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OPERATIONS
OPERA MANAGEMENT
TIONS AND PROJECT MANA GEMENT

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Efficient Project Management at the ERP software package, and the quarters of 2006. Emphasizing on the
TransWorks Information Services problems they faced during the entire development in SCM, UTC intended to
Pvt. Ltd., an Indian-based BPO exercise. prove that it could help in cost-reduction
of indirect expenses and add to its growth.
Company
Pedagogical Objectives Would the transition to “Growth through
This is a real life case taken from a service Operations Transformation” payoff?
industry; it discusses the real life problem • To analyse the software systems failure
faced by a BPO Company. It focusess on at Cisco system in 1994 Pedagogical Objectives
the problems faced by the calling agents • To understand the importance of ERP
and the management as a whole, many a • To discuss UTC's "Growth through
based system Operations Transformation" initiative
times it so happens that the management
perceives a problem in a different angle • To discuss CISCO’s restructuring process. • To discuss the reasons for its disastor in
and the solution eludes them; this causes a 2006
Industry Routing and Switching
lot of frustration on the part of employees
Equipment
and management resulting in mass • To discuss the transition to "Growth
Reference No. OPS0021K
attrition. The real concern today for any through Operations Transformation"
Year of Pub. 2006
call centre company is its high attrition and its payoff?
Teaching Note Not Available
rate; the basic reason being the discord
Struc.Assign. Not Available Industry Diversified Business
between the management and the
Reference No. OPS0020B
employee. The employees look out for a Keywords Year of Pub. 2007
congenial and empathetic management and
Cisco Systems; Enterprise resource Teaching Note Not Available
shift to the other competing companies
planning (ERP) package; Implementation; Struc.Assign. Not Available
when offered a good work environment.
This case study throws light on one such Operating Strategies Case Study; System Keywords
aspect where a mass attrition was avoided failure; Information technology (IT)
by the top management by strategic and systems; IT strategy; Oracle ERP product; UTC; Kent Brittan; Jothi Purushotaman;
lateral thinking. ERP implementation; Rapid application Supply Chain Management; UT500;
development; Conference room pilots; Growth through Operations
Problems Transformation; Cost-reduction; IBM
Pedagogical Objectives
Global Services; Open Rating; Operating
• How a manager dealt with such a Strategies Case Study; DNBi Supply Chain
Management
challenging project with support of his Will UTC's Transition to "Growth
team of 14 fresh trainees through Operations
• How he managed to save the project Transformation" Payoff?
and bring about some wonderful changes Wal-Mart: Implementing RFID
to glide through the difficult times United Technologies Corporation (UTC),
a universally recognised market leader in In 2004, Wal-Mart announced its plan to
• How innovation and teamwork can several sectors with its presence in over implement Radio Frequency Identification
change things for an organisation. 180 countries had worldwide revenue of Devices (RFID) technology. RFID was to
$42.7 billion in 2006. Recognising a need be pilot tested at its three distribution
Industry Business Process Outsourcing centers at Dallas before being fully
to better leverage the purchasing power of
(BPO) implemented. The top 100 suppliers were
UTC and to manage its diverse businesses,
Reference No. OPS0022 given a deadline of January 2005 to be
the management decided to implement
Year of Pub. 2008 RFID compliant. Wal-Mart wanted to
Supply Chain Management (SCM).
Teaching Note Not Available revolutionise the supply chain through real-
Struc.Assign. Not Available In 1997, Kent Brittan, an experienced time tracking of products. According to an
executive of UTC was given a target of analyst, Wal-Mart would save around
Keywords reducing indirect expenses at UTC. By US$8.4 billion annually once the project
Project; Team Work; Innovation; Troubled 2000, he not only successfully achieved was completed. However, during the initial
Times; CHASE MANHATTAN BANK the target but also surpassed it. In 2001, he phase of implementation, various issues
USA; CRM; TransWorks Information designed a program called UT500 through like cost of compliance, consumer privacy,
Services Pvt. Ltd; Management; Manager; which he saved $1.5 billion. In 2005, Jothi and insufficient knowledge of RFID tags
Operating Strategies Case Studies; BPO; Purushotaman was made Vice President of made the suppliers skeptical about the
Services Operations and supply management team system. Industry observers in general and
started reporting to him. Purushotaman’s suppliers in particular, doubted whether
main aim was the growth of UTC through Wal-Mart’s RFID implementation was a
operational excellence. He started an wise decision.
CISCO Systems: Implementing initiative in 2005 called ‘Growth through
"Customized" ERP in Nine Months Operations Transformation’, whereby the Pedagogical Objectives
Cisco Systems, the well-known data growth of UTC was envisaged as a program
that would bring in operational excellence • The efficacy of RFID at Wal-Mart
communications company, faced a
by combining supply management, distribution centers
software systems failure in January 1994.
The business was stuck for almost two days. manufacturing and quality.
• The reaction of suppliers towards RFID
As result, Cisco decided to change the UNIX After deploying SCM in 1997, UTC made implementation
based legacy systems of the company to a 31% increases in their revenue from 1997-
modern ERP based software package. The • The challenges faced by Wal-Mart
2001 and an increase of 53% from 2001-
case discusses why the company decided to during RFID implementation.
2005. But Jothi Purushotaman’s initiative
go for an ERP package rather than of “Growth through Operations Industry Retailing
enhancing the legacy systems that it Transformation” had a disastrous start with Reference No. OPS0019B
followed, the implementation life cycle of just an increase of only 9% in the first two Year of Pub. 2005

