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QSO-700 FINAL PRODUCT MILESTONE
HUSK POWER SYSTEM NEW PRODUCT
SOUTHERN NEW HAMPSHIRE UNIVERSITY
PROFESSOR CHRISTINA BEHLING
OCTOBER 31, 2020
Table of Contents
Project review.. 3
New product features 6
Project Methodology summary. 7
Quality tools and techniques. 8
ProductDetailed and system requirement 8
Production Process Flow Chart 10
Manufacturing Systems. 11
Supply Chain Management 13
Capacity plan. 16
Inventory Management Plan. 19
Staffing Plan. 20
The group has already an existing company (HPS) that produces electricity from burning rice husk for fuel. To create a new product from the residue of rice husk. The critical method for a new product (in this case is toothpaste) in the company’s internal system collected expertise and experience during the course. This project will entail the development of the manufacturing related requirements necessary to support the introduction of the new product (toothpaste). For the manufacturing product scenario, I created a manufacturing and inventory plan that addresses the following: Production Process Flow Chart Manufacturing Systems Supply.
In 2012 four students living in the same rural home area introduced a group, to help the villagers with their problems. The result was to help these students learn and apply their expertise and skills. I was in the part of the group that had to come up with a cheap and locally made toothpaste for the village. In this situation, I recommend the group means of building and establishing strong foundations beyond the reach of financial assistance through proceeds from new goods, purchases, acquisition, or contributions for years to come.
I proposed to grow the group as a small company, a toothpaste manufacturer, to sustain the main product financially. The by-product of the current company phase, there was the creation of the new product. This product is needed because the villagers do not use a comparable product to brush their teeth using wooden sticks. The new commodity is from ashes left after husks have absorbed energy.
Design & manufacture new product (toothpaste) The remaining husk, left by ash after the husks burning to generate energy, needs high-quality toothpaste and quality control. Details of the whole process from ground zero R & D provide the manufacturing department with all the product details, including its value and drawback, cost-benefit analysis, and economic appraisal of the new work, full development schedule.
It is developing a new product (toothpaste) that is cost-effective, a new product economic assessment, and a full manufacturing strategy detailing all operations from ground zero.
Provide safe, filtered toothpaste to the villagers. Generate HPS (By-product) additional profits
Investors Staff Workers Villagers Community members
New product (Toothpaste) compliance with (ADA) American dental association
The project manager/team has no know-how or expertise to start and monitor the project. high prices due to a miscalculation of prices Risk timetable (activities take longer than anticipated) Risk of performance (product not meeting specifications) Economic vulnerability (strategic errors) Risk of governance (bad performance board and management) Risks of the market (competition, the chance of interest rate,)
Project manager authority
They will be acting on behalf of the HPS or as a project sponsor manager. They will allocate roles and milestones given in compliance with the mission and communications schedules.
Purpose of this charter
Provide a rough definition of the position and responsibility for outlining the project goals.
Report approved for project guidance Manager, project managers responsible for project implementation and monitoring
Is a map to convey the message to all parties Requires stakeholders participating in a project that is vital to any project.
New product features
The group has an existing product from the production of electricity from husks. The byproduct is the ash that will be the raw materials the that will be used in the production of toothpaste. The group intends to use these remaining to generate sales of toothpaste. The new product’s production will open a significant market between villages, where advanced toothpaste products are not yet familiar. People are still using tree stems’ wood sticks to brush their teeth will expand in the village lifestyle. Activists and researchers suggest that the villagers in many parts of India are unaware of oral treatment. The new product addresses the financial challenges and education as afar as teeth cleaning is concerned. It also helps the company profit from the waste of the existing process, using minimal toothpaste production. The firm also has a problem selecting a method for extending electricity generation and generating more electricity as a limited power scheme.
