Part 5

Just visited a production facility and met the team members responsible for various roles. He learned about the importance of inventory management, maintenance, and safety. Then, he toured the shipping and receiving building, impressed by its scale and efficiency. Just also met the shipping and receiving manager and learned about the facility's layout and function. He discovered that the company purchases certain products instead of producing them in-house for strategic and cost-effective reasons. just nodded graciously, expressing his gratitude for the warm welcome. He recognized the importance, role, and efforts of Ms. Rebecca in the production planning process and her crucial role in ensuring efficiency of the process. The introductions continued with Ms. Emily Wynn, the inventory control specialist, who greeted just cheerfully, highlighting her role in managing inventory efficiently. Emily explained the importance of inventory management in ensuring the availability of materials for production, sharing insights into the strategies she employed to optimize inventory levels and minimize stockouts. Just returned Emily's smile, recognizing the importance of her role in ensuring the smooth flow of production operations. Afterward, Champ introduced Mr. David Martinez, the maintenance coordinator, underscoring his essential role in ensuring the smooth operation of production machinery. David greeted just warmly, sharing anecdotes about his experiences in troubleshooting and resolving equipment issues to minimize downtime and maximize efficiency. Just nodded in acknowledgement, impressed by David's hands-on approach and understanding of his crucial role in maintaining the reliability and performance of the production equipment. Next, Champ pointed out Ms. Sarah Johnson, the health and safety officer, emphasizing the importance of prioritizing safety in the workplace. Sarah greeted just with a firm handshake, sharing insights into her role in developing and implementing safety protocols to protect the well-being of the production staff and minimize the risk of accidents or injuries. Just nodded in agreement, recognizing the significance of Sarah's efforts in maintaining a safe working environment and ensuring compliance with health and safety regulations. Continuing their tour, Champ and Just made their way to the administrative area, where Champ introduced Emily, one of the administrative assistants, highlighting her proficiency in handling various tasks. Emily welcomed just warmly, providing insights into her role in the business of offering assistance with scheduling, documentation, and other administrative duties to support the day-to-day operations of the facility. Just expressed his appreciation for Emily's efficiency, realizing the vital role of the administrative team in maintaining organizational efficiency and productivity. By the end of the introductions, Just felt a sense of gratitude for the dedicated team members and the collaborative spirit that permeated the production facility. He made a mental note to engage further with each team member and to appreciate their contributions to the company's success. Champ led Just to the equipment room adjacent to the office area, where rows of safety gear awaited them. Before we embark on the facility tour, safety comes first, Champ emphasized, handing Just a hard hat, safety goggles, and a reflective vest. You'll need these to protect yourself while we're in the production areas. Just felt a sense of responsibility wash over him as he donned the safety gear. He adjusted the hard hat securely on his head, put the goggles in his shirt's upper pocket for the time he will need them, and fastened the reflective vest around his torso. Prepared and eager, he followed Champ's lead, ready to explore the production facility. With Champ leading the way, they exited the office and proceeded towards the first stop on their tour. It was only a few steps away towards the right, after exiting the office building. Walking alongside the green park, Just could clearly read the names specified on the top stating, shipping and receiving. Champ, very excited to show Just what's inside, takes him to the large glass doors and opens it for Just to enter. I believe that John must have told you that we manufacture everything related to the generators in-house. He is 50% correct to state that. However, we don't produce everything, that will be impossible. The products that we need for manufacturing, and we cannot produce ourselves are bought and stored in this facility. Just's curiosity peaked, prompting him to inquire, what are the products you purchase here? Champ responded cryptically, promising that Just would soon find out. As Just followed Champ's lead into the shipping and receiving building, he was immediately struck by the enormity of the structure and the vastness of the space within. The building loomed large, supported by a few narrow metal pillars that seemed almost dwarfed by its sheer size. What appeared modest from the outside revealed itself to be a cavernous expanse once inside. The architecture of the building was sleek and minimalistic, designed with functionality in mind to maximize the available space. The clean lines and simple aesthetic contributed to the sense of spaciousness, allowing for efficient movement of both goods and personnel. Inside, Just's eyes widened as he took in the bustling activity. Pallets of raw materials and components were being unloaded from delivery trucks, with workers diligently inspecting each shipment to ensure quality standards were met before accepting them into inventory. The space was alive with movement and purpose, with forklifts maneuvering skillfully to transport cargo to designated areas. Along the left side of the building, Just noticed four docks for trucks to load and unload cargo, indicating volumes of incoming and outgoing shipments from the warehouse. The layout was optimized for smooth logistics operations, with ample space for vehicles to maneuver and efficient workflow processes in place. Overall, the shipping and receiving building was a hub of activity and organization, essential for the smooth functioning of the production facility. Just couldn't help but be impressed by the scale and efficiency of the operations taking place within its walls. Champ led Just directly to the shipping and receiving manager, Sanjay, who was stationed at his desk. Hi Sanjay, good morning. What are we receiving right now? Champ inquired, prompting Sanjay to look up from his computer screen and acknowledge Champ's presence. We're receiving a shipment of sheet metal at the moment, Sanjay responded, gesturing towards the incoming delivery. Noticing Just beside him, Champ introduced him to Sanjay. Oh, yes. This is Just, and he's here to learn about the manufacturing process, Champ explained. Sanjay greeted Just warmly, extending a welcome to his domain. Sanjay then elaborated on the significance of the shipping and receiving area. This is the primary contact point of the facility with the outside world. All the raw materials and finished products leave from here. From here, our own trucks transport the products to other buildings in the facility. He explained, pointing to two more dock doors on the other side of the warehouse. We handle all the loading and unloading here and supply the SKUs as needed elsewhere in the facility. Just, intrigued by the operation, asked about the variety of products in the facility. Champ stepped in, eager to show Just around. Let's go and check it out, he said, leading the way. Champ guided Just to a layout board positioned in the facility for safety purposes, pointing out all the fire exits. Using the board as a visual aid, Champ began to explain the layout and function of the facility. Gesturing towards different areas on the board, Champ started to describe each section. This is where we entered from, he began, tracing his finger along the path. Directly ahead is the office area where Sanjay was seated. To the left is the equipment area, where we stored heavy and light equipment such as forklifts, pallet jacks, loaders, and other supplies needed by workers in that zone. We also used this space for additional storage, particularly for slower moving inventory. Champ continued his explanation, indicating the location of the storage adjacent to the dock doors and equipment area. This storage area serve as a buffer for incoming and outgoing products. It was where we inspected and prepared items before they were moved to the main storage area at the back of the facility, he clarified. Pointing towards the rear of the building, Champ directed Just's attention to three distinct aisles. These aisles of racks are the main storage area, he explained. Here, we organized and stored our inventory based on product type and demand. Transitioning to the types of products they handled, Champ listed them off while referencing the layout board. The products we procured from our suppliers included sheet metal, copper wires, screws, nuts, bolts, tools, paint, metal scraps, O-rings, engine oil, and various utility items necessary for both manufacturing and maintenance operations etc. There are a lot of items that we purchased from different suppliers. He detailed, providing Just with a comprehensive overview of the facility's operations and inventory management. Just's curiosity peaked as he questioned why the company didn't produce everything in-house. He reasoned that the items Champ mentioned did not seem too difficult to manufacture on their own. Champ offered a thoughtful response, explaining, it was a strategic decision. We needed to find a balance between our core competencies that we excelled at and what would be more cost-effective to purchase. He elaborated with an example, take our wires, for instance. Wire manufacturing starts with smelting copper ores and then treating the copper with different chemicals to purify it. Only the copper that has been through this process can be used to manufacture copper wires. While we do manufacture our own wires, we do not smelt the copper ores. As that is not our area of expertise. Moreover, we would need a lot of monetary resources to set up a production plant for this purpose. Instead, what