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Teaching Note Not Available 2005, Paul Otellini announced his plan to 21 st century FedEx transformed both

OPERA
OPERATIONS
Struc.Assign. Not Available re-organise Intel’s operations, in order to customer and business transportation
boost sales of its high-end microprocessors, model with higher speed, reliability,
Keywords by penetrating new markets. Under the application of information technology,
Wal-Mart; Radio Frequency Identification guidance of the new CEO, the company improved material handling system and
Devices (RFID); Tags and readers; set up five new divisions to develop streamlined logistics network. The
Inventory control; Operating Strategies advanced features for products like desktop company popularised the concepts of ‘just-

TIONS AND PROJECT MANA


Case Study; Wal-Mart suppliers; Wal-Mart computers, notebooks, Personal Digital in-time’ and ‘build-to-order’ which reduced
distribution centres; Consumers of Wal- Assistants (PDA) etc., in order to focus on customer ’s lead time and increased
Mart; Data storage; System integration; specific segments like domestic customers, productivity. Apart from venturing into
Tag standards; Linda Dillman; Electronic corporate customers and small-businesses. ‘logistics solution provider’ the company
product code; Barcode; Auto identification To increase the sales of its processors, the was able to maintain its leadership position
standards; MIT (Massachusetts Institute of company considered the non-PC devices in small package and light freight market
Technology) centre such as digital cameras and other electronic through its unique ‘hub and spoke’ model.
equipments. The Case discussed Intel’s re The case gave a detailed description of the
organisation in order to become more operational efficiency of FedEx, the way
the company operates and the trends in
Embraer – Flying High Through customer oriented along with the
global express delivery industry.
Segmentation challenges that the company might face.

Pedagogical Objectives
Embraer, the third-largest aircraft Pedagogical Objectives
manufacturer in the world focused on the • To discuss the global express delivery
niche market segments. The company • To analyse Intel’s strategy before Paul
industry, trends and patterns, major
focused on regional jets with high growth Otellini
players and market share
potential in commercial, defense and
• To discuss Paul Otellini’s strategies to
executive aviation. The regional jets • To discuss the concept of multi modal
reorganise Intel
accounted for 40 percent of the transport operators and third party

MANAGEMENT
commercial aircraft in the US and Europe. • To discuss Intel’s strategy of emphasising logistics service providers
Embraer expected that there would be a the non PC devices
• To discuss how logistics operators
market of US$170 billion for 7800 new
• To analyse Intel’s strategy of entering gradually move up the value chain
jet deliveries worldwide by 2024 and so the
company wanted to grab the major share into different geographical segments.
• To discuss the operational aspect of

