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Kristen's Cookies (A)

Process description
operation equipment time capacity
Mix mixer (1) 6 minutes 3 dozen
Spoon tray (3) 2 minutes 1 dozen How long does
Load Oven oven (1) 1 minute 1 dozen an order take?
Baking oven (1) 9 minutes 1 dozen
Cooling counter 5 minutes ? It Depends
Pack counter 2 minutes ?
Customer Pays counter 1 minute ?

One Dozen order:

Mix
Spoon
Load Oven
Baking
Cooling
Pack
Customer Pays

total time 26 minutes

Does two dozen take 52 minutes? NO!

Two Dozen order (assumes one worker, one oven)

Mix operator interference: cannot start any earlier

1 Spoon
1 Load Oven
1 Baking
1 Cooling
1 Pack
2 Spoon
2 Load Oven
2 Baking
2 Cooling
2 Pack machine interference
Customer Pays

total time 36 minutes

Throughput time
Bottleneck determines capacity

Bottleneck = operation that limits production (oven)

Oven does one dozen per ten minutes = cycle time

capacity = output (units) / cycle time = 1 dozen / 10 min = 0.1 dozen/min = 6 dozen/hr

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Labor Requirement

operations requiring labor total 6+2+1+2+1 = 12

bottleneck oven produces a dozen every ten minutes, so working alone you'll get behind

1 Mix
1 Spoon
1 Load Oven
1 Baking
1 Cooling
1 Pack
1 Pay
2 Mix
2 Spoon
2 Load Oven
2 Baking
2 Cooling
2 Pack
2 Pay
3 Mix
3 Spoon
3 Load Oven
3 Baking

oven has 2 minutes wasted

With one person can only do 5 dozen per hour

Utilization

With two people, during 10 minute cycle, 12 minutes of work, 20 minutes available = 60%

One person mixes, the other spoon, load, pack and pay (6 minutes each)

What if two dozen orders?

Only one mix and one pay, so total labor is 6 + 2(2+1+2) + 1 = 17 minutes

one person does mix, spoon, spoon (10 minutes)

one person does load, load, pack, pack, pay (7 minutes)
Have second person do some spooning to balance the load?

Now 40 minutes of labor available, so utilization is 17/40 = 42.5%

Can this be done by one person? Hard to tell. Need to "feed" the bottleneck.

Oven Load
Bake

Person Load
Mix/spoon
Pack/Pay

Yes it can be done.

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Add another oven?

Consider one dozen orders

cycle time capacity
Mix/spoon 8min 7.5 doz/hr NEW BOTTLENECK
Load/bake 5min 12 doz/hr

Pack 2min 30 doz/hr

Pay 1min 60 doz/hr

Adding an oven does not double capacity, raises it from 6 to 7.5 doz/hr

Consider two dozen orders

Mix/spoon 10min 12 doz/hr Now capacity does double

Load/bake 10min 12 doz/hr

Pack 4min 30 doz/hr

Pay 1min 120 doz/hr

Mixing "setup" causes the tradeoffs:

Larger lot size = more efficient operation (labor utilization)

Smaller lot size = lower throughput time (better customer service)

Consider a conveyor process (like Gino's or BK).

Mix 0.5 minute

Spoon 0.167 minute
Load Oven 0
Baking 9 minutes
Cooling 5 minutes
Pack 0.167 minute
Pay 1 minute

15.8 minutes for a one cookie order

Delivery Commitment

If someone calls, can you tell them when their cookies will be ready?

Use cycle time and assign each 10 minute block in the oven to the next order.
From the block this new order falls in, just add the cooling and packing time.

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