we do is let the experts take care of the purification of copper and we buy copper from them in the form of large cylindrical blocks. Further we process these large cylindrical beams into wires that fit our requirements, as you will see today. Now this is only one example. Just like the copper wires there are some other products that will either need a lot of investment in research and development or are simply very expensive to manufacture in-house. Champ emphasized that such decisions were carefully considered, based on thorough cost and benefit analysis conducted during the business planning stage. This insight provided just with a deeper understanding of the strategic considerations involved in the company's operations. Just swiftly retrieved his notebook, jotting down cost and benefit analysis and business plan for further investigation later. Champ inquired if there were any other queries regarding the area they were discussing. With his mind still focused on gathering evidence for Ovil's innocence, just couldn't help but ask, considering the facility was closed off from the outside world, does that mean all waste was managed within this location? I didn't see a designated area for waste management. Champ couldn't help but commend Just's remarkable knowledge and foresight, considering his age. He responded affirmatively, confirming that all waste generated within the facility was indeed managed from that location. However, he clarified that the waste disposal area was located outside, adjacent to the yard, eager to witness the waste management area firsthand, Just expressed his desire to see it. Champ readily agreed and led Just outside to the yard area. There, at the corner of the yard, stood two large bins, one green and the other brown. Pointing towards the bins, Champ elucidated their purpose, saying, the green bin is designated for recyclable waste, while the brown bin is for non-recyclable waste that needs to be discarded. Any waste metal is returned to the supplier, although you won't see it here as all the scrap metal is collected and shipped out from inside the shipping and receiving building. Satisfied with Champ's explanation, Just pulled out his phone and snapped a picture of the bins as evidence. Champ couldn't help but feel intrigued by Just's actions, expecting him to be more interested in capturing images of the office interior rather than the outdoor waste management area. Nevertheless, he brushed aside his thoughts and proceeded to guide Just to the next building within the premises, the packaging facility. Approaching the building, it was notably smaller compared to the other expansive structures in the vicinity. However, what distinguished it was the solar panels adorned on its roof. This installation indicating a commitment to sustainable energy practices. Upon entering, they found themselves in a modest office space, but the persistent humming of machinery and the rhythmic sounds of pneumatic pistons hinted at the bustling activity on the other side of the office. As they stepped further inside, a small, energetic Asian man emerged and greeted them enthusiastically. Hey, Champ. Good morning. What brings you here to the packaging facility? He exclaimed, his voice filled with warmth and familiarity. Champ, with a playful tone, jokingly announced, I came to say you are no longer needed. The man's expression immediately shifted to one of seriousness, prompting Champ to burst into laughter. He reassured the man that it was just a jest, and the purpose of his visit was to introduce him to a young man named Just. This is Just, Champ continued, gesturing towards the newcomer. He's here to learn about the packaging and fulfillment process. And Just, meet our packaging facility operator, Kimo. Relieved by Champ's clarification, Kimo greeted Just warmly. Hi, Just. I'm glad to see you here. So, what would you like to know? With a welcoming gesture, Kimo indicated the door at the back of the office, leading to the source of the humming sounds. Champ nodded, signaling for Kimo to take the lead. As they approached the door, Kimo began to explain, this facility is nearly automated. My role is to oversee the process and ensure smooth operations. Opening the door, Kimo stepped inside, and the room suddenly filled with the cacophony of mechanical parts in motion and pneumatic pistons at work. The noise was deafening, justifying why the office area was kept closed off from this bustling activity. Upon entering, Just was greeted by the sight of a high-tech packaging line stretching out before him. On the left, a large open garage-like door revealed neatly arranged fully manufactured generators, patiently awaiting their turn for packaging. On the opposite side of the packing line sat a storage area stocked with supplies such as boxes and tapes. Given the weight of the generators, a crane stood ready beside the packing line's starting point, allowing for efficient movement of the heavy machinery. Only two workers could be seen on the floor, one tasked with operating the crane and replenish SKUs like boxes, protection foams, tapes etc. Further towards the end a worker operated another crane and fixing stickers at the end of the packing line. They then carefully loaded the packed generators onto a truck parked at the dock door. The operation appeared straightforward, with minimal activity in the facility and limited storage capacity. Once the generators were packed and labeled, they were swiftly dispatched for delivery. As Kimo elaborated on his responsibilities, he detailed his role in coordinating with various departments to manage the flow of inbound finished products. He also mentioned his duties of ordering supplies from suppliers, such as boxes and labels, and maintaining a strict maintenance schedule for all the machines in the facility. The speed of the packaging process, he explained, depended largely on the demand and available stock in the outbound warehouse adjacent to the facility. Just absorb this information, realizing there was much more to learn, particularly about the intricacies of the packaging machine itself. However, he understood that he would have to return to delve deeper into that aspect. Champ, eager to continue the tour, urged just to move along, noting the time constraints. He knew they had more ground to cover, and time would be needed for the upcoming departments. Champ expressed his gratitude to Kimo for taking the time to explain the packaging process. Then, turning to just, he inquired if there were any further questions before they moved on. Just, feeling confident in his understanding of the process, politely declined, indicating that he had no further inquiries at the moment. Kimo reassured him that he was welcome to return anytime to delve deeper into the operations. As they walked back toward the office, Kimo accompanied them, and just thanked him once more for his time before bidding farewell. Transitioning to the next topic, Champ began discussing the significance of quality assurance and its impact on customer loyalty and satisfaction. Just, seizing the moment, snapped a photo of the solar panels adorning the roof of the packaging facility, remarking, here is the quality assurance team's headquarters. Upon entering the building, Just observed the meticulous analysis being conducted on running generators by individuals holding files and various instruments, the sound of generators humming in the background as they proceeded through a narrow walkway. Champ led Just to an area of the facility that he confessed was one of his least favorite places. Despite his reluctance, he emphasized its vital role in the manufacturing operations. He pointed out the layout, with offices to the right and an empty conference room to the left, explaining that they were about to meet with Mr. Richard Jacobs, the person in charge. Upon entering the office space, Just noticed the hustle and bustle of activity. Desks filled the room, each appearing identical, resembling a typical office environment. Amidst the commotion, one individual stood out, focused on his computer screen, seemingly unperturbed by the chaos around him. He wore large glasses and emanated an aura of intense concentration. As Champ and Just entered with a purpose, the room fell momentarily silent. Employees paused in their tasks, casting curious glances at the unexpected visitor. Whispers and murmurs circulated as they speculated about the newcomer's presence. It was clear that Just's arrival had stirred intrigue among the office staff, who pondered the reasons behind his visit and his attire, adorned in protective gear. Some surmised that he must be a new trainee, while others speculated about his role in the facility. Champ approached the first desk where a man with glasses was engrossed in his work. With a hint of irritation in his tone, Champ called out to the man, addressing him as Mr. Richard Jacobs and mockingly inquired about any problems he had encountered. Mr. Richard, stood up from his desk to approach the two men and address Just, ignoring Champ's presence entirely. There seemed to be an unspoken rivalry between Champ and Mr. Richard. Hello there, young man. What is your name? Mr. Richard greeted Just warmly, seemingly pleased by the unexpected visit. He continued to address Just, expressing his surprise at receiving visitors in the office, while Champ's presence was brushed aside, indicating a subtle tension between the two individuals. Just introduced himself as Just Gray, explaining that he was there to learn about the manufacturing facility, with Champ guiding him on the tour. Mr. Richard, slightly irritated by Champ's mention, displayed a hint of annoyance at his presence, addresses him and says, so, this means you needed our expertise. Champ, with a smirk on his face, teased Mr. Richard by replying, I am here only for business. Their interaction hinted at a long-standing rivalry, yet they maintained a professional working relationship. Just observed their dynamic, feeling surprised but opting to ignore the tension between them, making a mental note of the situation. Mr. Richard addressed Just directly, acknowledging his interest in learning about the quality controls and procedures at the facility. He then turned to the