manufacturing of plastics. The company has projected yearly earnings of $46 million and employs over 550 personnel. Riordan’s development and research is conducted at its headquarters in San Jose. The company owns three major producing plants: Albany, GA produces plastic beverage containers; Pontiac, MI produces custom plastic fabrication, and Hangzhou, and China operates a decentralized unit of the company producing plastic parts for electric fans. In the creation and development in the process design for Riordan’s fan production operation, it is important to install a production system that addresses a variety of aspects for production, including total quality management, material requirements planning (MRP), process design, supply chain global opportunities such Six Sigma, production forecast, and a implementation plan. Total Quality Management
In Riordan’s Manufacturing mission statement, the principal focus is a lean Six Sigma (U of P, 2002). Six Sigma is a very ingenious way of branding and packaging (business balls). It emphasizes on fast delivery and minimizing costs, while providing the highest quality products to consumers. The consumer needs is the drive behind Six Sigma and the determination of what the consumer actually wants and what is relevant to process improvement. Analyzing production data and process workflow would make for improvements in the process and delivery speed. This process would improve consumer relations and increase profitability. Riordan Manufacturing Six Sigma projects should begin with focusing on the wants of the consumer and studying the actions of the consumers when comparing competitors to the company. Riordan Manufacturing Six Sigma is based on production efficiency data, production numbers, and workflow processes. The company must concentrate on its operations in China so that they can be more efficient when using more resources. These resources would be able to track and monitor relevant data that’s specific for process and order flow. This method would involve: receipt of components by truck, molding the blades for the electric fans with colored pellets, clearing blades of excess trimming, assembling the entire units (blade, housings, and motors), packaging and shrink-wrapping the product, and releasing to be loaded and shipped to the consumer. Riordan production strategy is effective but there should also be a well-documented template (checklist) to keep record on how the work is being done and how the amount of work moves between employees and workstations. A change in the process improvement would be to merge the molding and trimming processes into one area as well as merge into one area packaging and conveying. With these combining efforts and improved communication, training and empowerment of the Chinese employees over their job functions would improve efficiencies and reduce operational expenses. Material Requirements Planning
Material Requirement planning or MRP is considered mostly valuable in organizations that produces more than one produce with one equipment. Generally MPS is breaks down a master production schedule and sorts them into their component parts and creates a sub component to make a materials plan. This ensures each parts inventory and what needs to be replaced to complete which ever products are being produced. Most manufacturing companies such as Riordan have MRPs in place to help with parts inventory and to keep track of items produce within the company. The first step in increasing sales and enhancing productions for Riordan is a successful MRP plan. Currently riordan is having trouble with its current model because it inventory stock system looks at prior year sales. By implementing a new system that will take the production of Riordan’s fans and...