Soap Project Name _____________________________ Date____________ Per____
Task: In a cost-effective and creative manner, your company is to produce one pound of packaged, quality soap that meets and appeals to the consumer’s demands of a specified soap market.
Background information: We (the class) are an existing company based in Ewa Beach, Hawai’i that plans to enter the market of producing bar soap for families in the Leeward community. Our marketing division in Honolulu, has provided us with an initial analysis of the Leeward Community. Assuming that we can take over 20% of the Leeward “family” market, that each family would purchase seventy-five 140-g bars per year, and that we stick to a basic recipe of lard, lye and water, we could make a minimum profit of 10% per bar sold. From our research division at the University, we have obtained an initial small-scale basic recipe that makes ~21 grams of hand soap. This recipe will serve as our foundation for producing the one-pound prototype. Prior to the project we will become familiar with the process of saponification by using the recipe to make initial soap samples. In addition a soap expert will inform us of the chemistry behind saponification and take our questions.
Project Objectives:
Project Assessment
You are competing against other companies to produce the best soap, best presentation, best portfolio. See categories below.
Job Application – (indivdual)
You will be graded on professionalism and content of your resume/application.
Upper management member or department grade member Portfolio
Each upper management member and each department is responsible for keeping a portfolio which includes but is not limited to: table of contents, time line, daily plans, project summary, paychecks and copies of memos sent and received. Your portfolio should reflect what you or your group accomplished during the project (project summary). In other words, you should document something every day so that you can write an accurate project summary at the end. Your portfolio will be compared and ranked to like members/groups from other companies in terms of quality in the areas of completed tasks and goals stated above. Please reread your job description so that you’ll know the unique materials necessary to include in your portfolio. (Please note: This is a competition against other companies, not your own!) Remember: Every plan, decision, report, transaction and action should be documented and placed in your portfolio! If you send a note and/or submit a report, keep a copy for yourself! Due by the bell on June 3, 2015.
Company Product Grade
Soap products will be ranked on quality and quantity with other companies. This includes pH, latherability, scent, appearance, consistency (both types), packaging and cleaning ability. Due by the bell on June 3.
Company Public Relations
Remember, you are trying to sell your company. The point of PR (posters, handouts, fliers) is to prove that your business and science approaches are best (cost-effective, meet consumer demands, reproducible large-scale production, your company knows the chemical process of making soap.)
Character role-playing grade (individual)
Your grade will include participation through on-task behavior in the classroom. On-task behavior means you’re in character throughout the period from bell to bell, every day. If you’re not doing your job, you will be demoted (grade deduction). This is a challenge! Rise to the occasion!
JOB VACANCIES! APPLY NOW!
Please read the job openings available below. Every member must choose 1 job. Jobs will be chosen on a first come, first served basis.
Area I: Company departments
RESEARCH SCIENTISTS (10-14)
Using the initial recipe, the research scientists are responsible for planning and performing experiments that will produce the quality of hand soap that meets federal standards, your company’s quality program standards, and the public demands of Ewa Beach community families (obtained through marketing’s research). Specifically, the research scientists are responsible for determining how five variables [fat/OH- ratio, NaOH vs. KOH, reaction temperature, color addition, and scent addition] affect the pH, latherability, scent, appearance, consistency and cleaning ability of the initial soap recipe product. They are not concerned with the quantity produced (that’s the engineer’s job) so much as the quality. However, they are expected to assist engineers in doing lab research to help find corrections for any problems that arise during the engineer’s final large-scale production of the soap. Because of the slow reaction rate for saponification, the research scientists will be expected to put in overtime in order to maximize lab use. The manager (chosen by the department members) is responsible for reporting to the supervisor on the group’s accomplishments, problems, possible solutions to problems, and adherence to the time line. The manager is also responsible for having his/her group prepare the portfolio, which should summarize the experimental plans, lab procedures, data (chart format), data analysis (in appropriate graph format) and conclusions. The research scientists are responsible for submitting chemical and equipment purchase requisitions to the accounting department so that supplies may be procured. An initial purchase request order is due on the 1st day (5/27) of the project so that you have lab access by day #2. Only those items on the requisition will be given. Those unavailable will be noted. You may not use the materials from other departments in the school. Things from home may be used, but only if they meet regulatory standards. All labs MUST take place here!