The group of four started with electricity production from husks. Husk is around 20% of the weight of the paddy. In 2008, the output of paddy worldwide totaled 661 million tons, with rice husk produced by 132 million tons. While rice husk is also often used in the rice mill as a waste product and therefore often either is burned openly or discarded on wasteland. Husk has a high heat content and can therefore be used as a green energy (Quispe, et al., 2017). The Company’s four creators, all together, began to do everything to their benefit. As many people live in a developing country like India, with many rural villages and close to millions without electricity access, we are built to provide safe, environmentally responsible, and productive enterprises. The management process and operation that the organization offers are at varying stages of defining, evaluating, preparing, and processing in a team. The group must have leadership and staff to continue doing business for the existing and new products.
To introduce a new product the group needs a lot of research and preparation to create a small-scale product, as consumers are farmers with a population of 200 to 500 people in each village. Our project would meet the first demand for 10,000-20,000 inhabitants. The manufacturing schedule will begin with selecting the factory site, identifying the raw materials’ source, as certain chemicals to be in use for the product are part of the process. The produce, supplies, packing, and marketing need employees too.
Project Methodology summary
I have implemented the waterfall approach, which breaks down initiation, drafting, preparation, research, design, development, quality control, and monitoring processes into comprehensive and sequential tasking. Each task is begun and finished by a given date; the previous finishing task guarantees the start of the new scheme (this means the last assignment will directly impact the next job, affecting the whole project). Every task at hand has its date of starting and ending. From the Gantt chart, there are 15 different jobs. From these jobs, each has two dates (start and finish), the Identification number or task number, the name of the task, period of the task, and the task’s mode. Every task has a hand of contribution to the final project. For any purpose, it is contingent on the completion of the previous job. The business atmosphere also leads to the right product (labor climate, business task, meaning, ethics, anticipation, and goal).
Quality tools and techniques
Many companies are faced with many different challenges in their ability of tracking the quality of their products. In facing these challenges, they will employ a quality tool track to assist them in gauging the total quality during the production phase. The key is to be familiar with all these quality tools and relaxed so that you can withdraw them from the toolbox when a challenge needs to be solved. Value control tools help workers recognize common issues and the root causes of them (Castello, et al., 2019). Quality control tools allow workers to interpret the data and to define procedures for fixing errors and for finding solutions to issues.
I will use Total quality management in my project by reducing the product defected to make the correct time. TQM is a structured method for all business control to increase the consistency of continual product changes. TQM lets the business do the same things right and saves time and expense of repairing a defect product. This kind of quality management continuously improves quality by concentrating on customer requirements, demands, and specifications (Castello, et al., 2019). It represents a management philosophy that integrates the entire organizational department (design, planning, technology, marketing, manufacturing, sales, and services). Also, VSM is an efficient method designed to capture task steps/activities, knowledge flow, and related data that introduce and enhance product operation (Castello, et al., 2019). VSM is also a valuable instrument for identifying waste, minimizing operation cycle times, and optimizing processes.
ProductDetailed and system requirement
Toothpaste is a gel used to disinfect and keep the tooth healthy; it has a component that can help to extract the plaque of a teeth from the enamel, which is fluoride (Todkar, et al., 2016). It is the most active component that leads to prevention of tooth decay; and can be present in plants and animals which has various forms of fluoride, such as sodium fluoride among others.
Wake up in the morning and take part in boring tasks like fixing the bed, hopping into the cold water, running for breakfast, or even avoiding breakfast may be hitch hopper. But when it is time to pick up your toothbrush in this part of the daily ritual, squeeze the toothpaste tube into the toothbrush and brush your teeth. It’s time for the day to finally start looking fresh.
During our daily lives, the ability to have tubes of toothpaste readily available becomes vital for the oral health. The various formulations, the efficacy and consistency of toothpastes are considered, each with distinct characteristics. Its absolute utility in teeth safety and embellishment depends, ultimately, on the efficiency and accuracy of these mixers in our food stores in refining and producing these toothpastes.
