MGT 314.

GROUP PROJECT
Production Management
Submitted to: K. M. Saqiful Alam (Sqi) Faculty Member, North South University

Submitted by: Name Saif Ahmed M. Marif Hasnain Safin Kamran Amir Mishal Nishnat Sultana Shahdat Hossain Id # 1020789030 1010532030 1020444530 1010656530 1130579030

Date of Submission: 21st January 2014

Letter of Transmittal
21st January, 2014 K. M. Saqiful Alam Faculty Member North South University Subject: Submission of a report.

Dear Sir, With due regards and respect we state that we are very thankful to you as you assigned us this project. It is a great opportunity for us to acquire theoretical and practical knowledge about Production Management. We have tried our best to gather what we believe to be the most complete information available. Your kind acceptance and any type of appreciation would surely inspire us. We would always be available and ready to explain further any of the contexts whenever you ask.

Sincerely yours, Saif Ahmed . .. .. Nishnat Sultana Shahdat Hossain

M. Marif Hasnain Safin Kamran Amir Mishal

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Acknowledgement
With regard to the project paper, we would like to thank each and every one who offered help, guideline and support whenever required. First and foremost we would like to express gratitude to our most honorable course instructor K. M. Saqiful Alam for his support and guidance. Without him we couldnt visualize the project. His valuable advice, guidelines and continuous monitoring have made this task possible. We would also like to add a few hearty words to the people who helped us in numerous ways.

We are proud to be a student of Saqiful Sir. We have thoroughly enjoyed working for the project paper and hope it will be appreciated.

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Table of Contents
Introduction ................................................................................................ 4 Company Background ................................................................................. 4 Operations Strategy Analysis ...................................................................... 5 4V ................................................................................................................ 5 Polar Diagrams ............................................................................................ 6 Process Analysis .......................................................................................... 8 Recommendations .................................................................................... 11

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 Introduction
The main objective of the project is to find out the position of Johnnys car wash service in the related field. To find out the position certain measures has been taken which includes 4V diagram, Process map and Polar diagram. To ensure more decent organizing we have developed a new process map showing the improvised steps that Johnnys car wash can adopt to provide service that is more delightful. After doing the new process map we have showed what impact it will have on the Polar diagram. To show the differences more clearly we have also compared the existing Polar diagram with the new Polar diagram.

Company Background
Johnnys Car Wash situated in Cincinnati, Ohio. We have particularly chosen this company because we have access to its operation through a friend of ours living and working there. The firm is not the biggest car wash among all but its current condition is quite good to put a competition in its state. Johnnys car wash is more upgraded among all other car washers in Ohio. They provide fabulous quality of products, price is competitive and customers are provided with a great experience. Furthermore, they do not use harmful acids or strong alkaline in wash process and use polymer soap that pulls off the dirt easily and they will re-wash your vehicle until you are satisfied. They ensure best service in the industry and believe that service ties everything together. However, it can be improved even more by reducing time and managing process. The key process of Johnnys Car Wash is the process of car washing system and managing it according to customers requirement. Therefore, in our project we have tried to improve this process in order to save time and enhance customer satisfaction.

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 Operations Strategy Analysis

4V (Volume, Variety, Variation, and Visibility):

Johnny's Car Wash Low High High High

Volume Variety Variation Visibility
Fig1: Johnny's Car Wash 4V Analysis Diagram Volume: Johnnys car wash has a moderately low volume. It takes them more than twenty five minutes in the completion of a car wash whereas other well renowned companies in the same service line takes 10 minutes whether hand or automated wash. As a result, they are capable of washing less number of cars in a given time phase. This affects their volume, and thus it shows that they have a low volume capacity. Variety: Johnnys car wash has moderate variety compared to the other companies in the same service field. They came up with many innovative ideas and increased their varieties on car wash. They have categorized their car washing techniques into two functions: 1.Hand-wash (manually) 2.Automated-wash. Moreover, they also provide facilities to customize the car washing procedures and can chose to wash their car according to preferred plans. Variation: Johnnys car wash is a neighborhood oriented business. They have got a set of loyal customers, which helps them to keep the demand at a stable position. Moreover, most of the car washes are designed and built with respect to neighborhood applications. This shows that they have moderately low variation in demand. Visibility: Johnnys car wash has a high visibility as the business is a customer oriented one. They try to provide services to their customers at its very best. To keep their customer happy, they often come up with discount offers and even provide free services on every Mondays for the premium members. They also provide guaranteed satisfaction for a clean car, if any dirt or something could be seen anywhere on the car they would rewash it for free. Their goal is to satisfy their customers in any possible way.
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High Low Low Low

