Schraffen Berger

Chocolate Maker
AF1

P R E S E N T E D B Y:
A P O O RV S H A R M A P RA S A D
ARUNANCHAL KUMARI
RAHUL JAIN
S AYA K B I S WA S
ELZA BABU SHANY

Process Flow Diagram

Beans

Cleane
r

Roast
er &
Racks

Winnow
er

Mixer

Conch
e
Temper
Conch
e

Bars

Packing

Mould

Process Flow Diagram

Bean Cleaner : 15 minutes
Roaster and Racks : 75+15 = 90 minutes
Winnower : 15 minutes
Mixer : 75 minutes
Conche : 48-72 hours (~60 hours)
Temper : 60 minutes
Mold : 20 minutes
Packing : NA

Bottleneck
Winnow
Cleaner Roaster er
Mixer
Capacity
Input (in kgs)
Output
Qty of Machine
No. of shifts(8 hrs
each)
Cycle Time (in mins)
Output (Kgs per
minute)
Output (Kgs per hour)
Output (Kgs per day)
Capacity(per month
with ball mill)

100
96
1

250
250
1

450
250
185
1

Conches and Ball

Mill

115
115
1

1400
1400
2

1
1
2
75
15
75
3.33333 12.3333 1.53333
6.4
3
3
3
384
200
740
92

3
1800

1
15

3072
40000

1600

5920

1472

Temper Mould
200
140
140
1

2
60
2.33333
0.777777778
3
46.66666667
140

1120

2240

140
140
1
2
20
7
420
6720

Adding a Ball
Mill

Average conch time to be reduced from 60 hours to 15 hours

Save $50,000 of not buying an extra mixer
Increase the production by 10%
Potential risk of bottleneck at the mixer in case the 2nd mixer is not bought

Verdict to Implement = NO
Implementation
Adding a new ball mill worth $300,000
Mixer could be the next bottleneck. Purchase additional mixer and refurbish for $50,000
Increase in the shift hours
Outsourcing the tempering and molding process to co packer will remove duplication.

Improvements after adding a

Ball Mill
Conches and Ball
Cleaner Roaster Winnower Mixer Mill
Capacity
Input (in kgs)
Output
Qty of Machine
No. of shifts(8 hrs
each)
Cycle Time (in mins)
Output (Kgs per
minute)
Output (Kgs per hour)
Output (Kgs per day)
Capacity(per month
with ball mill)
Current Capacity per
month
% increase in

100
96
1

115
115
1

1400
1400
2

1
1
2
75
15
75
3.33333 12.33333
6.4
3
3 1.533
384
200
740
92
3072
1600
5920 1472

3
450

1
15

44160
40000

250
250
1

450
250
185
1

Temper
200
140
140
1

2
60
2.33333
3.111111111
3
186.6666667
140
4480
2240

Mould
140
140
1
2
20
7
420
6720

Changes to be made to increase

capacity by 150%
Purchase an additional mixer worth $50,000

Increase in number of shifts of Temperer, Moulder, Cleaner, Roaster,

Winnower

Changes made to achieve 150%

Cleaner Roaster Winnower Mixer
Capacity
450
Input (in kgs)
100
250
250
115
Output
96
250
185
115
Qty of Machine
1
1
1
2
No. of shifts(8 hrs
each)
2
3
1
3
Cycle Time (in mins)
15
75
15
37.5
Output (Kgs per
3.33333 12.333333 3.06666
minute)
6.4
3
33
7
Output (Kgs per
hour)
384
200
740
184
Output (Kgs per day)
6144
4800
5920
4416
Capacity(per month
with ball mill)
100800
Current Capacity per
month
40000

Conches and Ball

Mill
1400
1400
2

Temper Mould
200
140
140
1

3
450

3
60
2.33333
3.111111111
3
186.6666667
4480

140
3360

140
140
1
3
20
7
420
10080

Concerns during expansion

After adding the ball mill, the increase in capacity is just 10% whereas expected increase in
capacity is 75%.
We need to remove the bottle neck from the mixer to achieve its maximum functionality or
else it will restrict our capacity to just 44160 Kgs.
Remove the bottle neck by purchasing the mixer available and get it refurbished.
Even after this the maximum productivity will not be 75%.
Increase the number of shifts to increase productivity.
To meet capacities of 80,000Kg and 100,000 Kg we need to transfer the liquid chocolate to a
third party or else we need one more temperer and moulder.
Remelting and retempering needs to be done before packing by the third party.
Choosing the correct amount to increase capacity to avoid inventory surplus or supply
shortage.

THANK YOU