GEMENT
of the expected revenue. The case gives Industry Microprocessor & DSP companies from express delivery
an insight into Embraer’s history with a Reference No. OPS0017K industry
brief overview of the global aviation market Year of Pub. 2006
and Embraer’s outlook. • To discuss the evolution of companies
Teaching Note Not Available
like FedEx from a courier company to
Struc.Assig. Not Available
third party logistics service providers
Pedagogical Objectives
Keywords
• The B2B marketing and B2C marketing
• To understand the global aircraft
Intel Corp.; Reorganisation; Desk top; and different aspect of these two types
manufacturing industry
LAN; HP; IBM; Paul Otellini. of marketing
• To understand the evolution of regional
• The two different operational aspect,
aircrafts
hub and spoke model and point to point
• To discuss competitive dynamics of Fedex: The Cutting Edge operational model.
global aviation industry
Federal Express (FedEx), globally the Industry Express Delivery
• To analyse the competitive advantages second largest express delivery company Reference No. OPS0016K
of the regional jets was one of the most admired company in Year of Pub. 2006
the US. The company involved in Teaching Note Not Available
• To analyse Embraer’s ability to sustain connecting 39 hubs across the globe, Struc.Assig. Not Available
profitability in the long run. operating 677 planes and 90,000 vehicles,
monitoring 200,000 employees and Keywords
Industry Commercial Aircraft
manufacturing delivering six million (mn) packages daily FedEx; Hub & Spoke; Build to Order; Point
Reference No. OPS0018K in 220 countries where every second was to Point; JIT; UPS; DHL.
Year of Pub. 2006 important. This was the ‘FEDEX EDGE’,
Teaching Note Not Available for which the company was known for.
Since its inception in 1971 by Fredrick W.
Struc.Assign. Not Available
Smith FedEx pioneered the express Reliance Communications: The
Keywords delivery industry. The company focused Technology Dilemma
on the core business of express delivery
Embraer; Airbus; Bombardier; Boeing; It was the year 2006 – boom time in the
and provided overnight delivery services
Aviation. Indian Mobile Industry. Sales were on the
to the customers globally. However, the
rise and operators had been bombarding
transformation of businesses and customers
the public with promotional offers and
from old economy to the new economy
value added services in order to increase
Intel Corp.: The Customer forced FedEx to reposition itself from
their subscriber base. Though India had a
Oriented Reorganization ‘overnight delivery service’ to a ‘one-stop-
huge number of subscribers, it generated
shop’ for the entire logistics requirement
Intel Corp. entered a phase of transition, the lowest revenue in the world due to the
of the business. The company became the
when in November 2004, its board named poverty of masses, high levels of industry
logistics service provider of leading
Paul Otellini (president and chief operating specific taxes and inadequate margins due
organisations, like, General Motors. In the
officer), as the new CEO. On 17th January to high levels of competition. The service