other members of the office, prompting their attention with a firm command. Listen up, everyone, he announced, causing a pause in the ongoing activities as all eyes turned towards him. Today, we have a special guest among us. Mr. Just Gray is here to understand our processes and the importance of upholding quality standards. Let's give him a warm welcome and introduce yourselves. Mr. Richard, quietly turned toward Champ and very softly spoke, so that no one else could hear, I hope you also learned something valuable today. Champ did not say anything and only observed everything unfolding in front of his eyes. Mr. Richard took the lead, requesting everyone to gather around Just and Champ as he spoke. I am Richard Jacobs, he introduced himself, his tone carrying authority and expertise. As the Quality Assurance Manager, it is my responsibility to ensure that we adhere to industry best practices, implement quality protocols throughout our manufacturing process, and oversee regular checks with my dedicated team. He emphasized the importance of meeting government standards and striving for maximum customer satisfaction. And of course, he continued, gesturing towards his team, I couldn't do it without this exceptional group of individuals you see before you. They are the backbone of our quality control efforts. The leftmost team member stepped forward, introducing herself as Sarah Johansson. I am Sarah Johansson, she began, her voice confident and firm. As the Quality Control Inspector, my team and I serve as the frontline of quality assurance, she emphasized the meticulous nature of their work, which involved conducting thorough inspections, audits, and testing throughout the production processes. Our keen attention to detail is essential, Sarah explained, to ensure that products meet rigorous quality standards, before they move forward on to the next stage of packaging. She highlighted the crucial role they played in identifying and addressing any quality issues that might arise during manufacturing, underscoring her close collaboration with Quality Assurance Engineer David. David stepped forward after Sarah, acknowledging her remarks. Thank you, Sarah. Our roles indeed align closely, he began, his tone reflecting a sense of purpose. I am David Smith, a Quality Engineer. He explained that his responsibility was to develop and implement quality control measures aimed at upholding product quality. I analyze data to identify trends and areas for improvement, David continued, emphasizing his role in providing technical expertise to resolve quality-related issues. My focus is on continuous monitoring and optimization of production processes to ensure consistent quality. Following David, Emily stepped up to introduce herself. My name is Emily Thompson, she began confidently. I am the Quality Assurance Technician. She elaborated on her role, explaining that she was responsible for testing and collecting data, which formed the basis for David's analysis and continuous improvement efforts. I focus on finding irregularities and increases in variance, Emily clarified, highlighting the importance of her role in maintaining the integrity of quality assurance efforts. I use various calibration tools and ensure the maintenance of testing equipment to ensure accuracy and reliability, she added, underscoring her contribution to upholding quality standards throughout the production process. As Emily finished speaking, the next person in line started speaking, my name is Michaela Brown, and I am the Documentation Specialist. I am responsible for handling and storing all the digital and physical documents related to tests, analysis, and quality assurance process changes, and issuing new documentations to other departments. Basically, I manage all the data that is collected and analyzed by the team here, and record any changes made by the team over a course of time. The goal is to have all the data available for the business to compare performances and compliance with respect to old procedures and practices. Hence, it is important that all documents are accurate, up-to-date, and easily accessible when we need them. Next person started speaking, hello, my name am Daniel Miller, and I am the Compliance Officer. My job is to make sure that the production processes and products adhere to relevant government regulations, standards, and industry best practices. Basically, I am the auditor among the team. I have the authority to randomly audit or do scheduled audits to make sure we comply with the regulations in the manufacturing processes and product quality. This helps us to mitigate risks and uphold organizational integrity. My role is more focused towards risk mitigation and preventing future allegations on the business for misconduct. My role is different from the engineers because I primarily focus on process optimization, whereas engineers focus on the quality of individual components of the process. As soon as just heard the job description from Daniel, he knew that he was one of the most important persons whom he should talk to before Ovil's hearing next week. However, he refrained from discussing the litigations openly and instead asked a question. Does your work include complying with waste management processes? Daniel responded affirmatively, yes, that is correct. In fact, my role requires me to be certified in the knowledge of best practices, which also includes waste management practices. Just felt relieved hearing this. He quickly made a mental note of Daniel's name and his crucial role in the business. Moving on to the next person. Hi, my name is Jessica Lee, and I am the training coordinator. I am responsible for training the new and old employees about policies and regulatory changes as instructed by Daniel. Hence, my role includes everything from developing and delivering comprehensive training programs on quality assurance procedures, standards, and best practices. We have scheduled monthly meetings with the staff members and sometimes unscheduled training sessions depending on the urgency of regulatory changes. The main goal of this position is that all staff members are knowledgeable and proficient in quality-related processes, promoting a culture of continuous learning and improvement. I also help Michaela in filing incident reports related to quality control as it is usually complemented with additional training for the staff. Finally, the last person spoke. Hi, my name is Ryan Davis, and I am the continuous improvement specialist. This is an analytics position where I focus on identifying opportunities for process improvements, efficiency enhancements, and cost reductions within the quality assurance function. Further, he described his role as a change agent in the production process, collaborating with other teams to implement improvements based on identified trends or areas for optimization. Just was deeply impressed by the expertise and dedication of the employees he had just met. Their attention to detail, forward-thinking approach to risk management, and commitment to enhancing processes and product quality left a lasting impression on him. He resolved to return and spend more time with this team to gain further insights into their operations. With the introductions concluded, Mr. Richard stepped forward to express gratitude to everyone and instructed them to return to their tasks. He then turned to Just and invited him to follow him outside, eager to showcase their office facilities and the tools they utilized. Just and Champ followed Richard outside into a room filled with the hum of generators positioned along the left side of the building. Each generator was neatly positioned on its stand and running continuously as some people checked its output and operations. Richard explained that the energy produced by the generators while testing was used to power the assembly line. This reduced their dependence on external power source grid and also contributing to sustainability efforts. The room also housed a computer workstation, where technicians monitored generator performance in real-time. Richard elaborated on the importance of data collection and analysis in identifying potential issues before they escalated, minimizing downtime, and ensuring optimal performance. He emphasized the role of predictive maintenance in preemptively addressing equipment failures, allowing for proactive interventions and cost savings. Just listened intently, absorbing the wealth of information being shared with him. He marveled at the seamless integration of technology and innovation into the facility's operations, recognizing the significance of such initiatives in driving efficiency, productivity, and sustainability. Richard then led Just and Champ to a nearby storage area where spare parts and tools were neatly organized on shelves. He explained the critical role of inventory management in maintaining uninterrupted operations, ensuring that essential components were readily available whenever needed. Richard stressed the importance of accuracy in inventory tracking and replenishment, highlighting the adverse impact of stockouts on production schedules and customer satisfaction. Just admired Richard's attention to detail and commitment to excellence, recognizing him as a key leader within the organization. He felt privileged to have the opportunity to learn from Richard and gain insights into the inner workings of the Quality Assurance Department. As they concluded the tour of the office facilities, Richard extended his gratitude to Just for his interest and engagement. He expressed his hope that Just had gained valuable insights into their operations and welcomed any further questions or opportunities for collaboration in the future. Just thanked Richard for his hospitality and expertise, promising to stay in touch and explore potential areas for partnership. With the tour of the Quality Assurance Department complete, Just and Champ bid farewell to Richard and made their way back outside. Along the way, Just reflected on the wealth of knowledge he had acquired and the valuable connections he had made during his visit. He felt inspired by the dedication and professionalism of the employees he had met, reaffirming his belief in the importance of