10 Alternatives that you can use to solve a problem of: optimization of the raw material reception service in the "INGENIO" by using some suitable software.
The problem in this factory is as follows:
In the "INGENIO", in the area of reception of raw material (sugar cane) problems have been registered at the time of receiving said material, since sometimes more tons of cane cannot be received in the same day, registering too many cars in the row.
Due to the varied climate change, it causes the raw material to spoil or lose the sugar concentrate it has.
This problem causes both the producer and the mill itself to lose production and therefore profits.
Problem Solution Table.
The following table shows some alternatives that may help us to solve this problem, making it less expensive or cheaper.
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ALTERNATIVE |
ADVANTAGE |
DISADVANTAGES |
|
JUST IN TIME Work philosophy: "raw materials and products arrive just in time, either for manufacturing or for customer service." |
Reduces the necessary inventory levels in all steps of the production line and, as a consequence, the costs of maintaining
higher inventories, purchasing costs, purchasing financing and warehousing costs, and minimizes losses due to obsolete supplies. requires) the development of a closer relationship with suppliers. Shortening of delivery time, among others. |
The danger of problems, delays and suspensions due to lack of supplies, which can cause delays and suspensions of the production line and negatively impact expenses. Limits the possibility of reduction of purchase prices if purchases are of low quantities although, depending on relationship
with the supplier, this disadvantage can be mitigated. |
|
KANBAN It uses cards that are glued on the material containers and that peel off when these containers are used, to ensure the replacement of said materials. The cards act as a witness to the production process. Other more sophisticated implementations use the same philosophy, replacing the cards with other flow visualization methods. |
Reduce or eliminate intermediate stock (between processes). Meet the delivery times demanded by the client.
Improve product quality through better detection of product defects. Avoid excessive handling of materials. Facilitate production control. Obtain a flexible production system according to demand. |
Too long a lead time precludes the choice of the Kanban method. Well, it would have very unemployed
workers. The system has no anticipation in case of very large and unpredictable fluctuations in demand. You can anticipate them but not fix them. It is difficult to impose this method on providers. Applications are limited (only for continuous or repetitive production). The KANBAN method is applicable to "mass" type productions for which the number of references is not very high, and the request is regular or with low variations. |
|
MRP Its purpose is to have the required materials, at the right time to meet the demands of customers. The MRP suggests a list of purchase orders. Schedule purchases from suppliers based on scheduled production. It is a system that tries to make three main objectives known simultaneously: Ensure materials and products that are available for production and delivery to customers. Maintain adequate inventory levels for the operation. Plan manufacturing activities, delivery schedules, and purchasing activities. |
1. Ability to set prices in a more competent way.2. Reduction of sale prices.
3. Inventory reduction. 4. Better customer service. 5. Better response to market demands. 6. Ability to change the master schedule. 7. Change order quantities |
The main problems of MRP are based on the failures of the installation process, the main factors are at the organizational and behavioral level. Three main causes have been identified: Lack of
commitment from senior management, failure to recognize that MRP is just a software tool that does not generate decision-making, and integration of MRP and JIT. The second cause of The problem is that MRPs were presented and perceived as a complete and unique system for managing a company and not as a part of the total system. |
|
Prognoses It is used to forecast the demand in this case of raw material required for the production of sugar |
The demand for raw material would be more easily predicted so that raw material is not in stock and that it spoils
. |
It would be very tedious to be forecasting daily demand for raw materials. |
|
WAREHOUSE. Rent or build a warehouse in which the raw material is stored without being exposed to the change in temperatures and thus can have the degree of sweet that is needed. |
It would be an easy way to save the raw material that is good and we would save on gasoline for the cars,
we could also use the cars for other things. |
Greater investment Greater use of space.
Increase in inventory costs |
|
RAW MATERIAL INSPECTION. See if the raw material is ready to be cut and taken to the factory for processing. |
It would be easier to know how much raw material will arrive and how much will have to be produced so that it is not
wasted. |
Daily inspections would need to be carried out and that would imply a cost which, perhaps for the company, is not feasible. |
|
THEORY OF TAILS Mathematical study of queues or waiting lines within a system. This theory studies factors such as the average waiting time in queues or the working capacity of the system without it collapsing. |
It is possible to know more exactly what time it will take for a car to enter. | Low application |
|
SIMULATION Simulation of a process by means of a computer for analysis |
Optimize the process or speed it up and thus be able to receive the raw material faster. | Investment Training |
|
BOARD OF INSPECTORS |
Decide and plan how the raw material cuts will be by area, making sure that the raw material is already ready to
be cut. |
Consecutive meetings Greater availability in offices. |
|
SCHEDULE OF ACTIVITIES |
Greater insight into what is needed and on what date. | Constant review. |
