The key deficiencies in the Playpower organization are:
Poor management – too opinionated and lack or real-world plant level manufacturing experience
Lack of planning – the plant ran in an expedite mode. “Production” meetings were to determine what could be shipped that day.
Protracted long work hours (up to 68 hours per shift) cause a loss of high skill level positions. Because of the reputation of Playpower qualified replacement could not be hired fast enough to compensate for the attrition.
The “forecast” which the current budget was based upon was low by as much as 90% - the operations was over capacity for most work cell.
POOR planning or lack of planning