Dooly County Doughnuts Discussion Preparation Worksheet

1. State the problem of the case in your own words.

2. How many doughnuts can he currently sell in a day?

3. Organize the given information and describe the process by creating a diagram of the process.
Remember, diagramming is a tool used to communicate and analyze a process.

Batching Mixing EXtruding Frying Glazing Customization

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4. Find the capacity and cycle time (in seconds per doughnut) of each step.
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Batching 240 batches per day, 2 min/batch 480 min per day/ 2 min per batch
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240 batches
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5. Which step is the bottleneck? What is the current capacity and cycle time (in seconds per
doughnut) of the process?
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6. What is the cycle time needed to meet Dewey’s demand?

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Takt time= 28,000 Seconds/ 13,200 2.18 Seconds

7. How many batches (8 lb. batch size) does Dewey need to make in a day to meet his daily
demand?
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8. What is the maximum total time per batch (in minutes)?

9. What are the options for increasing the capacity of the process? What are the pros and cons of
each?
Add more cutters to extruders, improve manual steps, increase batch size.

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 Dooly County Doughnuts Discussion Preparation Worksheet

10. Take what you know and create an Excel model in which you can change the options noted in the
answer to number 9 above and see how the changes affect the process.

The key is calculating the capacity and cycle time of each process step. Since this is a batch process, you’ll
need to do this by first calculating how many batches can be made in a day for each process step. For any
step with a setup time, you’ll need to calculate the total time for the batch as the setup time plus the run
time (the time it takes to process the whole batch). For some steps, you’ll notice that run time is
independent of the batch size. For other steps, run time is dependent on the batch size. Some steps may
not have any capacity constraints relative to the rest of the process. In this case, you may just note that
the steps can produce whatever quantity is required.

In order to make a flexible Excel model, you’ll need to include some input cells for variables which, when
changed, result in immediate recalculation of the capacity and cycle time of each step. These variables
should include any assumptions or inputs (like batch size) you may want to change to increase the
output of the process.

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Excel information and tutorials: To better understand why you shouldn’t hard code values that may

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change in your Excel sheet, you should watch this short tutorial video from Exceljet.

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https://exceljet.net/lessons/dont-hard-code-values-that-may-change. You should also learn the

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difference between relative and absolute cell references in Excel, explained here

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https://exceljet.net/glossary/absolute-reference. Here is how to use keyboard shortcuts to toggle
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between absolute and relative cell references https://exceljet.net/keyboard-shortcuts/toggle-absolute-
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and-relative-references.
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8lbs per batch/ batch x 16oz/lb = 128oz/2oz per donut

=64 donuts/ batch.

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