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providers operated using GSM or CDMA (ARPU); Ambani; Co-branding; Mobile organised retailing industry. The case
technology. application; Market share of mobile briefly talks about the changing retail
subscribers; Cellular tariffs. industry in India, and the changing
Till 2003, a typical upper middle class consumer habits, led by its cities, with
household had an annual income of improving purchasing power. It describes
$10,000 to $13,000 and acquiring a GSM how PRIL was addressing the unique issues
handset required $60 while CDMA handsets Nestle: Streamlining Operations
that are faced by organised players; how
required about $80 and at times more. In PRIL developed its four main formats to
Nestlé S.A, the Switzerland-based Food and
spite of the low income levels, technology target various segments in the market and
Beverages Company was the global leader
was an important criterion for Indians. One the strategies it was adopting for branding,
in the industry. The first half year results
in ten Indians had access to safe drinking marketing and operating these stores. The
of 2005 surpassed analysts’ predictions.
water but one in three had a color television case highlights the key elements that go
The profits of the company were predicted
and one in seven had a cable television. into creating viable retail operations in a
to fall for the period due to the increasing
To generate revenues in such a market, raw material and packaging costs and the dispersed market with diverse buying
mobile operators had to concentrate on falling demand in France, Germany and habits. It also highlights the factors that
the upper segment of the society and Italy. Nestlé was able to achieve higher affect profitability in retailing in
charge a premium pricing. This was the profits mainly because of its operational developing markets such as India.
case until the entry of Reliance, India’s reforms, acquisitions, divestments and
largest business house, into the mobile product innovations for better market Pedagogical Objectives
industry in 2003. Reliance entered the penetration. The company had set and
mobile market in a massive way through achieved targets for considerable reduction • Organised retailing industry economics
its subsidiary known as Infocomm and in marketing, manufacturing and • Unique issues faced by organised players
targeted the mass market by adopting cost administrative expenses. The case discusses in the Indian retailing industry
leadership strategy. Though it faced a lot the various operational efficiency
of teething problems in the initial stages, programs and marketing strategies adopted • Building competitive advantage in
it was able to overcome them all and by Nestlé to counter the difficult market retailing
achieve the second position in the Indian conditions in parts of Europe and to exploit
• Importance of understanding consumer
mobile market within a short span of time. the opportunities in the developing nations
attitudes in a growing, traditional
The success formula of Infocomm helped markets.
economy
by changes in government policy enabled
The case provides ample scope for
Infocomm’s competitors to adopt a • Analyse if PRIL can replicate its
discussion on the effectiveness of Nestlé’s
business model similar to that of category management method across all
strategies in retaining its leadership
Infocomm. The higher average revenue its retail formats
position. An analysis can also be done on
per user (ARPU) and economies of scale
whether exclusive strategies have to be • Can in-house brands succeed the same
of GSM technology also enabled the GSM
evolved for developing markets which way in all product categories
competitors to realise a much higher profit
provide ample growth opportunities.
than Infocomm, thus acting as a serious • How would PRIL’s plans change if
threat to it. Due to this, the parent foreign investment is allowed in India.
company of Infocomm planned to enter Pedagogical Objectives
the GSM segment as well. But it faced Industry Organised Retail
• To discuss operational efficiency
government restrictions which would limit Reference No. OPS0013B
programmes and marketing strategies of
its operations. It would also have to incur Year of Pub. 2004
Nestle
handset switching costs and infrastructure Teaching Note Not Available
costs. This left the company in a dilemma • To discuss effectiveness of Nestle’s Struc.Assig. Not Available
about the shift. strategies in retaining leadership.
keywords
The case briefly examines the cost Industry Food and Beverages
Organised Retailing; Retail Store Formats;
reduction strategies adopted by Infocomm. Reference No. OPS0014C
Merchandising; Store Design; Consumer
It also discusses the strategic changes and Year of Pub. 2005
Shopping Habits; Category Management;
the feasibility of its GSM venture. Teaching Note Not Available
Supply Chain; Private Labels; Innovations
Struc.Assign. Not Available
in Retail industry; Profitable Retail
Pedagogical Objectives Keywords Operations; Food Retail; Fashion Retailing.
• Cost leadership strategy used by Nestlé; Operational efficiency;
Infocomm Management strategies; Leadership
retention; Nestlé’s financial results; RFID in Wal-Mart: Willy Nilly
• Various strategic changes adopted by
Infocomm and the technological Nestlé’s Target 2004; Operational Compliance by its Suppliers
dilemma - GSM vs CDMA. Excellence; Nestlé’s Fitnes; Global Business
Wal-Mart is the largest retailer and one of
excellence; Product innovation; Cost
Industry Mobile Services Industry
the largest companies in the world based
reduction Marketing strategies; Market
Reference No. OPS0015C
on revenue. In 2005, Wal-Mart reported a
penetration; Strategic effectiveness; Food
Year of Pub. 2006
net income of US$10.3 billion on US $285
and Beverages industry.
Teaching Note Available
billion of sales revenue (3.6% profit
Struc.Assign. Not Available
margin). Wal-Mart achieved success by
focusing on technology enabled supply
Keywords Pantaloon Retail India: Creating chain in order to provide service to the
Successful Formats customers. In 2003, Wal-Mart deployed
Technology dilemma; Reliance RFID (Radio Frequency Distribution) in 8
Communications; 3G GSM; CDMA; The case is set in 2004 and talks about distribution centers (in cases and pallets)
Infocomm; Cost leadership strategy; India Pantaloon Retail (I) Ltd. (PRIL), which through pilot approach and witnessed 1%
mobile market; Telecom industry; Entry emerged as one of the most successful improvement in inventory control. In
strategy; Average revenue per user companies in the still nascent Indian
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2005, when Wal-Mart asked 200 suppliers • Whether Blue Nile will continue to grow keywords

OPERA
OPERATIONS
to comply with RFID, they expressed their with the same strategy, given the
unwillingness to comply with RFID competitive scenario? Retailer; Hypermarket; Carrefour; Hard
implementation. In spite of all the discount stores; Private labels; Price cuts;
objections raised by the suppliers, Wal-Mart • If traditional diamond retailers start their Retail industry in France; 35 hour week;
wanted RFID enabled supply chain in all own online sales, would Blue Nile get Galland law; Raffarin law Adoption of Euro;
its stores and distribution centers by the affected? Consumer spending; Hyper market loyalty