quality assurance and continuous improvement in driving organizational success. As they approached the entrance of the production facility, Champ turned to Just with a smile. Well, what did you think? He asked, eager to hear Just's thoughts on their tour of the Quality Assurance Department. Just returned Champ's smile, feeling grateful for the opportunity to learn and grow. I'm truly impressed, he replied. The level of expertise and dedication displayed by everyone we met was truly inspiring. I have a newfound appreciation for the critical role that quality assurance plays in ensuring product quality and customer satisfaction. Champ nodded in agreement, pleased to see Just's enthusiasm. Indeed, quality assurance is the cornerstone of our operations, he remarked. Without it, we wouldn't be able to maintain the high standards that our customers have come to expect from us. I'm glad you had the chance to see it in action. And so, their journey continued, with Just and Champ embarking on the next leg of their adventure, eager to discover what lay ahead. As they approached the next building, Just noticed the name on the building as Assembly Line. But Champ told him next building was Production Plant. Noticing the difference, he couldn't resist asking, Champ, what's the difference between a manufacturing plant and an assembly line? They sound like different things. Champ paused for a moment, considering Just's question. Technically, he began, this entire facility is called the production plant, and the next building is an assembly line. Assembly line is the heart of a manufacturing plant. You see, all the different components of the generators are made in other locations and brought here to be assembled. But since the final product comes out from the assembly line, we informally call it the production plant. Just nodded, taking in Champ's explanation. As they neared the manufacturing plant, the rhythmic hum of machinery grew louder, signaling the bustling activities inside. As Just stepped onto the production floor, he was enveloped in a symphony of sounds and sights. Conveyor belts hummed as they transported materials from one workstation to another, while workers, dressed in safety gear, expertly assembled components with precision and skill. Champ guided Just through the labyrinth of machinery and workstations, unraveling the complexities of each process as they went along. From the arrival of raw materials to the emergence of finished products ready for testing and packaging, Just gained a comprehensive understanding of the production workflow. As they navigated the production floor, Champ introduced Just to various team members, each contributing their expertise to the manufacturing process. Just listened intently as they shared their experiences and insights, absorbing all the knowledge thrown at him. He couldn't help but notice the efficiency of everyone's work. Tools were always within reach, and no one strayed far from their workstations. Champ attempted to explain this efficiency to Just, mentioning manufacturing techniques like Lean Sigma, Lean Layout Design, and Kizen Continuous Improvement. Just's curiosity was piqued, and he bombarded Champ with questions about these concepts. Champ, realizing that delving into the details might overwhelm Just, gently deflected his inquiries, suggesting that Just read up on the topics to gain a basic understanding before diving deeper. Understanding Champ's advice, Just jotted down the terms in his notebook, eager to explore them further on his own. As Champ continued introducing Just to various team members and workstations, Just found himself increasingly immersed in the world of manufacturing. With each introduction, he gained a deeper appreciation for the vast scope of operations and the crucial role of teamwork in achieving success. As they navigated through the bustling production floor, Just couldn't help but marvel at the seamless coordination and efficiency of the production team. Just, intrigued by the intricacies of the operation, turned to Champ with a question. The production building doesn't seem to have much storage space for finished goods. How do we manage storage for all the products? Champ, ever the knowledgeable guide, responded with a confident smile. Oh yes, that is a good observation, Just. You are right. We don't store finished goods here. Instead, all the finished generators are swiftly dispatched to other buildings. Some are sent to the QA team for testing, and some are sent to the packaging facility. Finally, the products end up at the shipping and receiving building, and that is our main storage area for this entire facility. Just nodded, absorbing Champ's explanation. So, the shipping and receiving building is used to store raw materials and also the finished products? Is that facility big enough for all this? Champ continued, Yes, the shipping and receiving building is large enough to store all the raw materials and finished products. In fact, it can hold up to three months of sales forecast during peak seasons. Of course, we rarely produce enough generators to fill it to capacity, as we ship out the generators to our distributors and retail shops on regular intervals. Further, to understand how we manage to keep all the raw materials and finished products in that space, there is another topic that you should learn about called inventory rotation or stock rotation. Okay, let's do this, next time you are here you will tell me about the inventory rotation, also known as inventory turnover. How does that sound? As Champ and Just traversed the production floor, they approached a row of workstations where several workers gathered for a briefing. Champ halted, indicating the significance of the scene unfolding before them. Here, we have our production supervisors and team leaders. Champ explained further, these individuals play a crucial role in maintaining the smooth operations of the manufacturing process. They oversee training and act as a bridge between upper management and the workers, ensuring support at every turn. Just watched intently as the supervisors moved among the workers, offering guidance and assistance where needed. Their balanced approach, authoritative yet approachable, left a lasting impression on Just, emphasizing the importance of effective leadership in driving productivity and upholding quality standards. Noticing Champ and the newcomer, one of the supervisors, a seasoned veteran, approached with a welcoming smile. Welcome to our production floor, he greeted Just warmly, recognizing him as a VIP guest. I'm glad to see new faces here. Turning to Champ, he inquired, and who might this be? Champ introduced Just, explaining his purpose for being there. The supervisor nodded, understandingly. Ah, you are here to learn about our processes. He remarked, his enthusiasm evident. Well, it is a straightforward process. The most important part here is the assembly line. The housings of the generator enter on the assembly line from the extreme left there. He pointed to a direction indicating the start of the assembly line and continued, as they move along the assembly line, new components are added to the generator like pistons, valves, timing belts, wires and finally the entire assembly is enclosed in the sheet metal housing. He pointed to the other end of the assembly line indicating once the generator reached the end, they are done and fully assembled. Just nodded understandingly, as he saw the entire assembly process in front of his eyes. The site supervisor addressed him again and spoke, if you have any questions or need assistance, don't hesitate to ask. We are here to help. Just was deeply impressed by the camaraderie and supportiveness among the production team members. Following Champ, he continued to absorb the sights and sounds of the bustling facility, each piece of machinery and equipment contributing to the intricate dance of manufacturing. As they neared the exit of the production facility, Champ turned to Just with a smile. That wraps up our tour of the assembly line, he announced warmly. I trust you have gained some valuable insights into our operations and the integral role each team member play in our success. Just was indeed impressed seeing the assembly line and the level of meticulous planning that goes into it. This time he was simply looking forward to seeing the pre-assembly stages of the manufacturing process. Just, Champ began, noticing the eager anticipation and Just's eyes, I understand your desire to learn more. From here the manufacturing process gets more technical. But first, it's time for a quick lunch break. Just nodded enthusiastically, his curiosity momentarily set aside by the promise of food. We'll head to the cafeteria now, Champ continued, checking his watch, everyone will rush out for lunch in 10 minutes. Before it gets too crowded we can grab our food. With that, Champ led the way to the cafeteria, eager to continue sharing his knowledge with Just. About this time, Maya and Bella were also contemplating taking a break from their respective tasks. Bella was at the local cafe, deftly serving customers while discreetly asking about the impact of Ovil's businesses in the nearby community. Meanwhile, Maya was at her office desk, diligently working on a report while simultaneously delving into Ovil's case file to uncover clues and evidence. They both couldn't help but wonder what Just would be up to at the production plant and if he had unearthed any valuable evidence. Meanwhile, Just and Champ came out of the assembly line building, and the cafeteria was right across the street. It was a beautiful airy building with exceptionally large windows and could be considered a piece of art. Among all the other buildings this one stood out with some character. Upon entering the cafeteria, Just noticed a large sitting area with hundreds of benches. Mesmerized seeing the sheer scale, another question popped into his mind, how many people work in the production facility? This place looks like it could accommodate thousands of people. Champ nodded in agreement, explaining, currently, there are about 470 people employed in the factory. However, this cafeteria was designed to accommodate a maximum of 1200 people. Despite its