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Easy Operations

Bumpers R Us

#Manufacturing
ProHub Comment

This is a well-structured operations case focused on process bottleneck identification and optimization. The case tests candidates' ability to analyze a multi-stage manufacturing process, identify the constraint (Painting stage at 16 hours), and recommend cost-effective solutions that meet specific targets. The interviewer-led format allows flexibility in how candidates approach the problem while maintaining clear evaluation criteria.

Estimated Time 15 minutes
Difficulty Easy
Source Duke
50 / 100
Your client is Bumpers-R-Us, a manufacturer of plastic automotive bumpers. Bumpers-R-Us is a Tier-1 supplier for a major global OEM called CNW and is based in the southeastern United States. The client receives raw materials from around the world, which are then used in its plant to produce the plastic bumpers. The bumpers are shipped by truck 360 miles away to the local CNW plant. Bumpers-R-Us has been a Tier-1 supplier to CNW for over 5 years, but over the past 6 months, the client has seen an increase in the amount of time it takes for parts to arrive at the CNW plant. CNW has issued a warning of potential fines and loss of future contracts if the lead time is not returned to the previous levels. Bumpers-R-Us is eager to find the source of the change in lead time and fix the issue as soon as possible.

Clarifying Information

  1. Bumpers-R-Us is a domestic supplier that purchases raw materials from around the world and supplies solely to the local CNW plant.
  2. The client profited $25M last year, with $10M in costs.
  3. The manufacturing process consists of four stages: molding of plastic parts from raw materials, painting of molded parts, the bonding & assembly of the bumpers (Bonding/Assembly), and the shipment between the manufacturer and CNW.
  4. The pre-6 month lead time was 29 hours.
  5. The General Manager of the plant has directed a budget of up to $5M be dedicated to addressing the lead time issue.