ACTPIE Production Optimization Report
Added on 2020-03-07
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UTS: ENGINEERINGAssignment Cover SheetSTANDARD ModeSUBJECT NAME: Operations EngineeringSUBJECT NUMBER: 49989ASSIGNMENT NUMBER: Individual Assignment 1STUDENT LAST NAME: STUDENT FIRST NAME:STUDENT ID: Declaration of Originality:The work contained in this assignment, other than that specifically attributed to anothersource, is that of the author(s) and has not been submitted in any other subject or publishedelsewhere before.It is recognised that, should this declaration be found to be false, disciplinary action could betaken and penalties imposed in accordance with University policy and rules.Signature: __________________________________0
Operations EngineeringAssignmentDesigning, Managing and Improving the Operations of a ManufacturingCompanyFaculty of Engineering and Information Technology1
Executive SummaryThis report is based on Patties Foods and it focusses ondesigning a new product for the company called ‘ACTPIE’ which is aconcept of producing pies in the shape of action figures. The reportcarries out critical analysis and takes care of various factors ofproduction like a detailed design of the product using the De Bono’sSix Thinking Hats process. It also gives a detailed design of theoperations of the production unit including the value map stream anda detailed floor plan of the unit. Then the report discusses about the management of variousoperations like supply chain management, inventory and stockcontrol. After which it discusses the improvements that should bebrought in the operation of the production unit. Finally it makescritical suggestions like avoiding wastage of resources, improvingmaintenance activities and providing adequate training to the staff forimproving the operations of the production unit.2
Table of ContentsContentsPage No.Executive Summary2Introduction4Process of Designing a New Product5Designing the Operations11Managing the Operations16Improving the Operations18Conclusion22References223
IntroductionPatties Foods, is an Australian food manufacturing company that produces bakedgoods, ready-made desserts, frozen fruits, pastries and meat pies. Patties Foods war foundedin 1966 by the Rijis family, who were originally immigrants from the Netherlands. Theirheadquarters is at Bairnsdale in Victoria, Australia. They are the largest meat pie producers inthe world and are publicly listed on the Australian Stock Exchange. Their production includesHerbert Adams Pie, Snowy River pie, patties and Four’N Twenty pies. Patties Foods haveseveral subsidiaries namely Four’N Twenty, Chefs Pride, Herbert Adams, Creative Gourmet,Patties, Nanna’s and Snowy River brands. The business was originally started as a cake shop in Lakes Entrance, Victoria, inAugust 1956 as Patties Bakeries. It was they bought by Peter and Annie Rijis in 1966, thedemand for their products started increasing after the introduction of bread rolls and pies.Due to the increase in production they started expanding and the production of the food itemswere moved to Bairnsdale in 1985 as the main production unit of the plant till date. As their business expanded, they started distributing their products in Melbourne in1986 and by 1995 they started exporting to New Zealand. They then started launching newproducts like Arriba, a Mexican flavoured food range and sold their bread business so thatthey could focus on their Pastries business as it was growing in demand. They then renovatedtheir factory in Bairnsdale so as to include the production of finger foods, sausage rolls andpasties with an increased capacity. By 2003 they started acquiring iconic brands like Four’nTwenty, Nanna’s and Herbert Adams and added gluten free food items to their productroaster.Steven Chaur is the chief executive officer of Patties Foods, as of this day PattiesFoods consists of 570 people producing over 300 different food items every year. Theirproducts are sold all over Australia in major hotels, restaurants, clubs, cafes, groceries andconvenience stores. They sell their products to various caterers, schools and stadiums throughtheir distribution network. They even sell their products in overseas markets like America andEngland. 4
Most of Patties foods subsidiaries have their own factories and outlets and some oftheir main outlets are mentioned here. Four’n Twenty have their main outlet in Bendigo,Melbourne Showgrounds and an even larger bakery at Ascot Vale from where deliveries aremade across entire Australia. The Herbert Adams bakeries started out in Prahran andBrunswick but it now has around 60 stores in various cities of Australia with main bakeries atCanberra, Ballarat, Melbourne, Bendigo and Greelong. They sell their products at over 450stores spread over Australia. Whereas Nanna’s, another subsidiary of Patties started out atPitt Street in Sydney in the early 1950’s moved its business to Cremorne and then to Gosford.Now Nanna’s crumbles and fruit pies are made in the Bairnsdale factory of Patties with itssame original recipe.Figure 1. Steps followed in the food production unitsThis report starts with the application of De Bono’s six hats technique to design of anew product, then it discusses the operation of the production plant which include the floorplan and the Kanban plots, then it discusses about the management of operations after whichit suggests the improvements in the operations so as to optimize the production process.Process of Designing a New ProductNew product Design using De Bono’s Six Thinking HatsThe six thinking hats model was developed by Edward de Bono for improving parallelthinking by cohesively planning the thinking process so as to effectively think together.Storing and Despatching different productsAssembling and Depositing the packed productsPacking and Labelling the cooked productCooking the mixed raw materialsMixing differnt ingredientsWeighing, Sorting and GradingRaw Material Storage5
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