Toothpastes are primarily made up of the following in various quantities in a company: binders, shudders, abrasives, wetting agents, cleaners, sweeteners, fluorides, whiteners, preservatives, and water. Hydrated silica, calcium and bicarbonate sodium are fillers and abrasives that are also required in toothpaste. Its function is dealing with plaque and release the particles on your teeth; another ingredient is the fluoride like Sodium Perborate that is used in preventing decaying of tooth by increasing the teeth strength. Sodium lauryl sulfate is an example of Sudsers that is used in making foam in the product foam (Todkar, et al., 2016). Without a flavor the toothpaste is good to be used, Flavor like Mint or bourbon among others can add test in the toothpaste. This Contributes to freshness alongside the palatability of the paste (Price & Giniger, 2019). To prolong the shelf life of toothpaste, sodium benzoate can be used as Preservative. The last requirement is to give the toothpaste the color, where a coloring agent can be used.
The following steps are defined as the normal process of mixing the above toothpaste ingredients. First, liquid ingredients like water, sorbitol / glycerin are packed. Powdered components are combined dry with other components. The next step will be the sweetener and the preservation. The solvent base is applied to the premixed abrasive / filler then Added fragrance and coloring. Finally, the detergent is applied to reduce foaming during slow speed mixing.
The new production method is seen in the flow chart (toothpaste), accompanied by production steps. The ingredients and components are applied and combined to produce the new product by applying rice ash; residue remaining from the rice ash to be burnt and then dried and categorized using the sieving technique(Todkar, et al., 2016). Production steps will accompany the process and procedure. To make fair use of energy, rice husk ash, and whiten the toothpaste are the primary commodities and are among the essential components.
Production Process Flow Chart
The process flow for the above new product has a new wave of product concepts and the overall strategy for the toothpaste’s latest production. In this process, it is recommended to follow the sourcing process by a contract with suppliers to supply the appropriate materials for the new product’s output. The latest development is on the stage where separate parts, including the plastic sheet around the scale’s operating channel, are joined. For confirmation and certification, the finished product is monitored by the quality management team. Once both are finished, after all the planning for product release, the new toothpaste is ready for the market (Malea, 2017). The whole process for the latest product development completes the product launch period.
Figure 1: Production process flow chart
There are several schemes, each with its optimal case and collection of advantages and drawbacks. A good manufacturing system will offer positive benefits for providing an acceptable project production method, including the potential to have a high product quality. There are several production processes, such as assembly lines, batch processing, and computerized production (Hitomi, 2017). Four different kinds of production systems are usable, constant, sporadic, versatile, and customized.
The product’s construction includes manufacturing specifications or processes to satisfy consumer needs. The method to be used for this purpose is a continuous system for the new product (Gershwin, 2018). In the continuous system, the work to be manufactured is under processing, in various phases of operations like most other goods (Hitomi, 2017). The product is assembled in a continuous phase. The current work prevents conflict with the existing product’s consumer order, owing to the toothpaste’s new characteristics with the sheath concept.
Since the Sheath concept of toothpaste’s high efficiency will automatically satisfy the expense of consumer demands, incorporating the continuous manufacturing system will allow the use of unique equipment methods designed to reduce production costs (Gershwin, 2018). Besides, the workforce’s output activities are in groups of comparatively little parts that can be learned and executed effectively.
The new product (toothpaste) requires distribution processes that shift the work down a separate assembly line; the staff will combine multiple components to manufacture the product. The existing product that the company is working on is electricity; it will save the group the costs of buying electricity elsewhere. With these, the group can concentrate on other requirement of manufacturing toothpaste.
After mixing the components of the toothpaste, the next step is shipping the blend to toothpaste tubes. The new step also needs some new work. The necessary step of packaging the toothpaste is taken into consideration like compliance with the consumer needs and the business’s manufacturing capacities. This will improve the toothpaste’s production capacity.
Supply Chain Management
Supply chain Management, shortened as SCM, is essential in boosting the business performance, maximizing the success, satisfying the consumers, and sustaining its competitiveness (Kshetri, 2018). According to (Tseng, et al.), (2019) a well-organized SCM allows the organization to deliver the goods quicker and more cheaply. The project manager must coordinate with the supply chain to ensure vendors have to provide the specified products in a proper order to provide good quality at a good time. Supply Chain management must consider all suppliers, distributors, bulk distributors, and warehouses.
