Making operations better, and planning for what can go wrong
A dairy plant in Gujarat that cannot keep up in summer
| Step | Machines or packing stations | Bottles per hour, each | Step capacity per hour |
|---|---|---|---|
| Fill | 2 | 3,000 | 6,000 |
| Cap | 1 | 7,000 | 7,000 |
| Label | 1 | 4,500 | 4,500 |
| Pack into crates | 3 | 1,800 | 5,400 |
The prompt
A dairy in Gujarat, India bottles flavoured milk. In summer, shops want 5,500 bottles an hour, and the plant runs 16 hours a day. Each bottle earns INR 6 of contribution (price minus the costs that move with each bottle). The steps, machines and rates are in the table with this case. The plant manager wants to buy a faster filling machine. What should the dairy do? (The dairy is fictional and the figures are illustrative.)
Before you reveal anything, plan your own structure and first move on paper. Then reveal one part at a time and compare.
Clarifying questions, with the interviewer's answers
The exhibit
| Step | Machines or packing stations | Bottles per hour, each | Step capacity per hour |
|---|---|---|---|
| Fill | 2 | 3,000 | 6,000 |
| Cap | 1 | 7,000 | 7,000 |
| Label | 1 | 4,500 | 4,500 |
| Pack into crates | 3 | 1,800 | 5,400 |