ENGINEERS (5-6)
Scaling up from the initial recipe, the engineers are responsible for planning and performing experiments that will lead to a better understanding of what process will reproducibly produce the one-pound quantity of hand soap that meets federal standards, your company’s quality program standards, and the public demands of Ewa Beach community families (obtained through marketing’s research). Specifically, the engineers are responsible for using stoichiometry to figure out the amounts of each reactant needed, designing a safe lab apparatus, and writing safe lab standard operating procedures and controls that will produce one pound of hand soap in one batch. They are expected to utilize experimental results gained by the research scientists to correct problems that arise during the large-scale batch production runs. In addition, they are responsible for designing/selecting a soap mold that will balance marketing’s options of soap shape and withstand the caustic nature of the hydroxide reactant during the saponification reaction. Because of the slow reaction rate for saponification, the engineers will be expected to put in overtime in order to maximize lab use. The manager is responsible for communicating with the science supervisor on the group’s accomplishments, problems, possible solutions to problems, and adherence to the time line. The manager is also responsible for having his/her group prepare the portfolio for the science supervisor, which summarizes the experimental plans, stoichiometric calculations, lab apparatus designs, standards operating procedure/controls, data (in chart format), data analysis (in appropriate graph format) and conclusions. The engineers are responsible for submitting chemical and equipment purchase request orders to the accounting department so that supplies may be procured. An initial purchase request order is due on the 1st day (5/27) of the project so that you have lab access by day #2.
ACOUNTING (2-3)
The accounting department is responsible for all financial transactions of the company. Specifically, it must prepare a budget statement for the business supervisor’s approval, which appropriately allocates the $15,000 over the 1.5 week project to the four departments and the upper management team. In preparing this budget statement, it must research average weekly salaries for all positions in the company and determine expected expenses from the department managers. The expected expenses must include but are not limited to lab operations (chemicals, energy use, and equipment) advertising, federal fines, and copying expenses. The initial budget statement is due (Friday 5/11) to the business supervisor. The accountants must develop leger for debits and credits to the company budget so that daily, consolidated reports of the company’s financial status can be given to the business supervisor. This group is also responsible for processing purchase order requests from the science division for chemicals and equipment that will procured. All paychecks are to be written and distributed to each employee on (Tuesday, June 2). A progress report will be written for the business supervisor and will summarize the work of this group over the course of the project. This will be included in the portfolio.
MARKETING/ADVERTISING/PUBLIC RELATIONS (2-3)
The MAP (Marketing/advertising/public relations) department is responsible for taking a statistically significant hand soap survey, a market/price study on hand soap, and creating an advertising campaign for the company’s final product. Specifically, the survey will assess Ewa Beach community families on their demands for shape, color and scent of hand soap. The market/price study will consist of an analysis of the range of current soap bar prices available in the community and an analysis of the company’s projected profit per bar. The projected profit must take into account the advertising costs in Ewa Beach, raw materials costs – reactants (see engineers, lab production costs – salaries, equipment, electricity (see accountants), packaging costs, and delivery/shelving costs for at least three key stores in Ewa Beach. The advertising campaign must include but is not limited to, product name, slogan, flyer, 2 posters per company, no school announcements) and a jingle. The manager is responsible for communicating with the business supervisor on the group’s accomplishments, problems, possible solutions to problems and adherence to the time line. The manager is also responsible for having his/her group prepare a progress report for the business supervisor and science division that summarizes the results of the survey. A second report for the business supervisor will summarize the results of the group’s market/price study. The advertising campaign will be tested during 5/28-6/1 and documented in the group’s portfolio. The advertising campaign must be aligned with the results of the research scientists and engineers. This group must be sure that all aspects of the advertising campaign are submitted to the company lawyer for copyright and trademark approval.
Area II: Upper management team
PLANT MANAGER/VICE PRESIDENT OF COMPANY (1)
The plant manager is in charge of the company, and in turn is responsible for the final production of the soap, company budget and market analysis and campaign. The vice president will work with the upper management team (prior to the beginning of the project) to develop a detailed timeline of daily goal that you think your departments should accomplish throughout the project. This timeline will be given to the department managers on the first day of the project. It is the vice president’s overall responsibility to ensure that the company is following the developed time line, making adjustments when necessary. The vice president requests, receives, analyzes, assesses and reports back on the daily written progress reports received from the business supervisor, science supervisory and quality control representative. The vice president makes all final decisions on the direction the company will take. These decisions are based on concise, accurate, daily information provided to her/him by the business and science supervisors. The vice presidents will be in an office working for most of the project. The vice president will prepare a progress report due on (June 1) for the company president, that summarizes the developed time line, the company’s accomplishments and adherence to the time line, decisions made, problems encountered and plans for resolution.
