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Exercise Questions on Process Fundamentals Solutions

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Question 1: 1. From Figure 3, we can easily see that the cycle time for the whole process is ¾ hours per 100 loaves. So the daily capacity is (100 loaves / 0.75 hours) * 8 hours = 1066 loaves.

2. Now the cycle time of packaging increases to 1 hour per 100 loaves. For each bread-making line, the cycle time is 1 hour per 100 loaves. So the cycle time for the entire system is 1 hour per 100 loaves. Now daily capacity = 800 loaves.

Question 2 1. Although a new batch of filling could be prepared every 10 minutes, the batch of dough necessary to begin the fill & fold task can only be available at 15 minutes intervals. So the cycle time of the process of preparing the dough and mixing the filling is determined by the longest cycle time of the two flows, which is preparing the dough. Dough preparation has a cycle time of 15 minutes per batch of 50 croissants. Now it is easy to see that for the entire process, the cycle time is determined by the baking step, which takes 20 minutes to bake one batch of 50 croissants. The daily capacity of the process is (50 / 20minutes) * (8*60 minutes) = 1200 croissants.

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5 minutes 2. See Figure 5 for the Gantt chart. 2/2 . Answer: 41 + 10 + 350 + 102. Figure 5 Gantt Chart for Croissant Making Mix Filling Proof Roll & Cut Mix Filling Fill and Fold Bake Pack 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 TIME Batch #1 Batch #2 Question 3: 1.84 batches per day 4.5 = 503. Answer: Cutting =1170. The average MLT is 60 minutes. Lasting = 480 3.2. Answer: 3. Kitting = 4800. Answer: release one batch into the system every 125 minutes. Stitching = 384.