TIONS AND PROJECT MANA


end of 2006. Programme; Ed; Government regulations.
• What stops other online diamond
retailers to follow Blue Nile’s strategy
Pedagogical Objectives successfully?
Strategies of 7-Eleven Stores
• To discuss how technology plays a vital Industry Diamond retailing
role in retailing Reference No. OPS0011B In 2003, 7-Eleven was the largest global
Year of Pub. 2005 convenience retailer chain with revenues
• To understand how Wal-Mart witnessed Teaching Note Not Available of $10,784.7 million. 7-Eleven operated,
growth through its technology enabled Struc.Assig. Not Available franchised and licenced around 25,000
supply chain stores and served around 7 billion customers
keywords daily, 24 hours, seven days a week in 17
• To understand the advantages and
disadvantages of RFID in retailing. Blue Nile; Online retailing; Diamond countries, apart from the US and Canada.
retailing; Targeting; Positioning strategy; The retailer was facing competition from
Industry Retailer Wal-Mart and other stores like Walgreen
Diamond buying Customer education;
Reference No. OPS0012B and Starbucks. In order to differentiate
Diamond trade; Diamond wholesale;
Year of Pub. 2006 itself from its competitors 7-Eleven
Tiffany; Amazon; Online advertising;
Teaching Note Available developed various strategies in IT (Retail
Operational efficiency; Diamond rings;
Struc.Assig. Not Available Information System), merchandising
Customer service.
(including fresh foods in its merchandise),
keywords
and distribution (combined distributed

MANAGEMENT
Wal-Mart; RFID; suppliers; bar codes; system). The case discusses in detail these
technology; supply chain excellence; Carrefour’s survival strategies in strategies and further discusses on the
challenges; RFID compliance; cost; France business model and the network of 7-eleven
investment in technology; return on stores.
Carrefour was the second-largest retailer
investment RFID tags; IT enabled supply of consumer goods and groceries worldwide,

GEMENT
chain.
after Wal-mart. The company pioneered Pedagogical Objectives
the concept of hypermarket in their home • The state of convenience store industry
country, France, as early as in the US and competition from other
Blue Nile – A Guy’s Best Friend! 1960’s.However, towards late 1990’s; formats
Carrefour saw a decline in their French
The case is set in 2004 and talks about hypermarkets owing to certain unfavorable • How will 7-Eleven maintain its position?
Blue Nile, the largest online retailer of government regulations and competition
diamonds in the US. Blue Nile followed a • The network of 7-Eleven stores and the
from hard discount stores. Carrefour
unique strategy in a very traditional efficacy of its retail information system.
introduced a series of strategic initiatives
industry. Traditional diamond retailing in an effort to revamp the ailing French Industry Convenienve Store
involved creating and maintaining an aura hypermarkets. As a result, French Reference No. OPS0009B
of mystery and secrecy around a diamond hypermarkets started showing signs of Year of Pub. 2005
purchase. So, customers never really recovery towards late 2004. The case Teaching Note Not Available
understood what they paid the premium discusses about the emergence and growth Struc.Assig. Not Available
for or what the true value of the diamond of hard discount stores in France. This case
was. Traditional diamond retailing also also provides scope for discussion of decline keywords
targeted only women in all its advertising of Carrefour’s French hypermarkets and
and promotions, though majority of the 7-Eleven stores; Wal-Mart; US
its revamp strategies. Convenience store industry; Retail
purchases were made by men. In such an
industry scenario, the case talks about how Information System; Franchising;
Pedagogical Objectives Licensing; Combined; Distribution centers;
Blue Nile built its online retailing business,
its unique targeting and positioning strategy Merchandising strategy; Walgreen
• The state of Hard discount stores in
and the way it delivered the promised value Starbucks; James W. Keyes; Multi format
France
to its target customers. The case describes retailers; Retailing; Starbucks; James W.
how Blue Nile had taken advantage of the • Impact of government regulations on Keyes; Multi format retailers; Retailing;
Internet and the gaps left by the brick- French retail industry Convenience Retailing; Business Model.
and-mortar retailers to build a new channel • Growth of Carrefour’s hypermarkets in
of distribution and emerge as a competitor France
to established retailers such as Tiffany and Safeway Inc.: Is it on a Safer
Zale. • Revamp strategies of Carrefour Way?
hypermarkets in France.
Pedagogical Objectives Safeway Inc., one of the largest grocery
Industry Not Applicable chains with over 1,800 stores across the
• Rationale behind the targeting and Reference No. OPS0010B US and Canada ran into trouble in 2000.
positioning strategy of Blue Nile Year of Pub. 2005 Safeway was facing internal labor problems
Teaching Note Not Available and external threats from peers and mega
• How does an organisation design and Struc.Assig. Not Available retailer, Wal-Mart. To cope up with the
implement its marketing and operations
declining profits and to lure back the
based on the target customer?

