Table of Contents

Chapter 1: Introduction......................................................................................................................4

1.1 Background..................................................................................................................................4

1.2 Justification..................................................................................................................................5

1.3 Business Model............................................................................................................................5

1.4 Production Line Layout................................................................................................................9

1.5 Work Breakdown Structure (WBS)..............................................................................................9

1.6 Gantt Bar Chart..........................................................................................................................10

Chapter 2: Process Modeling............................................................................................................11

2.1 Integrated Computer Aided Manufacturing Definition 0...........................................................11

2.1.1 The First Layer.....................................................................................................................11

2.1.2 The Second Layer................................................................................................................12

2.1.3 The Third Layer...................................................................................................................12

2.1.4 The Fourth Layer.................................................................................................................12

2.2 Data Flow Diagram....................................................................................................................12

2.2.1 Process Hierarchy Chart......................................................................................................12

2.2.2 Context Diagram.................................................................................................................12

2.2.3 Level 0 Diagram..................................................................................................................12

2.2.4 Level 1 Diagram..................................................................................................................12

Chapter 3: Data Modeling................................................................................................................13

3.1 E-R Diagram...............................................................................................................................13

1|Page
 3.2 Entities Relationship..................................................................................................................13

3.3 Microsoft Access Database File..................................................................................................13

3.3.1 Forms..................................................................................................................................13

3.3.2 Tables..................................................................................................................................13

3.3.3 Queries...............................................................................................................................13

Chapter 4: Improvements................................................................................................................13

4.1 Theoretical Proposed Improvement..........................................................................................13

List of Figures

Figure 1: Papa John's Logo....................................................................................................................3

Figure 2: Preparing Table......................................................................................................................4

Figure 3: Dough Mixer Machine...........................................................................................................4

Figure 4: Cutting Dough and Inspection Area.......................................................................................5

Figure 5: Roller Machine.......................................................................................................................5

Figure 6: Rounder Machine...................................................................................................................6

Figure 7: Arranging in Boxes................................................................................................................6

Figure 8: Dough Freezer........................................................................................................................6

Figure 9: Flow Chart.............................................................................................................................7

Figure 10: Production Line Layout........................................................................................................8

Figure 11: Work Breakdown Structure..................................................................................................8

2|Page
 Chapter 1: Introduction
1.1 Background
Papa John’s restaurant is one of the most famous pizza restaurants in the world that was
founded in 1984, it starts in a broom closet in Indiana, USA, and now there are more than
5,000 locations in 45 countries and territories around the world.
Services and products are many and varied, different types of pizza is provided, and some
locations include tables and chairs for eating in, it has as well carryout and delivery orders,
and also consider currently the world’s third-largest pizza delivery company.

Figure 1: Papa John's Logo

1.2 Justification
One of the features that made Papa John’s restaurant has a high advantage upon the
competitors is the dough itself, it is always achieved with respect to high quality and
efficiency standards. Knowing how the main product “Pizza” is produced starting from
dough preparation is such an interest subject to be studied and improved in this project.

1.3 Business Model

Making the dough begins at the preparing table, where the worker starts to check the weight,
adding water, flour, and other ingredient. The preparation time of the dough using these
ingredients is variable depending on the worker’s performance.

Figure 2: Preparing Table

3|Page
After preparation is complete, the worker moves from the preparing table to the dough mixer
machine to mix the ingredient perfectly, the duration time of mixing is constant of 7 minutes.

Figure 3: Dough Mixer Machine

The mixed dough is then transported to the cutting and weighting table, it is then cut based on
its categorization of three different smaller sizes: small, medium, and large depending on the
order received by the factory. The worker then starts cutting it based on its category: 180
doughs for small sized order, 144 pieces for medium sized order, and 88 pieces for large
sized order. The cutting time is variable depending on the worker’s performance.

Figure 4: Cutting Dough and Inspection Area

After cutting is done, the worker moves the cut doughs to the roller machine which is
responsible to reshape it to the proper shape that conforms to standers. The duration of rolling
process is constant for each dough 4.5 second.

