(a) Process Flow diagram and bottleneck:

<process flow diagram>

From the table above, process P7 takes the maximum time, that is, 25 min. Hence,
process P7 is the bottleneck.

(b) Cycle time and Total processing time:

In this case, cycle time = bottleneck = 25 min. That means, output from every batch will
be available after every 25 minutes.

Total processing time = sum of processing time taken by each of the processes.
= 10 + 2 + 5 + 15 + 8 + 20 + 25 + 5 (minutes)
= 90 minutes

(c) Gantt Chart:

(d) Capacity of the factory:

Given: Number of pizzas produced and packaged per batch = 1000

Number of Working hours per day= 9 hours = 9 * 60 min = 540 min
Number of Working days in a week = 6
Number of Working minutes in a week = 6 * 540 min = 3240 min

Time taken by first batch = 90 min

For every next batch to come, time taken = 25 min
Therefore, number of batches per day = (540 – 90)/25 + 1
= 19
Hence, the capacity of the factory = 19 * 1000 pizzas
= 19,000 pizzas (per day)
*Ignoring the time taken for first batch, pizzas produced per minute = 1000/25 = 40.
Therefore, number of pizzas produced in 540 min = 40 * 540 = 21,600 (per day)
Therefore, capacity per week = 21,600 * 6 days = 129,600 pizzas.

(e) Utilisation rate:

1. Demand per day = 25,000 pizzas
 Number of batches = 25
Time available = 540 min
Process Time per batch (in min) Capacity Demand Utilisation (%)
P1 10 54000 25000 46.29
P2 2 270000 25000 9.26
P3 5 108000 25000 23.15
P4 15 36000 25000 69.44
P5 8 67500 25000 37.03
P6 20 27000 25000 92.59
P7 25 21600 25000 115.74
P8 5 108000 25000 23.15

2. Demand per day = 22,000 pizzas

Utilisation rate of the process = 22,000/21,600 * 100 = 101.85%