Revere Plastics Case Study

1.Revere Plastic,Process Flow and Project Scope
A. Company Profile
Revere Plastics Systems LLC, an ISO certified company that make commercial-grade and household appliances function are plastic injection molders with presses ranging in 25 – 1,500 tons. It is headquartered in Clyde,Ohio. Revere Plastics has three other locations in Brampton, Ontario and Jeffersonville. The company has a rich client base as listed below:
• Dura Automotive System
• GE
• Whirlpool
• Maytag
• Briggs Stratton
• Grupo Antolin
• North American Lighting
• Kohler Engines Tyco
• Husqvarna and Dura Automotive Systems.

The company’s single largest market is appliances and automotive. Reveres Brampton location with a total of 96,000 sq ft plant size has a total of 116

To study the DRP system at Revere Plastics

2.Inventory Management of finished goods at Revere Plastics with a focus on negative impacts and recommendations
a. Inventory Management of Finished goods

1. Finished goods (plastic components) are packed in carton boxes
2. Each carton box is weighed on a weighing machine and the number of plastic components that goes in one box is set in the machines (Eg-Once the operator fills 1000 plastic components in a carton box, the machine will start beeping if extra pieces are added)
3. Each carton box is filled based on either:
• Size of the plastic components
• customer requirements
• Or the size of the carton boxes

4. Each box is the labelled with a scanned sticker. These stickers are scanned before it is stuck on the box.
5. Each label has a barcode which defines:
• Part name
• Customer name
• Part Description
• Previous quantity (number of plastic components in one box)
• BOM

6. Once a label is scanned at the kiosk it updates the inventory quantity in IQMS( Eg: If one box contains 1000 plastic components and a customer requires 5000 pieces then 5 labels will be scanned by the operator which will update the number in IQMS as

Negative Impacts

1. Within the company of revere plastics, there are inventory inaccuracies, which occur during the end of the manufacturing process.
2. There is a shortage of finished goods on the pallet. The exact number of goods that are supposed to be on the pallet, do not match the actual amount on it.
3. There is an error and discrepancy in this manufacturing process, during the time the product comes off the manufacturing belt, and when it is finally scanned and packaged.
4. These discrepancies have several negative effects and implications on the customers, suppliers, manufacturing, inventory levels, product costs, and employees.
5. In relation to customers and suppliers, they both experience an increase in lead-time when there are inventory inaccuracies. Whenever revere plastics is short on their count, they have to add the missing items to the pallet, this causes a delay in delivery and increases the original lead-time. The slightest delays can have a negative impact on service quality, decreasing the customer’s overall experience.
6. The increased lead-time will affect suppliers by resulting in a decrease or a delay in sales because of the inventory inaccuracies delaying their