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Exercise Questions On Process Fundamentals: Solutions

This document contains solutions to questions about analyzing process cycle times and daily capacities. Question 1 calculates daily loaf capacity for a bread production line before and after packaging cycle time increases. Question 2 determines the cycle time and daily capacity of a croissant making process based on the longest individual step time. Question 3 provides calculations for batch processing times and daily batches for a shoe production process.

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140 views

Exercise Questions On Process Fundamentals: Solutions

This document contains solutions to questions about analyzing process cycle times and daily capacities. Question 1 calculates daily loaf capacity for a bread production line before and after packaging cycle time increases. Question 2 determines the cycle time and daily capacity of a croissant making process based on the longest individual step time. Question 3 provides calculations for batch processing times and daily batches for a shoe production process.

Uploaded by

vincent2100
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Exercise Questions on Process Fundamentals

Solutions:
Question 1:
1. From Figure 3, we can easily see that the cycle time for the whole process is ¾
hours per 100 loaves. So the daily capacity is (100 loaves / 0.75 hours) * 8 hours
= 1066 loaves.

2. Now the cycle time of packaging increases to 1 hour per 100 loaves. For each
bread-making line, the cycle time is 1 hour per 100 loaves. So the cycle time for
the entire system is 1 hour per 100 loaves. Now daily capacity = 800 loaves.

Question 2
1. Although a new batch of filling could be prepared every 10 minutes, the batch of
dough necessary to begin the fill & fold task can only be available at 15 minutes
intervals. So the cycle time of the process of preparing the dough and mixing the
filling is determined by the longest cycle time of the two flows, which is preparing
the dough. Dough preparation has a cycle time of 15 minutes per batch of 50
croissants.

Now it is easy to see that for the entire process, the cycle time is determined by
the baking step, which takes 20 minutes to bake one batch of 50 croissants. The
daily capacity of the process is (50 / 20minutes) * (8*60 minutes) = 1200
croissants.

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2. See Figure 5 for the Gantt chart. The average MLT is 60 minutes.

Figure 5 Gantt Chart for Croissant Making

Mix Filling

Proof

Roll & Cut

Mix Filling

Fill and Fold

Bake

Pack

5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 TIME

Batch #1 Batch #2

Question 3:

1. Answer: 41 + 10 + 350 + 102.5 = 503.5 minutes

2. Answer: Cutting =1170; Kitting = 4800; Stitching = 384; Lasting = 480

3. Answer: 3.84 batches per day

4. Answer: release one batch into the system every 125 minutes.

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