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day interviewing workers on the assembly teams. It was brought
to our attention that at certain points during the day the backup
of WIP carts was in fact problematic, from the standpoint of
worker safety and from the ability to locate the required cart
quickly and easily. There are approximately 80 to 90 carts in use
at any given time, which are loaded with raw materials on a per-
job basis and are tagged with a work order. After the carts are
loaded and tagged, they are placed in front of the assembly
workstations. Copies of the work orders are taken to the plant
control office. The plant supervisor then assigns the jobs to
assembly stations by placing the work order copy in assigned
bins located on the plant control office wall. The assembly
employees will go to their assigned bin, pick their next job
ticket, and then locate the corresponding cart for that job. Mr.
Alvarez mentioned that locating the cart required for the next
job could take anywhere from one to ten minutes depending on
the assembly backup (number of full carts used that day) and the
location of the cart within the facility. The manufacturing
employees are tracked on a 100th-of-the-hour time basis for
work, which means that there should, in theory, be very little
unproductive time during the day, with the exception of break
periods. This also reduces socialization of employees. We
decided to narrow our analysis to the immediate problem of
locating the correct cart. After brainstorming possible solutions,
we have concluded that Wiley should use an electronic paging
system similar to what restaurants use to notify customers that
their table is ready. We recommend that the carts be outfitted