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APPENDIX I

CASE STUDY 2: RUBBER EXTRUSION PLANT

Setting

A tier-1 automotive supplier was in the process of expanding one of its manufacturing plants. To support higher levels of production in the expanded plant, four new extrusion lines were going to be added (taking the number of lines from three to seven). Large reductions in work-in-process inventory were required to facilitate this expansion (due to floor space limitations and working capital constraints). Additionally, the ability to mold extruded rubber parts decreases as the parts age, with the secondary molding operations experiencing higher rates of scrap the longer the extrudate ages. ...

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