Vendor Managed Inventory (VMI) is a supply chain management strategy that uses technological innovation to promote new goods by offering efficient inventory management. “The paper-free, streamlined storage with continuous monitoring service allows cost-saving and deliverable, VMI methods like Kanban or Two Bin”(Sainathan, & Groenevelt, 2019).
In addition to strengthening current inventory control, the VMI supplier’s chain system or solution would also minimize the lead time needed to provide material for the new product creation. Han,et al., (2017) claims that the introduction of the VMI method not only lowers stock levels by about 80 percent on hand but removes logistical burdens, including the production of buying orders, inspection, and handling of goods, as well as forecasting.
Working in progress (WIP) is another method to inventory the production chain to handle and conduct the inventory of items. WIP Estimation is exceptionally critical since the actual stock and the products’ expense could be undervalued, understated, and unsustainable if this is not measured and reported on the business balance sheet. Furthermore, a high WIP is an indicator that the manufacturing mechanism may not fluidly; therefore, specific bottlenecks in the whole mechanism may be detected (Han,et al.,2017). It will help detect and fix any issues relevant to the manufacturing process by keeping track of WIP.
Vendor Managed Inventory (VMI) is an efficient approach to managing and purchasing inventory. The VMI is the contact separate from conventional purchasing between vendors and consumers (in stores, retailers, or end-user projects). VMI assists the company in communicating with vendors and consumers, enhances revenue, strengthens customer services, and handles inventory efficiently and reliably (Sainathan, & Groenevelt, 2019). Helps in product growth, prevents long lead times, and VMI timetable creation further helps with product development. It can reduce company costs (purchasing orders, store inspection costs) by keeping production on schedule and saving long lead time.
The two-bin inventory management system decides where the manufacturing products are to be loaded up. Kanban is correctly controlled the same way as the inventory method associated with the just-in-time (JIT) method. WIP’s cost includes raw materials’ prices, labor costs, and depreciation costs for a production facility (López-Ramírez, et al., 2017). All these facilities must be included in the new product and, in the meantime, require WIP’s cost time to measure the final costs because so many businesses are seeking to stop this meantime or reducing inventory amount.
The project manager will be in coordination with the sourcing service to ensure that the product management approach is reviewed (Sainathan, & Groenevelt, 2019). The materials have no long lead period so that we do not face long lead period items that can harm the date of completion of the project.
The project manager will collaborate with the service supply chain team to ensure that bottlenecks that can interrupt the distribution of parts are quickly corrected. The project manager and the management staff can work closely to define all procurement systems required to execute the project successfully (Sainathan, & Groenevelt, 2019). The Project Manager and the Sourcing Team will work closely on assessing acquisition techniques, such as the Manufacturer Managed Inventory and current work.
Again, the company may have to deal with both upstream and downstream consumer requests to efficiently handle inventory movements in the product production supply chain. In essence, this would allow the business to strike a considerable balance to meet consumer needs, which in most situations is difficult to anticipate with precision or accuracy while ensuring that products and goods have sufficient supplies (Sainathan, & Groenevelt, 2019). By strategic knowledge sharing, the organization will maintain this balance and enhance inventory management.
If a straightforward selection procedure is required, the Project Manager must propose any chosen approach, vendor, or another external resource. The project manager will also track the success as it applies to the method of contracting and distributor delivering required products and convey this to the buying committee and contracts. Again, the project manager will ensure that current contracting processes are reviewed and send to contracting committees by the Program Management Office (PMO). The essential purpose is to ensure that the time taken to bring components to the manufacturing process is minimized in the supply chain.
Figure 2: Supply chain
Capacity preparation is a method of deciding the industry’s production capacity to support the order in hand and any changing demands for the products. Productivity means the maximum amount of output that the company can produce in each period. A change in the company’s capacity can be done via labor increment or even material addition, change in capacity plan. The organization will require a strategy of production that needs a forecasting strategy (Hamling, 2020). This new product (toothpaste) has the market forecast as well as the production forecasted.