capacity, we've never had that many people working here, even during peak seasons. It was built with future expansion in mind, anticipating the growth of our production processes. At the far end of the facility, a long marble table stretched across the cafeteria, adorned with a line of food counters offering an array of enticing dishes. The air was filled with the irresistible aroma of freshly prepared meals. Just' stomach rumbled at the scent, and he couldn't wait to satisfy his hunger. Champ pointed out the setup, explaining, employees here pre-order their meals to minimize food wastage. Chefs prepare only what's been requested since some prefer to bring their own food. Just' face fell as he realized he hadn't placed an order or brought his own meal, resigning himself to going hungry. Noticing Just' disappointment, Champ reassured him, don't worry, John had already placed an order for you yesterday. Let's go and grab your meal. With newfound hope, Just' followed Champ eagerly to where white plastic plates were neatly arranged, ready to be filled with delicious food. As Just' and Champ filled their plates with delicious food, the cafeteria quickly filled up with workers from various departments. A long line formed at the food counter, highlighting the wisdom of coming early for lunch to avoid the rush. Amidst the bustling atmosphere, Just' remarked to Champ, I'm glad we got here early. It's getting crowded already. Champ nodded in agreement, yes, it can get pretty hectic during lunchtime. After finishing their meal, they waited for the break to end, engaging in casual conversation about Just' luck in getting such a learning opportunity, his family, school, and other topics. As the break concluded and the other employees returned to their workstations, Just' and Champ joined the crowd heading back to continue their exploration of the facility. As they approached the next building, Just' couldn't help but notice the bold letters atop the entrance, polishing and grinding shop. Stepping inside, he was greeted by a flurry of activity. Unlike the previous buildings, there were no offices or clear boundaries. Instead, the vast space was divided into four sections marked by yellow and black tape lines on the floor. The atmosphere buzzed with the sounds of metal being worked, the grinding of machinery, the scent of metal in the air, and the rhythmic operation of specialized machines. Champ gestured towards the bustling scene, explaining, All the components that we produce in-house must have a consistent quality and finish for longevity of the generators. We produce some components of the generator using foundry. The components that come out of that place are very rough, oversized, and cannot be used directly. This polishing and grinding shop is a vital part to make sure all the components that we produce fall under a specific tolerance level. Only the components that fall under the allowable tolerance level will move forward to the assembly line. Gest nodded, taking in the sights and sounds of the grinding operations and polishing. Although, he had read about the term tolerance level before, but he could not recall the specific meaning. He simply makes a note in his notes book to research it later. The first area of the shop towards the left of the entrance was a dock door and some space for receiving and storing huge metal bins. Next to the receiving area was a wall adorned with rows of lathe machines, milling machines, grinders, buffing, and polishing wheels etc. Some space in the middle was left for walking and movement of products with large aluminum bins. The other side of the walking space was dedicated for two large CNC machines occupying the middle space in the polishing and grinding shop. Champ started explaining, these large aluminum bins are used to transport the products from one part of the production facility to the other. As you can see these are general use tools and all the products and raw materials are transported using these bins only. Once, these workers receive the products from the dock doors, they start working on these products. Now, what operations they will perform depends on the type of part on which they are working. For example, if they are working on the pistons, they will work with lathe machines, when working with flat machinable parts, they work on milling machines and finally all the stator housings and engine housings are processed in the CNC machines. Champ continued explaining the role and importance of machining shop. Here, each component undergo a meticulous series of procedures to achieve the desired surface finish and dimensional precision. If we use the parts without processing them, the quality assurance team would reject all of the finished products. Just observed as workers deftly operated the machinery, their movements fluid and precise. Sparks flew as grinding wheels bit into metal, while polishers buffed and smoothed the surfaces to a mirror-like shine. As Just absorbed the sights and sounds of the workshop, he couldn't help but feel a newfound appreciation for the artistry and skill involved in manufacturing. With each passing moment, his curiosity deepened, fueling his desire to learn more about the intricate processes that brought the generators to life. As Champ and Just navigated away from the grinding and polishing section, they traversed through the bustling heart of the facility, heading towards the wire covering area. Just noticed a change in the atmosphere as they approached, the air thickened with the scent of heated plastics. This is where we cover the copper wires with plastic and other materials, Champ explained, gesturing towards the three large imposing machines. Each one similar in design but intricate in operation. The setup could be described as, large spools of copper wire positioned at one end of each machine. The copper wire spun continuously as they were pulled into the machine, and the wire exited on the other side with different color coatings, as it was wound on another spool. Just noticed replacement copper wire spools nearby on the racks and the coated spools of wire were symmetrically placed on aluminum bins for transportation. The room boasted ample ventilation, with strategically placed fans, and workers clad in protective gear, resembling firefighters. This is where we apply the protective covering to the copper wires, Champ elucidated, his voice echoing over the hum of machinery. The covering enhanced the wire's durability and insulation properties, ensuring it meet our stringent quality standards, Champ explained that this was the place where they produced all the wires needed for the manufacturing of generators and also to be sold as standalone products under their own brand name. These are some of the most advanced wire wrapping machines on the market, because they automate 90% of the workload when compared to traditional wrapping techniques. Now, the process of manufacturing these wires is simple. One worker feed a predetermined ratio of PVC, rubber, and nylon mixture into the machine, from the top. This mixture is heated, blended, and compressed inside the machine until it reaches a stage that we like to call slurry. The slurry is further dropped down into collection chamber. Collection chamber is further connected to extruder from where slurry is pushed out and the wires are pulled out of the extruder where they get wrapped in slurry. Champ pointed to the extruder on the outside of the machine and continued to explain, this is the extruder and it has a small outlet for the slurry to slip out. We use the same exit to feed the copper wire into the machine. As the copper wires pass through the extruder, slurry is evenly coated around the copper wire. Immediately after the wire leaves the extruder, it is rapidly cooled with water. This sudden temperature shock makes sure the slurry is cooled rapidly and compresses around the copper wires inside. Finally, the coated wire is wrapped on a different spool at the end of the machine. This is the overview of how wires are made. Champ was not done discussing about the wires. He continued, we make many different types of wires like solid copper wire, which has one copper wire inside, stranded copper wire, which has multiple thin wires inside, and flexible copper wire, similar to stranded copper wires but more flexible. Some wires are braided for flexibility, and some have aluminum wraps to protect the wires from UV rays if they need be installed outside. Now, a special thing about this machine is that, once these wires are cooled, and before they are wrapped around the spool at the end, wires pass through this inkjet printer where the wires get stamped with different details like date, location, brand, and other information for traceability. The process for wrapping different wires is different, but these machines can be calibrated to manufacture different types making them a great asset. Right now we are only manufacturing solid copper wires as we need them for our generators. So, you will have to come back to see the manufacturing of other types of wires. I hope this explains the process. If you have any questions, feel free to ask. Just recalled in the last conversation Champ told him that they buy copper and large cylindrical beams. But he does not see those large copper beams here. Intrigued he puts up a question, how are these copper wires made from the large copper beams? Champ replied, oh yes, you remember. I must say, you have a very keen ear. Okay, so how we convert copper beams into copper wires is a different process and takes place in a different facility behind this one. The wire making workshop is the latest addition to this old production factory, hence, it is a separate location. But we cannot visit that location today due to time constraints. But I am glad that you brought that up. To understand that process, I would like you to research another topic of engineering called extrusion. So, next time you are here, let me know what you discovered, and I will take you to that facility. Just nodded and he was finally satisfied with Champ's explanation of the wire manufacturing process. I understand how we manufacture wires. I do not have any other questions about it for now. But I have another question