Polar Diagrams:
Cost 80% 60% 40% Speed 20% 0% Dependability

Existing

Quality

Flexibility

Fig2: Polar diagram of the Existing Scenerio of Johnny's Car Wash

We assumed each of the factors under polar diagram at a scale of 100%. Johnnys existing scenario shows that unlike other car washing services they do not use strong acids or alkaline to minimize their cost. Their ultra soft car wash cloths, highest quality polymer soap and waxes ensure you the highest quality at 80%. Secondly, on an average they complete your personalized car wash service (automatic and manual) in 25 minutes or less which is much longer than any other car washing service, which relates to the speed being moderate at 45%. Johnnys dependability is relatively low at 30% since the Raw materials of car washing service keeps on changing constantly; to compete in the market Johnnys car wash also keeps on changing their materials to keep them updated. Moving on to flexibility that lies somewhere between moderate and high at 65%. They provide both manual and automated service. Manual system is the counter part of automatic system. While manual system is not that costly but require more time but automatic system takes less time but a little costlier. Johnnys car wash cost effectiveness lie at a moderate level of 55%. They serve using the traditional way for the queuing of the cars, which takes more time for each car to enter inside the belt than it is actually required. This consequently puts down the cost effectiveness at a moderate stage.

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Cost 80% 60% 40% Speed 20% 0% Dependability

New

Quality

Flexibility

Fig3: Polar diagram of NEW Scenerio of Johnny's Car Wash

In the process map, we have just emphasized on the time that each car takes on the belt. Previously it used to take twenty-five minutes but right after some modification and recommendation in the queuing line, it takes just seven minutes to wash a single unit of car. Therefore, the speed for the service to reach the consumers will be high because previously it used to take twenty-five minutes to wash a car, now it just takes seven minutes reducing the time by 72%. On the other hand due to innovative queuing system, it is found that more cars can be serviced each day (4 times more than the previous figure), which will subsequently lead to higher economies of scale and hence will increase the cost effectiveness to a handsome position from a old moderate stage. As shown in the process map, we have just emphasized on the queuing of the cars, so just speed and cost effectiveness will hike up to a high stage from a mere moderate one while as it will not have any impact on quality, dependability and flexibility and will remain unchanged. As queuing of the cars has nothing to do with these three components.

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 Process Analysis Johnnys Existing Process Map

Drive in

Position the front tire in a special conveyor belt

Only the cleaning water & solution comes in physical contact

Touchless process is done.

High powered Jets of water & strong detergent used Set car in Netral Mode

Car wash complete

Conveyor Belt glides car through the bay

Touchless/ Cloth Fiction

Touch up (clean the windows, wipe down the dashboard and doors, add some air freshener)

Roller pushes & rolls the car through the tunnel

Car turned off & placed in neutral

Car is placed in a conveyor truck

Dry (uses handdry/automated drier)

Pre-Soaking stage
Mitter Curtain Process Soft strips of clothes in a row, rubs back & forth.

Wax (creates water resistant coating)

Washers are run by electric motors & hydraulics

Various hydraulic pumps washes the car at once

Rinse Arch Done after major cleaning

Foam Application

Scrubbing through wrap around washer/high pressure washer

Blast process goes with high pressure washer

Water shooting from the nozzles causes the water jet to spin rapidly
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 Problems and suggested Improvements

In a car wash system, things are usually done manually or in automated way, and the packages also differ. But, in Jonnys car wash process, as the previous process map reveals- there was no clear way of getting it- how it was being done. It was automated or manual? Hence, to make it easier, and clear, we came up with a new and improvised version; Where we eliminate the fact of touch-less or cloth friction part, and instead we keep the option of- manual and automated. So, that one can easily choose between the packages, based on their demand and where they properly fit in. Secondly, we eliminate a few parts, trying to make things less lengthy and we introduce a smoother process that gets the car wash done in a faster way. At first, we had the different parts done in different segments, like- all the basic phases, and then, after mitter curtain process, and foam application, there used be a decision point, confusion related to which way should they choose for scrubbing. One way was- the water washer was run by electric motors and hydraulics and another way was- blast process. Then, rinsing part, and then was and the rest. But, here we combined scrubbing with water shooting part with rinsing. We do rinsing at the same time of cleaning, so that its less time consuming. Then wax layer is done and lastly, drying up and touch up is done at the same time. So, now its faster and not very time consuming like before. So, the improvised, new process map is helping the car wash process immensely & is leading Jonnys car wash to reach more customers in less time.

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Johnnys Improvised Process Map

For manual, Hand over the car with a slip, to the team of car wash
Interior-Dash, console, door panels will be wiped with hands.

Cleaning with body wash, polish, sealer will be done manually.

Exterior will be hand dried

Will give you a signal when vehicle is ready

Drive in

Manual/ Automated system?

Car is placed in a conveyor belt

With the claim slip, the vehicle can be retrieved. & the carwash is done!

Roller pushes & rolls the car through the tunnel

Car turned off & placed in neutral

PreSoaking stage

Mitter Curtain Process Soft strips of clothes in a row, rubs back & forth.

Foam Application

DRY & Touch up

Wax (creates water resistant coating)

Scrubbing, water shooting in blast process & rinsing goes on at the same time.

Car wash complete

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 Recommendations
As the improvised process mapping suggests that Jonnys car wash need to eliminate some steps to make it quicker than before. Low variability means the business is stable, but the firm should expand its business to increase the demand as well as sales. Jonnys car washing company should consider the matter of economy of scale by increasing the output and decreasing the cost.

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