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customers, Safeway had come up with a unable to respond to challenges in its In 2005, Suzuki launched their global car
new ‘Lifestyle’ store format and had also business environment, resulting in a decline ‘Swift’ in international markets and later
introduced a new slogan “Ingredients for in its profits. Kunio Nakamura became the in India. Swift was the first stylish compact
Life,” to reposition itself as a more upscale president of Matsushita in the year 2000 car from the stable of Maruti and was a
market with product selection and services and he aggressively restructured the differentiator from its earlier products. The
that addressed the lifestyle demands of company, laying special emphasis on launch of Swift had brought Maruti in lime-
modern consumers. This case discusses in remodelling the company’s manufacturing light and various global international
detail the various phases which Safeway techniques. The company adopted many automobile manufacturers announced their
passed through, the obstacles that came in manufacturing reforms in its domestic plans to boost their investments in India
its way, and the recovering strategy of the factories that created cost efficiencies. and launch competing cars. The
company. Within two years, Matsushita witnessed a competition was expected to intensify to
turnaround in its operations. grab the burgeoning customer base.
Pedagogical Objectives The case describes the Indian Passenger
Pedagogical Objectives car industry and the presence of Maruti in
• Study the grocery retail industry and its
various store formats • To analyse the Toyota Product System each of the categories. It traces the origin,
(its inception, evolution and benefits) growth and evolution of Maruti and the
• How strong is Safeway in the competitive role played by Suzuki in enabling it to
world? • To discuss the differences between Mass achieve dominance. The case highlights
Production System and Lean Production the global strategy of Suzuki and the
• With new Lifestyle format, can Safeway System
lure back its customers? marketing strategy of Maruti in launching
• To discuss the differences between the Swift. It describes the 5P’s of marketing
• The worth of $100 million spent in the Japanese and Western management around the launch of Swift in an endeavor
re-launch of Safeway as ‘Ingredients for practices to change the image of Maruti as a
Life’. manufacturer of fuel-efficient but non-
• To identify and analyse the factors stylish cars only. The case finally talks
Industry Grocery Retail Industry
which affected Matsushita’s profits about the plans of other competitors and
Reference No. OPS0008B
during the 1990s their strategy to gain dominance and the
Year of Pub. 2005
plans of Maruti to sustain its dominance in
Teaching Note Not Available • To discuss the restructuring effort of all segments.
Struc.Assig. Not Available Matsushita
keywords • To analyse whether cost efficiencies Pedagogical Objectives
should be transferred or shared between
Grocery Retail Industry; Wal-Mart; the parent company and its subsidiaries. • To analyse the passenger vehicle market
Albertsons; Retail Operations; Lifestyle; in India and the presence of Maruti
Ingredients for Life; Perishables; Industry Electronics Udyog Ltd., in the various segments
Proprietary Brands; Brand Repositioning; Reference No. OPS0007
Service Management; Store Size; Grocery Year of Pub. 2006
• To examine the marketing strategy of
Industry Strike; Safeway Select; Teaching Note Available
Maruti Udyog Ltd., based on the 5P’s,
Supermarkets. Struc.Assig. Available
around the launch of the car Swift

keywords • To discuss where India figures in the global


strategy of Suzuki and debate on the
Matsushita Electric Industrial Toyota Motor Corporation; Toyota future potential of the Indian passenger
Co.’s ‘Cost Efficiencies’: Should Production System; Japanese quality vehicle market.
revolution; Lean Production System; Just-
they be Transferred or Shared? Industry Automobile industry
in-time (JIT) system; Japanese
Reference No. OPS0006A
Prior to the Second World War, Japanese management practices; Taiichi Ohno; Eiji
Year of Pub. 2006
products were known to be riddled with Toyoda; Kaizen; Jidoka; Andon cord;
Teaching Note Not Available
defects. The circumstances following the Kanban cards; Kaoru Ishikawa; Shiego
Struc.Assig. Not Available
war triggered a quality revolution in Japan Shingo; Genichi Taguchi; Value Stream
that was led by the Toyota Motor Mapping; 5S; Quality Function keywords
Company. Toyota pioneered the Toyota Deployment; TPM; Quality circles;
Production System which is considered to Matsushita; Panasonic; National; Technics; Maruti; Suzuki; Swift; India; Asia; Research
be the originator of the famous Lean Quasar; Kunio Nakamura; Super & Development; New product
Production System of Japan. The Manufacturing Company; Restructuring; introduction; global strategy; marketing;
manufacturing efficiencies resulting from manufacturing reforms; Corporate promotion; media; advertising; new
the adoption of the Lean Production advantage; Cell manufacturing system; entrants; competition; market leader; 5 P’s
System enabled the Japanese manufacturers Fumio Ohtsubo. of marketing; passenger vehicle industry.
to develop high quality goods at a low-
cost. Japanese products, especially
automobiles and consumer electronics, Maruti-Suzuki's Swift Move General Motors North America
found a big market in the West. in 2005
Maruti Udyog Ltd., a joint venture between
One of the largest consumer electronics the Government of India and the Suzuki In 2005, General Motors, the world’s
companies of Japan is Matsushita Electric Motor Corporation of Japan was India’s largest automaker, had manufacturing
Industrial Co. Ltd. From selling a single largest automobile company in 2005. It operations in 32 countries and sold its
product at its inception in 1918, the operated in the passenger vehicle market vehicles across 200 countries. For the fiscal
company grew into a consumer electronics and manufactured affordable and fuel year ended December 2004, GM generated
behemoth, manufacturing more than efficient cars for the Indian masses. Maruti revenues of $193,517 million and net
5,000 products, operating in 55 countries. 800 was its flagship small sized car and was income of $2,805 million. The company
But during the 1990s, Matsushita was the best selling car in India since decades. lost $2.5 billion in the first half of 2005