about how we use these wires. I noticed the wires in the assembly line had plastic connectors and were organized very well. But the wires here are long and don't resemble the wires that we use for assembling the generators. Champ smiled at just question. Again, that's a great observation, he replied. The wires we manufacture needs more work before they can be used in our generators. Hence, we send the wires to one of our local partners. They buy the wires from us in bulk. Now, there is a complex contract between the two businesses, but that is a topic for some other time. They process the wires for us by cutting, organizing, and adding plastic connectors based on our needs. They send us back the wires we need for our assembly line and the rest are packed and sent to our distribution partners. It is like taking services from a local business who is expert in processing the wires. Just nodded in understanding. But another burning question was already racing in his mind, why do we have to make our own wires? It seems like we have added a layer of complexity on top of the already complex generator manufacturing process. He asked Champ without hesitation. Champ smiled patiently, ready to explain. This is because we buy copper and large cylindrical beams also called billets, instead of buying them as wires. We process the copper beams and convert them into our desired shapes and sizes. Manufacturing the wires in-house allow us greater control over the quality and optimize performance of our generators. Additionally, we save on costs by buying copper in bulk. This large volume of copper must be sold because any inventory sitting in the warehouse is a liability and no one likes liabilities. Hence, we scaled the wire manufacturing process and entered into the local market as a seller. It was a strategic decision taken by our owner or one of his trusted general managers, someone you might already know. Just understood that Champ was pointing towards John, and this must be his idea. Moving a little forward Champ showed just a table and some equipment. This table belongs to the quality assurance team. Champ pointed to the two workers sitting on the table and continued explaining, the QA team here is responsible to check all the products leaving this facility for consistency and quality of both wires and machine parts. Hence, their table is strategically placed close to the exit dock door towards the back. While explaining Champ points to the large aluminum bins placed next to the QA desk. The area was also used as a temporary storage for products that would move on to the next stage of manufacturing process. The two workers diligently checked all the bins and products. The bins that are full of products and cannot contain any more products, they are moved to this area. The QA team members check the products and place a check okay sticker on the products, whether it be wires or machine parts. Just observed as one full bin was pushed by a power jack to the area next to QA desk. He turned to Champ, nodding in understanding. So, once the truck is full with QA approved products, we ship all these bins to shipping and receiving building, he summarized, seeking confirmation. Champ nodded in agreement. Exactly. All the wires are shipped straight to the shipping and receiving building, where these spools of wire are picked up by the local partner once a week. The finished parts have two location where they can be shipped. They can either be shipped to the assembly line directly or a secondary warehouse location that we will visit soon. He explained, gesturing towards the truck parked by the dock door. Champ guided just through another section in the same building, where the air was thick with the smell of paint. Just wrinkled his nose at the strong scent, prompting Champ to start explaining. Pointing towards the central feature of the section, Champ said, this is our painting area. We use this area to paint our sheet metal parts and other parts. This is a good time to put on those safety glasses in your pocket. Just looked around, taking in the sight of the large bath and surrounding equipment. What's that big bath for? He asked, intrigued by the setup. Champ smiled, ready to enlighten him. That's our powder coating bath. We dip our parts into this bath and allow an even coat of powder to apply on the parts we want to paint. This is very interesting as you can see. The powder is solid, but you can see it moving like liquid, right? This is because we pump air beneath the powder bed, it causes a unique phenomenon to occur called fluidization. He explained, as just listened, Champ continued, the powder sticks to the metal surface because of a property called electrostatic attraction. We preheat and ground the metal parts that need to be painted, while the powder is positively charged because of the method it is created and also the fluidization giving extra energy to the system. Once the metal part is dipped in the powder, we shake off the excess powder and finally send the metal part for heat treatment to be cured. As Champ was done explaining the painting process, he opened up the conversation for just to ask any further question. Just curious as ever asked, are these parts also inspected by the QA team? Champ replied, exactly, all the parts that are processed here are tested by the QA team and only then allowed to move on to the next stage. As Champ explained, they continued walking towards the exit, still immersed in conversations about the various processes they had witnessed inside. As they approached the next building, just noticed the bold letters spelling out foundry on top with big letters. Champ turned to just with a curious expression. Do you know what a foundry is? He inquired. Just shook his head, admitting his lack of familiarity I've never heard of it before. That's okay. Let me explain, Champ offered. This is one of the core practices of engineering, where we use molds or casts and molten metal to make a general shape of the parts we need for our generators. You saw people working with grinders, lathe machines, and milling machines in the last shop, right? All those parts were produced here. Champ continued elaborating, here we produce different components of the generator like housings, stator cores, mounting brackets, and supports, etc. It is more efficient to use foundry techniques for these large parts, rather than relying solely on deductive machining. Deductive machining takes a lot of time and resources to achieve the desired shapes. Champ tried explaining what a foundry is in simple words. There are three parts to foundry, melting metals, creating molds, and solidification of the cast. The process starts with creating a pattern with wood or other suitable materials in the desired shape that we want to cast. The pattern is then used to create a mold using a special sand mixture. Once the mold is set, the pattern is removed from the mold, leaving an empty space inside where metal can flow. Once the metal inside the mold cools, we break the sand mold and retrieve the metal cast inside. Champ paused for a brief second seeing just thoughtful expression. Champ continued, I understand if you find it hard to wrap your brain around it first. It is a complex topic. That's why I suggest checking out Brilliant Supply Chain. They have some great resources to help understand the foundry process better. It's important to have a theoretical understanding. Further, he inquired, have you heard about this website before? Just replied, yes, I have. Aval suggested me to research a topic on this website. Hence, I have already visited the website before. Champ was pleased to hear this. Further, he recommended that just should try to learn something new every day from that website. This would contribute to his continuous learning process and get him closer to his goal of understanding business. You can learn about foundry under manifesting section on the homepage and then going to manufacturing. Finally, Champ navigated just inside the foundry shop and started explaining the processes. Towards your left you can see two large furnaces. Most of the parts that we produce are manufactured with aluminum. Hence, we keep the furnace temperature around 650 to 800 degrees. Inside large batches of aluminum are melted. Right in front, you can see this wide area full of sand that we use for creating molds. The molten metal is poured into these molds for creating casts. As Champ was explaining, a worker pulled out a big bucket of molten metal from the furnace and poured it into a mold. They both observed this from a safe distance as they were not prepared for the intense heat emanating from the furnaces and the molten metal. After pouring the metal, the worker moved to the opposite side of where they stood. Champ asked just to follow the worker. Reaching on the other side, he started explaining again. Once the molten metal cools, we break the mold and retrieve our casting. As Champ explained the process, the worker used a long metal rod which had one end bent at an angle to break mold and pull out the metal piece from the sand. After breaking the mold open, we let these pieces sit to cool further in air and then transfer them into the large aluminum bins for transporting them to the grinding and polishing workshop. All this work requires a lot of area, safety precautions, and a highly skilled staff to handle this work. Reaching the end of foundry shop, Champ advised just that it was time to move to the next building. As they walked back outside, Champ continued his description, this workshop needs a lot of raw materials and space. As you can see, we don't have a lot of space in this shop for the raw materials. Hence, we have a secondary warehouse adjoining to this building. There we keep all of our supplies like aluminum reserves, sheet metal, nuts and bolts, etc. Let me show you what we have there. Upon entering the next building, it was a familiar sight for just. Familiar sight to the other two warehouses he had seen. An office with large windows, racks, forklifts, power jacks, clearly marked walkways, etc. Champ elaborated on the need for another warehouse and logistics for the movement of products. The shipping and receiving warehouse is the primary warehouse