ARRIVALS/RECEIVING

Wet BERRIES
Dry
Process
Receiving
Dry Berries
De-stoning
De-chaffing
Separator
Wet Berries
De-chaffing
Drying
Separator
TIME REQUIRED FOR DRYING
TRUCK COMES IN AT 7 AM
WAITING TIME 4 HRS
PROCESS STARTS AT 11 AM
7
8
9
10
11
12
13
14
15
16
18
19
20
21
22
23
1
2
3

44.00

SOLUTIONS
7 AM START WITH NO CHANGES
Receiving back up wet berries
Additional Time to unload trucks

Total time per worker

Regualr work hrs
Overtime
Overtime cost
Processing time/worker
Regular time for 20 days
Overtime
Overtime cost
Total overtime cost

7 AM START WITH 1 NEW DRYER

Receiving back up wet berries
Additional Time to unload trucks
Total time per worker
Regualr work hrs
Overtime
Overtime cost
Processing time/worker
Regular time for 20 days
Overtime
Overtime cost
Total overtime cost
Cost of 1 dryer
Savings in overtime cost from one new dryer
Return on investment in 1st year
Total payback

16000 /DAY
11200 /DAY
4800 /DAY
Supply capacity/HR
16000/DAY

Available capacity /HR

Implied utilization

400
400
400

4,500
1,500
1,200

8.89%
26.67%
33.33%

933
933
600

3,000
600
1,200

31.11%
155.56%
50.00%

18.67 HRS

3732
INFLOWS

OUTFLOW
933
933
933
933
933
933
933
933
933
933
933
933
933
933
933
933

=(933.33-600)*12-3200
=800/600

BUILDUP
0
0
0
0
3,000
3,000
3,000
3,000
3,000
3,000
3,000
3,000
3,000
3,000
3,000

800
1.33 hrs

933
1,867
2,800
3,733
4,667
5,600
6,533
7,467
8,400
9,333
10,267
11,200
-

(7am to 7pm + 1.33 hrs)*20 days

4 weeks*40 hrs/week
(266.6 - 160) * 15 workers
1599*8*1.5

266.6 hrs
160 hrs
1599
19,188

11,120 wet berries per day/600 berr=18.53*20 days

160*2 shifts
320
370.67 - 320 * 27
1,368.00
1368*13
17,784.00

370.67

36,972.00

=(933.33-800)*12-3200

0
0.00 hrs
240 hrs
160 hrs
1200
14,400

(7am to 7pm )*20 days

4 weeks*40 hrs/week
(266.6 - 160) * 15 workers
1599*8*1.5
11,120 wet berries per day/800 berr=13.9*20 days
160*2 shifts
278 - 320 * 27
1368*13

rom one new dryer

278.00
320
-

14,400.00
60,000.00
22,572.00
38%
2.66 years

NUMBER OF WET BERRIES PER TRUCK

149.3
CAPACITY

7200

WAITING INVENTORY

1,667
2,600
3,533
4,467
5,400
6,333
7,267
8,200
5,200
2,200
-

# OF TRUCKS BEING DELAYED

1.79
2.79
3.79
4.79
5.79
6.79
7.79
8.79
5.57
2.36

Dryer capacity is bottleneck and that determines speed of operations

11.16
17.41
23.66
29.91
36.16
42.41
48.66
54.91
34.82
14.73

Seasonal workers work only in receiving section

Full year employees two shifts

Full year workers work in processing section

WET BERRY TRUCK ARRIVALS/HR

12.4
12.4
12.4
12.4
12.4
12.4
12.4
12.4
12.4
12.4
12.4
12.4

1.28
18.69
42.36
72.27
108.43
150.84
199.50
254.41

17.4
47.3
89.7
144.6
212.1
340.6
439.3
313.4
147.3