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and lost an average of $1,227 on every However, the Big Three were challenged shopping portals. As it expanded into

OPERA
OPERATIONS
vehicle sold. Health benefits provided to not only across the product lines n their different markets, Avon had a tough time
retirees and their dependents, lack of home turf, but also across the globe. The meeting the spurt in demand and the
effective brand advertising, deteriorating competition came in the form of inefficiencies in its supply chain came to
supplier relations and increasing investor formidable Asian players - Toyota, Honda, light. To counter the situation, Andrew Jung
pressure were some of the problems faced Nissan and Mitsubishi from Japan, and launched a Business Transformation
by GM in North America. In its recovery Hyundai from South Korea. As a result, Initiative in 1999, and later Lou Mignone

TIONS AND PROJECT MANA


plan, GM announced job cuts. But GM had the choice of car models available to the was made in charge of the supply chain-
a large number of factory employees US consumers increased and the US specific initiatives. A major supply chain
nearing retirement age, so the cutbacks manufacturers found their market share overhaul was undertaken, resulting in
would have a major impact on workers. decreasing. Shorter longevity of car models savings from each stage of the value chain.
Shutting down several plants meant made it imperative for the US Inventory was centralised, supplier
workers would be laid off or transferred. manufacturers to repeatedly invest in relations were strengthened and demand
After gaining a 9.9% stake in GM, the third expensive modification of their production forecasting was automated. Supply chain
largest shareholder, Kerkorian demanded facilities, decreasing the profitability of overheads were cut down and the operating
a seat on the board of GM. their products. Chrysler Corporation found margins of the company improved.
an answer to address this problem in
Pedagogical Objectives Flexible Manufacturing System (FMS). It Pedagogical Objectives
is hoped that this system would help
• To discuss the recovery plan of a market • To understand the supply chain
Chrysler to not only improve its
leader which is facing fundamental transformation initiatives of Avon
problems like unimpressive revenue profitability but also ensure market Products Inc., in the light of increasing
growth, damaged brands, mounting losses leadership. demand
in home market, and substantial retiree
obligations Pedagogical Objectives • To discuss how supply chain strategies,
pertaining to subtle elements of the
• To discuss the operating strategies • To discuss the changing competitive supply chain, can significantly help in

MANAGEMENT
followed by GM dynamics of the US automobile industry improving a company’s bottom line.
• To debate how a large individual investor • To discuss the reasons behind the decline Industry Cosmetics and Skin Care
can pose a threat to the company’s in the market shares of the US car Reference No. OPS0003
management. manufacturers Year of Pub. 2005
Teaching Note Available