4|Page
 Figure 5: Roller Machine

After dough leaves the roller machine, it must rest for 5 min then enter to dough rounder
machine which it’s responsible of reforming the dough into spherical, 5 second for each
dough.

Figure 6: Rounder Machine

After rounding, dough goes inside the dough freezer for 20 min. By the end of the preparation
process, doughs are loaded into the boxes, and these boxes become ready to go to next
systems and processes (transportation, unloading, etc.).

Figure 8: Dough Freezer Figure 7: Arranging in Boxes

5|Page
The flow chart representing the whole production line are as follows.

Figure 9: Flow Chart

6|Page
1.4 Production Line Layout

2
Dough Mixer
Machine
3 1

Weighting Preparation
Table Table

4 5 6
Rounding
Machine Dough Box Dough Freezer

Figure 10: Production Line Layout

1.5 Work Breakdown Structure (WBS)

Industrial
Information
System

Initiation Data Documenting

Modelling Presentation
Phase Collection the Report

Group Visit the Designing Writing the

Creation Facility IDEF0 Recommended
Improvement
Search for Collect the Designing
Facility needed Data DFD

Select and Designing

Contact the E-R
Facility
Designing
MS Access
Model

Figure 11: Work Breakdown Structure

7|Page
 1.6 Gantt Bar Chart

Table 1: Gantt Bar Chart

No. Task\Week 1 2 3 4 5 6 7 8 9 10 11 12 13

Deciding Team
1
Members

Search and Selecting

2
the Facility

Visiting the Facility

3 and Collect the
Needed Data

Designing IDEF0 and

4
DFD Model

5 Designing E-R Model

Designing MS Access
6
Database Model

Providing Suggested
7
Improvement

8 Writing the Report

Prepare PowerPoint
9
Presentation

10 Present the Project

8|Page
 Chapter 2: Process Modeling
2.1 Integrated Computer Aided Manufacturing Definition 0
After analyzing the process, we concluded that our IDEF0 contains 3 layers. And the
breakdown structure is as follows:
A0 – Produce Dough System
A1 – Manage Orders
A2 – Inspect Storage
A3 – Produce Dough
A31 – Receive Ingredients
A32 – Inspect Ingredients
A33 – Prepare Dough
A4 – Ship Dough

2.1.1 The First Layer – A0

This is the layer where it has the main production line process in Papa John’s Dough Factory.
This layer has 5 inputs and outputs, 4 controls and 3 mechanisms, and they are as follows.
Inputs:
1. Branch Inquiries.
2. Branch Order.
3. Vendor Communication.
4. Ingredient From Vendor.
5. Vendor Bill
Outputs:
1. Factory Response.
2. Request Ingredients from Vendor.
3. Vendor Payment.
4. Shipped Dough.
5. Shipped Order Information.
Controls:
1. Saudi Food and Drug Authority – SFDA.
2. Municipality.
3. PJP Recipe.
4. PJP Standard and Regulations.
9|Page
Mechanisms:
1. Machines.
2. Labor
3. Material Handling Tools.

Figure 12: The First Layer - A0

2.1.2 The Second Layer – A1 to A4

In this layer every main process to produce and deliver dough is shown, first the branch order
and branch communication and the order gets managed at A1, and delivered as a response
from the factory, and another output goes to A2 to request to know what the status of the
storage is, and then the inspector inspects the ingredients in the storage, if it’s there then we
proceed with the stored ingredients to A3 to proceed in preparing the dough.
If the storage doesn’t have the wanted ingredients, then the inspector at A2 feedback the
managing personnel with the information. After that the factory send a requisition from
vendor for ingredients at A1, then the vendor communicates with the factory to provide them
with the quantity, delivery, and payment information. Then the inspector sends the ingredient
report and the factory pay to the vendor.
In the prepare dough stage A3, the stored ingredient and/or the delivered ingredient from
vendor and the bill is delivered. After that the dough is prepared according to municipality,
PJP recipe and SFDA Standards and the Workers well prepare and deliver the production
report and organize the production to the next stage. Finally, at A4 the workers make all the
finishing steps and ship both the dough and order data.

