The household items under brand name 'focus' remains almost stagnate i.e. in 1993 it was worth 6056,000 pounds and in 2005 it remains at 6533,000 pound. But the new product range under brand name 'concept' comprising storage years, mixing bowls, strainers, salad bowls, towel holders and other kitchen items, sales grown from 3411000 pound in 1997 to 16210,000pound in 2005. In 2005, company started a new product range with brand name 'concept office' comprising filing trays, storage boxes and a range of desk items. This latest and new range of products proved very successful at the very first year of its launch and contributed 1320,000 pound in sales. Company has diverted itself completely from its industrials customers. Company has inculcated a reputation for house hold products for its quality in the minds of the consumers'. It has used latest technologies and trained manpower but being in an industry, where entry barriers are low, it faces on inherent threat from smaller manufactures on the pricing front. Company has planed its manufacturing facilities with a process-based layout and having all sorts of injection - moulding machines of various ages from latest Robotic devices to operate manually. At the planning level, scheduling all the machines and maintaining inventory levels as well as utilization of equipments, output rates &scrap rates has to be monitored by the planning manager. In this particular area, company is facing the problem company is also inclined to develop new and innovative products regularly because of the market requirements. Needs and preferences of customers are changing fast and company has to cope up the changing need of its customers. So company is always trying to develop newer products but in the process faces some problems in developing products continuously and timely. Now company is facing a new dilemma that whether it may continue with its product range under brand name 'Focus' or to emphasize on the other product ranges namely under brand name 'concept' & 'concept office' in this situation company has to evaluate its production and operations capacities and to find out the right kind of strategies for production, warehousing and distribution.
Problem: In the process of planning and controlling the production, planning manager has experienced certain problems related to scheduling of the different product range; sequence of production for each machine and would faced the problem of proper scheduling due to fluctuating demand of products, seasonal demands and ever changing customer preferences. Scheduling and planning of production has faced the problem. To meet the fluctuating demand, problems to maintain proper inventory, dynamic and frequent schedule changes and longer production time with more wastage created the problem for the company. More number of moulds with large sizes and complex designs increase the change time, and this reduced the effective batch size as well as brought down average utilization. This situation has created the problem for production schedule also. Company has focused on new product development and innovations which needs well panned strategies but due to testing of moulds in the existing production facilities hindered the production schedule and may delay launch of new of new products. In the process of operations, new product trial increases the product cycle time and hence created the prob