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Introduction
The basic aim of this case analysis is to identify the problems faced at the Receiving Plant 1 of National Cranberry Cooperative during the cranberry harvesting period and thereby try and propose possible solution to resolve those problems.
Weighted/Gra ded
Tested/Sampl ed
Destone Dry
Dechaff
Freeze
4000 bbls
1500 bbls/hr
1500 bbls/hr
Bulk Bin - 800 bbls/hr
Both
Destone
1200 bbls/h
Separate Bulk Truck 2000 bbls/hr
2000 bbls
3000 bbls/hr
Wet
Dechaff Dry
1200 bbls
The capacities of the various processes are calculated as below: Dumping Capacity
Number of Kiwanee Dumpers = 5 Average time taken by truck to load the berries onto Kiwanee Dumpers = 7.5 minutes (7 to 8 minutes) Average weight of berries in a truck = 75 bbls. Dumping Capacity = 5 * 75 * 60 / 7.5 = 3000 bbls/hr.
De-stoning Capacity
No. of destoning units = 3 Capacity of each unit = 1500 bbls/hr Total destoning capacity = 4500 bbls/hr
De-chaffing Capacity
No. of dechaffing units = 3 Capacity of each unit = 1500 bbls/hr Dechaffing capacity dedicated to wet berries (2) = 3000 bbls/hr Dechaffing capacity dedicated to dry berries (1) = 1500 bbls/hr
Drying Capacity
No. of dryers = 3
Capacity of each unit = 200 bbls/hr Total drying capacity = 600 bbls/hr
the cooperative installed an additional Kiwanee Dumper last year (i.e. 1969) but that didn't help in solving the problem. We first analyze the average truck waiting time for the next year with present capacities and assuming 70% to be wet berries and rest dry.
With the processing starting at 11 am, the holding bins will continue to be filled at this rate subject to the maximum capacities for: Wet berries = 3200 bbls Dry berries = 4000 bbls
The bins capable of holding wet berries would be completely filled after 3200/1050 hours after 7 am i.e. at 10:03 am and the trucks carrying wet berries would have to wait after that. The bins capable of holding dry berries would be filled unto 450*4 = 1800 bbls.
Total qty of wet berries received at RP1 in a 12-hr shift Qty received in 1st four hours (starting from 7.00am) From 11.00 am to 7.00 pm, Qty of berries will be processed Unprocessed qty.(which includes 3200 bbls in temporary bins). Amount left in trucks =
18000*(70/100) = 12600 bbls 1050*4 = 4200 bbls 8*600 = 4800 bbls 12600 - 4800 = 7800 bbls 7800 - 3200 = 4600 bbls
The trucks will continue unloading up to 4600/600 (= 7 hours 40 min) hours after 7 pm that is up to 2:40am. Unprocessed qty of 7800 bbls will require (7800 / 600) = 13 hrs over and above the 8 hr shift, for getting processed till 8 am the next day.
Unprocessed berries will require time = (5400/600) = 9hrs, after 7.00 pm till 4 am the next day. Thus the truck waiting times has been reduced just by starting the processing at 7am instead of 11am.
The truck waiting has been reduced to zero. This also has the advantage that the workers at the receiving crew will now be working only for 12 hrs as compared to 15hrs 40min with only three dryers and processing starting at 7am.
Conclusions:
Increase Processing Start Time: Truck waiting time can be reduced by simply starting the processing activity at 7:00 am. Removing Production Bottlenecks Installing one extra dryer is imperative at this point as it reduces the truck waiting time to almost zero if processing starts at 7:00 am and moreover the overtime costs are significantly reduced. Light grading system should be avoided as far as possible and stricter grading rules should be implemented. Converting bins to hold both wet and dry berries would help in lending flexibility to the existing capacity and mitigating uncertainties in the proportion of dry and wet berries received at any point of time.
Appendices
Berry Flow during day (processing starts at 11 am)
Deli v. Time 7-8 8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 8-9 9-10 10-11 Dry 0 450 450 450 450 450 450 450 450 450 450 450 450 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Amou nt Wet 0 1050 1050 1050 1050 1050 1050 1050 1050 1050 1050 1050 1050 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Proce ss Dry 0 0 0 0 0 600 600 600 600 600 600 600 600 600 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Amou nt Wet 0 0 0 0 0 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 0 0 0
Store d Dry 0 450 900 1350 1800 1650 1500 1350 1200 1050 900 750 600 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Amou nt Wet 0 1050 2100 3150 3200 3200 3200 3200 3200 3200 3200 3200 3200 3200 3200 3200 3200 3200 3200 3200 3000 2400 1800 1200 600 0 0 0 0
Backu p Dry 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Backu p Wet 0 0 0 0 1000 1450 1900 2350 2800 3250 3700 4150 4600 4000 3400 2800 2200 1600 1000 400 0 0 0 0 0 0 0 0 0
Total Backu p 0 0 0 1000 1450 1900 2350 2800 3250 3700 4150 4600 4000 3400 2800 2200 1600 1000 400 0 0 0 0 0 0 0 0 0
Delv . Time 7-8 8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 8-9 9-10 10-11 11-12 12-1 1-2 2-3 3-4 4-5 5-6 6-7 Dry 0 450 450 450 450 450 450 450 450 450 450 450 450 0 0 0 0 0 0 0 0 0 0 0 0
Amou nt Wet 0 1050 1050 1050 1050 1050 1050 1050 1050 1050 1050 1050 1050 0 0 0 0 0 0 0 0 0 0 0 0
Proce ss Dry 0 450 450 450 450 450 450 450 450 450 450 450 450 0 0 0 0 0 0 0 0 0 0 0 0
Amou nt Wet 0 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 0 0 0
Store d Dry 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Amou nt Wet 0 450 900 1350 1800 2250 2700 3150 3200 3200 3200 3200 3200 3200 3200 3200 3000 2400 1800 1200 600 0 0 0 0
Backu p Dry 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Backu p Wet 0 0 0 0 0 0 0 0 400 850 1300 1750 2200 1600 1000 400 0 0 0 0 0 0 0 0 0
Total Backu p 0 0 0 0 0 0 0 400 850 1300 1750 2200 1600 1000 400 0 0 0 0 0 0 0 0 0