A central aspect of a business study is a market forecast. In the target market, it forecasts future figures, and patterns (Yildiz & Savelsbergh, 2019). A typical analysis indicates the number of prospective buyers expected (for the next 6 months) over a fixed period. There are 10 000 villagers (2 percent in the next six months), which is the increases. They will have about 10,200 customers in the next six months in group’s estimates. There are estimates; no one knows exactly but at least they are informed conclusions. The group also did market research, and this optional number of customers eventually was the result of their market analysis.
Wishart, (2019) defines capacities planning as “the process by which a company needs to determine production capacities to meet its product requirements.” Capacity must be strongly demand-projected for this new commodity. It can be done by increasing the capacity to meet market requirements in measured quantities, as the sales department forecast (Wishart, 2019). The staff’s ability to be flexible or the installations’ ability to be flexible can satisfy demand should be flexibly augmented on request. It relies heavily on predicting and reliable details, so investment decisions on the Sheath System’s current fiberscope adhere to the business provides (Wishart, 2019). On the other hand, failure to accurately forecast could result in lost market share or unnecessary capital opportunities.
The following formula can calculate the production capacity of this new product:
The number of Sheath Machine fiberscopes annually or more can be calculated depending on available time and money. Each product needs to spend 140 minutes, 240 workdays a year except weekends, 80 working hours for two shifts, at least 2 15 paying minutes and 30 minutes per shift = 14 hours a day, or 70 hours a week.
Then, capacity = = 7,200 of the new sheath system fiberscopes per year.
As a new product production capability, 7,200 sheath fiberscopes are expressed. This estimate implies that the product production team is thoroughly trained. If we hold the production for the following five years, then we have generated fiberscopes for the sheath device of 7.200 x 5 = 36.000. The capability plan for the next ten years will be extended in the following table, based on the above formula:
Ability preparation limitations include a scarcity of parts that can boost the amount of time expended on each product, extremes that can result in a business shut down for a full day or a few hours, and staff that call out ill in job insufficiency.
Figure 3: Population Forecasting
Inventory Management Plan
A successful inventory management strategy that lets the company efficiently finish production and satisfy clients with the correct product, the right information and requirements is significant (Chu et al., 2019). It also helps the company save money by minimizing loading or loading to reduce this harm production and meet consumer demand.
It involves monitoring the inventory of the business’s goods, ensuring that the best items can be at the correct location and the right price (Chu et al., 2019). Inventory control techniques are five different:
The analytics of Data
The best software for inventory optimization.
The inventory control system has an automated capability.
Integration of mobile technology
As inventory control methods, I consider using data analytics. Data analysis can forecast consumer needs and expectations to help the business change its stock by increasing or decreasing the inventory. Data analytics can reduce surplus stock, which improves cash flow and liquidity (Chu et al., 2019). Data analytics can estimate the exact product volume on hand and deter unsustainable stock or stock deficit. Through minimizing the discount, data analytics will increase the benefit ratio. The business will estimate revenue for the next two years through data analytics.
A personnel strategy is a set of protocols and instructions for ensuring that the company takes two crucial actions:
1. Numbers were met or taken care of in roles and events.
2. Various skills and knowledge staff for this new product are accessible and ready.
3. Helps HR practitioners to learn the requisite skills to complete the work.
During expenditure periods, the hiring schedule may assign variable expenses to the right types of accounting (Hunt, (2018). To plan a personnel plan, we must work together with Power System divisions, departments like Marketing and Operation, Research and Development, HR.
The management will form a cross-functional team from various divisions within the context of R&D, Quality Assurance (QA), marketing, and operations (corporation engineering, research, and development). The team members learned about the new product concurrently and began to collaborate on forecasts. The production phase will include all sales workers, and where there are human resources limitations, human resources will approach workers to establish additional roles and hire for production support.
Figure 4: Staffing Chart
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