for this manufacturing business. However, we needed a dedicated warehouse closer to the foundry shop as well. Sanjay works closely with the procurement team and our suppliers and distributors. We also have a requirement of internal dispatch and logistics service. This service caters primarily to the internal production processes. Hence, there was a need for an additional warehouse. Barry is the warehouse supervisor here and he reports to Sanjay directly. With Barry being here, Sanjay has divided his workload, as he is responsible for both internal and external logistics and warehouses. Because Barry is very good at managing the internal operations. Sanjay trusts him to manage the internal requirements of the production facility. Champ further explains that Barry was responsible for almost all the movement within the manufacturing business. Being at the center of the manufacturing process requires Barry to effectively manage the four trucks inside the production facility. Trucks are used for all the movements here, like raw materials, finished products and tools, which makes this a tedious job. Further he also have to maintain inventory in the warehouse so that it could be effectively used as a buffer stock location. The explanation about the warehouse and logistics got just thinking. He has read about dispatch before but could not apply his knowledge about how dispatch was useful in the production facility. He would need to do some more research before he is ready to get into deeper discussions about this topic. So, he notes the topic down to research it later. He knew that he would find it on the brilliant supply chain website. Soon they both reached the entrance of the warehouse office. Opening the warehouse office, there were three occupied desks of the team members of Barry. Barry's office was a room towards the back and was completely closed off from the view of the warehouse. This was a complete contrast for just after seeing the head office warehouse managed by Bill. Champ knocked and entered Barry's office, just right behind him. The office room was small and mostly filled with piles of papers and randomly placed items which seemed out of place. Champ stretched his hand to Barry for a handshake. Hi Barry, good to see you buddy. With the tone and energy Champ met Barry, just assumed that they were old friends. Champ introduced just in brief the reason for their visit. Hearing Champ, Barry quickly left his seat and expressed his enthusiasm in showing just around the warehouse. Walking out he started revealing his roles and responsibilities. Most of the work here is related to planning and working with other departments. I act as the buffer between the big warehouse and the production. This facility is able to swiftly fulfill the demands of the production process. We also have access to the production schedules which we use as a guide to stock up and transport the raw materials. This means my team managed the internal dispatch of this facility. We have a total of four trucks working in this facility, which we use strategically for all the movements within the facility. Just in Champ nodded as they walked behind Barry. Once outside in front of the office, Barry pointed in different directions while divulging, we have sheet metal components waiting to be delivered to the polishing and grinding shop for painting, then we have some stock of nuts and bolts for the assembly line. On this side we have spools of copper wire, paint stock, unprocessed aluminum metal, and much more. We follow the receiving process every time we receive anything from the shipping and receiving office and keep a record of movement of inventory. This helps us keep our inventory count correct in case of discrepancies, especially during cycle counts. Just made a note of another industry specific term cycle counts. He made a note to research it later. That's it, I don't think there is anything else important happening here, Barry reported. Champ stepped forward and thanked Barry for taking the time out from his busy schedule to help just. Now, we will take our leave. There is still one more place that we have to visit before heading back to the office. Saying their goodbyes, the group disbanded into two. Barry returned to his office and the other two left the warehouse. Champ guided just to the last building in the manufacturing facility, sheet metal shop. Entering the sheet metal shop, just noticed the absence of an office area. Some employees bustled around the workshop, and there was ample space between the working stations. Champ began explaining, all the sheet metal that we saw in the shipping and receiving warehouse is meant for this location. He pointed to the huge piles of sheet metal placed on pallets. These were massive flat sheets of metal lifted by magnetic arms extending from a crane above. The metal sheets were picked up one by one and placed on two large laser cutter machines next to the storage area. Here, we use high voltage electricity to cut the metal sheets from predetermined areas, creating holes and vents for the generator, Champ explained. This leaves us with the desired shapes and the rest of the sheet metal is recycled. We simply send it back to the supplier. As Champ spoke, a worker meticulously separated the cut parts and placed them on a pile next to where he was working. The remaining sheet metal that was not needed was also picked up by the worker and placed on top of another pile of similar sheet metals. This was ready to be shipped back to the supplier. Simultaneously, a worker operating the crane picked up another piece of sheet metal and placed it on the laser cutter to repeat the process. Right next to the laser cutting machine were four enormous machines emitting a loud clanging noise as workers operated them. The noise reverberated throughout the area, audible even from outside. Champ explained, these are bending and pressing machines, operated using hydraulic principles, hence the noise. The purpose of these machines is to shape, bend, and imprint logos and other design details onto the sheet metal parts. Workers manually handled this process. Champ further explained, once the workers finish processing these parts, they are moved to the next stage where these parts are welded and painted. Here we follow an inventory control method called FIFO, which means first in first out. The parts that come in first would be prioritized and shipped out first. The only reason for following FIFO is to prevent rusting of these parts. Powder coating method is very good but requires the surface to be clean and free from any impurities. Hence, we want the sheet metal parts to be painted as soon as possible. Next, all the parts are placed on these aluminum bins, as you can see they are used all over the production facility. Some large parts that do not fit into these bins are moved on the pallets. Especially the parts that need to be recycled or considered as waste are not put into these bins. Just tried to probe Champ into disclosing more information about the FIFO inventory control technique. To which Champ replied, we cannot get into too much details about how we have implemented FIFO in this facility. But the name implies what we are doing here. Essentially, the goal is to ship out the product that come in first. We track the inventory by these special stickers and barcodes on the bins. We also number and track each part individually. Further, we have an advanced tracking software system that allows us to manage the FIFO technique and also helps us with keeping the track of the inventory. Our time today is limited so you will have to visit back to learn more about that software solution. Just nodded in agreement, making a note to research FIFO later in his own time. Champ continued guiding him through the workshop until they reached another marked section, the welding, finishing, and QA area. Here, Champ explained, two QA team members constantly check the quality of the parts before they are moved to the next stage. The finishing team works closely with the QA team to address any issues like cracks, rust, or sharp corners and ensure compliance with quality standards. We also have a welding section which is used for welding the essential parts whether they are design or functional parts. Champ then concluded their tour, saying, Finally, all the finished products are moved to the outbound area where a company truck would pick up the parts and take them to the polishing and painting shop. The parts that are waste or need to be recycled are shipped to the shipping and receiving warehouse and this marks the end of our tour of the manufacturing facility. We are on time to check back with John now. Champ looked at his watch and asked just if he had any more questions. Just was elated by the opportunity to witness the intricate production processes firsthand, yet he couldn't shake off his determination to find evidence for Ovil's case. Despite the solar panels, windmills, and the utilization of energy produced in the QA department for the assembly line being notable, Just was still on the lookout for signs of toxicity. Turning to Champ with a curious expression, he voiced his inquiry, I do have another question. Do we work with any toxic elements in this facility? Champ's brow furrowed in thought as he began to explain, Well, there isn't much use of toxic elements in the manufacturing processes as you have witnessed yourself. The only part of the production that used to be toxic was the painting area. Since we have adopted the powder coating method, we have eliminated the toxic element from the production process. We made the switch from spray paints about two years back, prioritizing environmental consciousness. While our processes strive to minimize risks, it was important to note that no system is entirely closed. There may be some emissions during the curing process in the ovens, but they are minimal when compared to industry standards. Just inquired further, probing into the environmental impact of the production processes. Champ nodded thoughtfully before responding, While we have adopted some good practices to minimize environmental impact, it is important to recognize that there are always challenges and strides that remain to desire