10 | P a g e
 Figure 13: The Second Layer – A1 to A4

2.1.3 The Third Layer – A31 to A33

The first step in preparing the dough is receiving the ingredients from vendor with the bill
and do initial inspection for the package, if there is any defect in the package will be rejected,
otherwise it will go to Evaluate Ingredient process to evaluate between the stored ingredients
and the received ingredients from vendor. In this process, there is a detailed inspection to the
ingredients to decide whether the ingredient is approved or not, if it's approved, it will go to
the produce dough process to make the finished dough and its report.

Figure 14: The Third Layer – A31 to A33

11 | P a g e
2.1.4 The Fourth Layer – A331 to A336
to produce the dough first, the preparing workers prepare the approved ingredients manually
and mix them and reject then nonconforming mixed ingredients. after that, mixing the dough
by the mixing machine to impasse the ingredients and produce mixed dough which is ready
to be set on the specified temperature by the advance thermometer. If the dough did not reach
the wanted temperature, it will be remixed again until reaching the desired temperature.
However, the sufficient dough goes to the cut, roll and rounding process. This iterative
process is done by rolling and rounding machines. Now the door is prepared and ready to be
arranged in the boxes. after arranging the boxes, the dough is ready to be cooled by the large
freezer and then to be shipped.

Figure 15: The Fourth Layer – A331 to A336

2.2 Data Flow Diagram

Our concluded DFD diagram consist of 3 levels which are context diagram, level 0 diagram,
and the decomposition of process 3, level 1 diagram.

12 | P a g e
2.2.1 Process Hierarchy Chart

0
Produce Dough
System

1.0 2.0 3.0 4.0

Manage Order Inspect Storage Prepare Dough Deliver Dough

3.1 3.2 3.3

Receive Ingredient Evaluate Ingredient Produce Dough

Figure 16: Process Hierarchy Chart

2.2.2 Context Diagram

the context diagram consists of an overall process the Produce Dough System, 2 source/sink
which are vendor and branches, 1 sink which is the factory Management, and 8 data flows.

Figure 17: DFD - Context Diagram

2.2.3 Level 0 Diagram

At first the branches communicate with the factory, specifically if they can produce a certain
amount of dough at certain day such as, weekdays or weekend. Then process 1 start to ask
about the stored material at process 2, then process 2 will check the storage data and send
back the current storage status to process 1. If there is not enough material the factory
responds to the branches to hold a certain time until the vendor brings the new shipment.
Then the branch will send the order data to the process 1. Process 3 will receive the bill,
stored ingredient, and shipment data from storage and vendor and the output of this process is
13 | P a g e
a production report sent to both factory management and process 4 and also ingredient
rejection and evaluation report sent to factory management as well. Finally process 4 will
sent to the branches.

Figure 18: DFD – Level 1 Diagram

2.2.4 Level 1 Diagram

A shipment data and vender bill arrive at process 3.1. at this process there will be check in
vender shipment data. For example, if the vendor brings excess or ingredient that the factory
did not order, the rejected ingredient report will be the outcome of this process, otherwise the
received ingredient data will move to process 3.2. at process 3.2, the received ingredient data
from vendor and the stored ingredient data at the factory storage will be evaluated based on
the factory standard. If the ingredient meets the standards, the accepted ingredient data will
move to process 3.3 and also, the ingredient evaluation report will be created. Then process
3.3 will create a production report to proceed.

14 | P a g e
 Figure 19: DFD - Level 1 Diagram

Chapter 3: Data Modeling

3.1 E-R Diagram

3.2 Entities Relationship

3.3 Microsoft Access Database File

15 | P a g e
3.3.1 Forms

3.3.2 Tables

3.3.3 Queries

Chapter 4: Improvements
4.1 Theoretical Proposed Improvement

16 | P a g e