Question regarding Supply Chain Challenges at LeapFrog What

Question regarding Supply Chain Challenges at LeapFrog: What were the constraints that face Capable Toys Limited to produce the required quantity for the holidays and how were they overcomed?

Solution

The major constraint for Capable Toys Limited was limited capacity due to less number of moulds: Only two sets of mould were used for LeapFrog production.

Solution: To increase capacity the Capable runs its factory 24 hours a day, in three 8-hour shifts. Capable got the OK from Leapfrog for third and fourth set of tools after confirmation of LittleTouch success. With every new design the moulds were designed such that the productivity is increased from 3500 toys a day to 6,300 toys a day. Also the design was improved to reduce the fail rate inn toys from 5% to 0.3%. By increasing the number of moulds and improving their design Capable was able to increase its capacity.