GEMENT
Industry Automobile Industry • To discuss the concept of Flexible
Struc.Assig. Available
Reference No. OPS0005A Manufacturing System
Year of Pub. 2006 keywords
• To discuss how Chrysler Corporation
Teaching Note Not Available
implemented Flexible Manufacturing Avon Cosmetics; Supply chain; Demand
Struc.Assig. Not Available
System and improved its profitability forecasting; Centralised inventory; Value
keywords chain; Order fulfillment; Supplier relations;
• To discuss how Chrysler integrated its
Business transformation initiatives;
General Motors; Automobile Industry; suppliers into its new system of
Warehousing; Logistics; Sales
North America; Market Leader; Rick production
representatives; Direct selling; Back end
Wagoner; Mark LaNeve; US; United Auto operations; Packaging; Cost cutting
• To discuss human resource problems
Workers (UAW); Employee pricing for initiatives.
associated with the change in system of
everyone; Delphi; Health Care; Retiree
production.
Benefits; Special Utility Vehicle (SUV); Big
Three; Ford; Honda; DaimlerChrysler; Industry Automobile
Supplier Relations; Investor Relations; Reference No. OPS0004 BAA's T5: Novel Project
Strategy; General Motors Acceptance Year of Pub. 2006 Management
Corporation (GMAC); Restructure; Teaching Note Available
Product Design; Marketing; Brand BAA Plc., the world’s largest commercial
Struc.Assig. Available
Management. operator of airports, resumed its
keywords construction of Heathrow’s fifth terminal
(T5). T5 was not just a terminal building
Flexible Manufacturing System (FMS); but a transport interchange involving the
Chrysler's Product-mix North America automobile industry; boring of tunnels, construction of roads,
Challenges: Is Flexible Overseas competition; Flexible robotics; car parking, retail facilities, waste
The Big Three; Chrysler Corporation;
Manufacturing the Answer? management and airfield facilities. Ever
Build-to-order; Automated guided vehicle; since the idea of the project was proposed,
American automobile industry represented Plant profitability; Product mix challenges. there were different opinions expressed by
by the Big Three - GM, Ford and Chrysler various people. The plans of T5 were
(DaimlerChrysler) had enjoyed a subject to UK’s longest ever governmental
monopolistic environment in North Avon Product Inc.: Redesigning inquiry lasting for three years and 10 month
America and their inclination to innovate
its Supply Chain and costing 80 million pounds. The risks
had been rather limited because of lack of attached to this mega project compelled
competition. These companies, therefore, Avon Products Inc., the world’s largest BAA to tackle them in novel ways.
maintained production facilities that were direct seller of cosmetics and beauty-related
suitable for mass production of any single products, began reviving its supply chain Pedagogical Objective
model, which ensured economies of scale by the end of 1990s. Over the previous
and plant profitability. Absence of decade, the company had expanded into • To discuss the novel project management
competition also meant that new model several markets launching more brands. It techniques adopted by BAA in managing
launches were few and far between ensuring had also opened retail stores and on-line the T5 project.
full-scale utilisation of plant machinery.
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Industry Airport Infrastructure
Reference No. OPS0002
Year of Pub. 2004
Teaching Note Not Available
Struc.Assig. Not Available

keywords
BAAs novel project management;
Heathrow Airport’s Terminal 5; Tony
Douglas; British construction industry;
Transportation and logistics; Just-in-time
logistics; Architectural design; Linear
programming; Operational management;
Friends of the Earth; Twin rivers project.

The Evolution of the Toyota


Production System
After World War II, engineers and managers
from the ‘Toyota Motor Co.’ undertook a
‘pilgrimage’ to the US and visited the plants
of auto giants like ‘General Motors’ and
‘Ford’ to study the production system of
the US carmakers. During this trip, Toyota’s
people noticed many inherent flaws in the
mass production system of the US carmakers
that generated a lot of ‘waste’ at every step
of the production process. The mass
production system was also found out to be
unsuited for the then small and fragmented
Japanese automobile market. Taiichi Ohno,
then a Plant Manager at Toyota (who later
became the executive vice president), was
given a mission to develop a manufacturing
system that used the assembly line, but was
still flexible enough to enable low production
volumes. The result was the ‘Toyota
Production System’. Popularly known as
the ‘Toyota Way’, this system was the
driving force behind Toyota’s phenomenal
success, with the company becoming the
world’s second largest automaker with a 11%
market share at the end of 2003.

Pedagogical Objectives
• To understand the evolution of the
Toyota Production System
• To discuss how it established it as distinct
from other manufacturing systems
• To discuss the backbone behind Toyota’s
phenomenal success.
Industry Auto Manufacturing
Reference No. OPS0001
Year of Pub. 2004
Teaching Note Available
Struc.Assig. Available

keywords
Toyota; Toyota production system (TPS);
Taiichi Ohno; The Toyota way; Principles
of the Toyota way; Lean production; Just-
in-time (JIT); Kanban; Kaizen; Poke yoke;
Heijunka; Mass production; US big three;
Genchi genbutsu.

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