SCIENCE SUPERVISOR (1)
The science supervisor is the immediate boss for the managers of the science division: Research Scientists and Engineers. The science supervisor will work with the upper management team (prior to the beginning of the project) to develop a detailed time line of daily goals that you think your departments should accomplish throughout the next two weeks. This time line will be given to the department managers on the first day of the project. The science supervisor works in conjunction with the business supervisory to ensure that both the business and science divisions are working constructively toward accomplishing the goals set out in the developed time line. When adjustments to the time line are necessary, the science supervisor will be responsible for obtaining feedback from the research scientist’s and engineers’ managers, developing several alternative solutions, and reporting these possible solutions for approval by the vice president. The science supervisor will progress reports for the plant manager that summarize the science division’s accomplishments and adherence to time line, decisions made, problems encountered and plans for problems’ resolution.
BUSINESS SUPERVISOR (1)
The business supervisor is the immediate boss for the managers of the business division: Accounting and Marketing/Advertising/Public Relations. They will work with the upper management team (prior to the beginning of the project) to develop a detailed time line of daily goals that you think your departments should accomplish throughout the next two weeks. This time line will be given to the department managers on the first day of the project. The business supervisor works in the conjunction with the science supervisor to ensure that both the business and science division s are working constructively toward accomplishing the goals set out in the developed time line. When adjustments to the time line are necessary, the business supervisor will be responsible for obtaining feedback from the accounting and marketing managers, developing several alternative solutions, and reporting these possible solutions for approval by the plant manager. The business supervisor will prepare progress reports for the vice president that summarize the business division’s accomplishments and adherence to time line, decisions made, problems encountered, and plans for problem’s resolution.
QUALITY CONTROL SUPERVISOR (1)
The quality control supervisor is responsible for ensuring that the work done by the research scientists and the engineers is quality and passes all standards set by OSHA, the EPA, and the FDA (see the company librarian for a collection of articles). The QC supervisor will work with the upper management team (prior to the beginning of the project) to develop a detailed time line of the daily goals that you think the company’s departments should accomplish throughout the next two weeks. The QC supervisor is in charge of a documented and publicized quality control program which consists of developing a federal standards training session for lab employees, a test that each lab employee must pass to ensure that each employee is familiar with written safety and product standards, and a daily “report card” of the company’s adherence to the developed quality control program. This program must be in place and made known to lab employees by day 2 as lab employees will not be able to enter the lab area unless you have documentation that they have passed your quality control program test. The QC supervisor is responsible for creating standardized lab tests that the lab employees will use to measure the pH, latherability, scent, appearance, consistency and cleaning ability of all soap products made in the lab. The QC supervisor is also responsible for acting as lab safety manager, ensuring proper safety accident response and reporting, waste disposal and lab cleanup procedures. The quality control supervisor will prepare a progress report for the plant manager of the company’s adherence to the quality program and be responsible for providing the OSHA representative with the company’s “report card” during planned and unplanned inspection so f the lab.
OSHA, FDA AND EPA (ALREADY FILLED BY Ms. Henderson)
The Occupational Safety and Health Administration, the Food and Drug Administration, and the Environmental Protection Agency are the federal agencies whose regulations you must abide by. These three agencies have outline standards with which you must comply on a daily basis. Failing to do so results in fines and possible company shutdown. Compliance checklists will be written if fines are imposed. (QC should do research to find out what these standards are. See job description)
COMPANY LIBRARIAN (ALREADY FILLED BY Ms. Henderson)
The company librarian, Ms. Henderson, will help you obtain the resources concerning soap productions, federal standards, salaries and Ewa Beach community information. He currently has a collection of articles and books on these topics in the company library. Should you need further assistance, make an appointment to go see him.
COMPANY LAWYER
The company lawyer, is responsible for copyrighting all information given to him on the company’s behalf. The name of the company, the name of the soap, and any slogans need licenses. Borrowed slogans, etc. need permission. Trademarks for logos, etc. need licenses.
COMPANY PRESIDENT
KEEP THIS SHEET! USE IT AS A REFERENCE THROUGHOUT THE PROJECT!
Simple Soap Recipe
2.50 g lye (NaOH tablets)
3.64 g distilled water (chilled)
14.8 g lard/Crisco
Directions:
CUT/TEAR ALONG THE LINE
---------------------------------------------------------------------------------------------------------------------------------------COMPANY JOB APPLICATION
NAME____________________________________________________________________AGE___________
CURRENT ADDRESS ______________________________________________________________________
Phone___________________________________email_____________________________________________
Position(s) applied for 1.______________________________________________________________________
2.______________________________________________________________________
3.______________________________________________________________________
4.______________________________________________________________________
Highest level of education completed ________________________________________GPA_______________
Work Experience (describe prior experience or qualifications you have for the job)