for more. For instance, the energy-intensive ovens that we use for curing paint, relies on energy supplied by the city, we also burn coal in the furnaces in the foundry shop. City produce electricity using the hydroelectric power plants, coal, and petroleum. Each source comes with its own set of environmental considerations. So, while we strive to mitigate our impact, there is always some room for improvement. The main office where Champ and just started their field trip was a short walk from the sheet metal shop. They quickly traversed the short distance while discussing last few topics. Once back, Champ stopped in front of John's office, and knocked on his door. A familiar sound called out, come in. Upon entering Champ and just saw John sitting on his desk and engrossed in his work. John looked up and welcomed the two into his office. Oh hi guys, you are back. How was it? Did you guys have fun? Champ and just synchronized in their response, yes, it was fun. Noticing the timing and response both Champ and just looked at each other and chuckled. Champ continued to explain, we have covered the entire facility except for the wire extruding facility. It was a lot of fun, but we had to return as the day is about to end. I understand that you must reach back to the head office before the end of the day. So, we are here on time. Champ turned to face just and spoke, it was great to see you just. I hope you have learned something valuable today. I wish to see you again, whenever you are back for more. But don't forget, knowledge is the key. To understand everything it is important that you gain more theoretical knowledge. So, study and acquire that knowledge. You know where you can find all the information right? Champ paused and let just spoke. Of course, I know it is brilliant supply chain. I know it has a lot of information. I promise I will study and will be better prepared for my trip next time and thank you for showing me the production facility. It was a lot of fun with you. Just responded to Champ. John also stood up to thank Champ for his time. Thank you Champ, I know it was hard for you to take an entire day off from your busy schedule. But, thank you for everything. I am sure you must want to rush back to finish some of your work. We will also get going and I will see you tomorrow. John wasted no time and he was already preparing to depart. He stood up from his desk, pulled his laptop bag, and hurriedly packed his belongings. As they rushed back to John's car and embarked on their journey to the head office, John seized the opportunity to inquire about Just's field trip. How was your field trip? Did you learn anything valuable? John asked, his curiosity evident in his voice. Just had been waiting for John to start the conversation, there were so many things that he wanted to ask John. Yet, he tempered his excitement and replied thoughtfully, it was an incredible experience. I learned so much today and got a good grasp of the high-level processes involved in the manufacturing of generators. But Champ advised me that if I truly want to understand the intricacies of the processes, I must grasp some technical knowledge and then come back for another visit. John nodded in agreement, emphasizing, that's right. In fact, one more visit won't suffice to grasp every component of the manufacturing process. You'll need to spend multiple days in each section to delve deeper into the intricacies. Only then will you truly comprehend the why, what, when, who, and how of our operations. Just acknowledged John's advice with a nod, expressing his understanding. He affirmed his intention to revisit the production plant and delve into every aspect of the process. Just was not done, he had many more questions to ask John. He asked, is there some tension between Champ and Mr. Richard? John's expression shifted to seriousness, caught off guard by the question. With a thoughtful expression, he spoke, you're aware of Champ's role in the factory, right? Just replied yes, he is the production manager, John continued, so, you also know Mr. Richard's role? To which Just replied, yes, he's the quality assurance manager who works under Champ. John clarified Just's misconception and provided a detailed explanation, actually, that's not entirely accurate. While Mr. Richard does indeed report to Champ, the quality assurance team's accountability extends to all stakeholders, particularly OVAL. This department operates throughout the organization, not solely within the production facility. Managers like Mr. Richard report to the director of QA, whom you may not have encountered yet. Their diverse responsibilities make them exceptionally cautious to prevent potential quality issues. He continued, breaking down the dynamics for Just's understanding, Champ's objective is to maximize efficiency and speed in producing finished products. On the other hand, the QA team's meticulous approach slows down the process to assess quality, either removing or flagging subpar products for rework. This contrast in approaches often leads to disagreements and tension between the two teams. John reassured Just, offering a perspective shift, but there's no need to worry. Consider it more as friendly competition within the organization. Champ acknowledges the vital role of the QA team. Despite occasional tensions, they both contribute effectively within their respective departments for the benefit of customers and the business. Understanding dawned on Just as he processed the explanation. He realized that the apparent conflict stemmed from differing work styles rather than personal animosity between Champ and Mr. Richard. John again emphasized the fact to not worry, you should not worry, they both are mature and very professional to sort their differences. Even if we were to change one of them or both, the problem will remain the same, which is conflicting requirements and working styles of the departments. Moreover, they have known each other for many years now. Their current dynamic isn't always the norm. Perhaps next time you visit, you will see a completely different facet of their relationship. Just was impressed by John's wise words and his skill at interpreting human emotions. Aside from this topic Just had another question for which he waited all day to inquire from John. I have another question, when I was talking to Champ he hinted that you suggested the idea of manufacturing wires in-house. What was your mindset behind proposing that idea? John humbly responded, ah, so he told you about that as well. Let me be clear, even if I was the one to propose this idea, it was still a collective decision. At the end of the day OVIL has the right to make the final decision, whether to approve or disapprove any idea like this. I did some market research and made a report which discussed the feasibility and opportunities of the new market. I think, you should also learn how to conduct market research and then analyze the data collected from the research. It should be a vital part of your learning journey of business fundamentals. Just sat attentively as John delved into the intricacies of market research. Market research, John began, is all about understanding the landscape in which a business operates. It involves assessing the market situation, understanding customer needs and preferences, identifying competitors, and analyzing market trends. Just nodded, absorbing the information. But how do we conduct market research effectively? He asked, John smiled, pleased with just curiosity. Well, there is no one way of conducting market research. Instead, it is case sensitive. As it looks outwards towards the words there are many variables that can be addressed like politics, competitors, customers, existing networks, etc. There are infinite number of possibilities. Hence, some great people before us have created some useful frameworks that we can use to streamline and narrow down our search, he explained. For instance, there's SWOT analysis, which helps us assess strengths, weaknesses, opportunities, and threats. Then there's Porter's Five Forces, segmentation, PESL analysis, and more. Aside from these techniques and frameworks we also have some tools that we can use like MailChimp, user interviews, Google Forms, etc. Just scribbled down the names of all the frameworks and tools as John spoke. He understood that there were many more tools and techniques that could be used for market research. Hence, he would research this topic further in his own time. I have a lot of topics to research, when I am home just thought in his mind, speaking to himself. John was not done explaining, he continued speaking. Not all tools are applicable in every situation. It's about learning where and when to apply each tool effectively. And sometimes, it's about thinking outside the box and using old tools in new ways to achieve different results. Hence, experience in this line of work is considered a valuable asset. Just nodded, understanding the importance of versatility in market research. Did you and Abel learn all this during your business studies? He asked. John chuckled. Yes, indeed, he confirmed. We spent countless hours studying and practicing these techniques. And let me tell you, it's a journey of continuous learning. Just felt inspired by John's words. He realized that mastering market research would require dedication and a willingness to adapt. But he was eager to embark on this journey of discovery. Still, there was another question lingering in his mind, what happens after the market research is done? John replied, once a market research report is submitted, a meeting is conducted to discuss the implications and strategic alignment with the business and stakeholders' goals. The next logical step is decision-making where a decision is made to either accept or reject the proposal in the market research report. Finally, if the proposal is accepted, a team and some resources are allocated for the implementation. Once the strategy or change is implemented, we must track its performance and evaluate the market again. It is done by indicators that we call KPIs or Key Performance Indicators. Only after successfully completing the last step can we conclude the implementation of a new strategy or change.