Calculate the capacities of each step and the whole system.

Describe the bottleneck process.

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Double the batch size to 16 pounds.

Calculate the same number as 1.

Assume that setup time and cycle time do not change.

Dewey wants to keep the 8-lb batch size.

What is the minimum setup time to extrude?

Dewey may decide to buy the 6-cutters set. What setup time is required to meet the demand of a batch of 8 pounds?

Dewey: What would your recommendation be?

To calculate Best Case, Worst Case, and Practical Worst Case, make sure you clearly state your assumptions in the report. You may also include setup times to help with the processing time. Finally, provide the charts for each scenario within your report.

Report’s purpose

The report examines the manufacturing process of drougnuts in order to identify bottlenecks.

It also examines the possibility of changing the manufacturing process to obtain the desired results.

The report also discusses different mechanisms that can be used to meet both the demand and supply needs of the company.

Dewey Johnson was the author of the report. It identifies bottlenecks and offers solutions.

Dooly County Doughnuts, which is based in Vienna Georgia, is owned and operated by Mr. Dewey Johnson.

The owner’s focus on marketing strategies has helped the business perform well.

Doughnuts have been in strong demand. The business sells an average of 132000 Doughnuts per day.

But, current production cannot meet the demand. Dewey explores other alternatives to increase production to meet the demand.

Four steps are involved in the current manufacturing of doughnuts.

You can find the same here:

Production

Batching

The first step in making doughnuts is to keep all ingredients in a bowl.

The machine used in this process can hold between 2 and 20 lb. It takes about 2 minutes for the operator of the machine to place the ingredients in the bowl.

Additionally, each doughnut is 2 ounces in weight

Weight of each doughnut: 2 oz

1 LB =16 Ounces

Maximum Number of Doughnuts That Can Be Produced: (20*16)./2= 160 Doughnuts

Current Capacity 8 Lb

1 LB =16 Ounces

Current Doughnuts That Can Be Produced: (8*16)./2= 64 Doughnuts

Doughnuts made in one minute: 64/ 2= 32 Doughnuts

Mixing

In the second step of making doughnuts, all the ingredients have been mixed and the batch has been added to the mixer.

Mixing all the ingredients necessary to make a doughnut takes about 2.5 minutes.

Two mixers are also available to the business.

Weight of each Doughnut: 2 oz

1 LB = 16 ounces

Maximum Number of Doughnuts That Can Be Produced: (20*16)./2= 160 Doughnuts

2.5 minutes for processing of the same

Doughnuts processed in one minute: 320/2.5=128

Current Capacity 8 Lb

1 LB =16 Ounces

Current Doughnuts That Can Be Produced: (8*16)./2= 64 Doughnuts

Doughnuts made per minute: 128/2.5=51.2

Production

Three steps are required for the third stage of production. These include extruding and frying, as well as glazing.

Extruding

The dough is then cut into small pieces using cutters.

After baking and glazing, the cut nuts are then transformed into finished product.

There are currently three cutters in the business, and they can produce 54 doughnuts per min.

The setup time for each batch is 1.5 minutes.

Weight of each Doughnut: 2 ounces

1 LB =16 Ounces

Maximum Number of Doughnuts That Can Be Produced: 20 *16 = 160 Doughnuts

Time taken to Cut the same: 160/54= 2.96 Mins

Start time: 1.5 minutes

Doughnuts are cut in a minute: 160/4.46=35.88 Doughnuts

Current Capacity 8 Lb

1 LB = 16 ounces

Current Doughnuts That Can Be Produced: (8*16)./2= 64 Doughnuts

Time taken to Cut the same: 64/54= 1.18 Mins

Start time: 1.5 minutes

Doughnuts are cut in a minute: 160/2.68=23.8 doughnuts

Frying

This stage allows the doughnuts to be cut from the extruder and fried in an oven.

The fryer can run continuously and has an unlimited amount of capacity. Doughnuts are usually fried in the fryer for 90 seconds, regardless of how many they are.

After being fried, the doughnuts cool down on a conveyor for approximately 45 seconds before being transferred to a glazing machine.

It’s similar to glazing but is an intermittent process that runs continuously. This allows for unlimited number of doughnuts to be glazed.

Customization

The last stage of doughnut manufacturing is to pack them in boxes to make it easy for customers to order.

You can add different toppings to your doughnuts at this stage, from sprinkles to unusual toppings.

The process takes about 3.5 seconds to complete and 2 doughnuts are ready for sale.

There are 2 doughnuts ready to be sold in 3.5 seconds = No doughnuts

No number of doughnuts ready within 1 minute= 60*2/3.5=34.28 doughnuts

A bottleneck refers to a manufacturing problem that prevents the production or distribution of a particular commodity or product beyond a given point.

This means that the entire chain’s capacity is reduced due to its limited capacity.

This also slows down your business.

Analysis has revealed that the company’s manufacturing process was a bottleneck. This analysis is detailed below:

Current Manufacturing Process

Sl No

Particulars

Information

No Doughnuts in 8 Hours

Comment

Shift

Single

Time

8 Hours

7 days

Batching Capacity

You can find more information at

2 Minutes

b

Size range

2 lb – 20 lb

c

Batch Size

8 lb

D

Cookies and doughnuts required

e

No batch(c*16/d).

f

No doughnuts per Minute (e/a).

2nd Bottle Neck

You can find more information at

Number

b

c

Number of Doughnuts Per 2.5 Minutes

D

No Doughnuts per Minute (c/b).

4th Bottle Neck

Production

A

Extrusion

You can find more information at

Number

b

No batch of doughnuts

c

Time needed to bake 54 doughnuts

1 minute

D

Time taken to make 64 doughnuts

e

Cleaning Time

1.5 minutes

f

g

No Minute of Doughnuts

1st Bottle Neck

B

Frying

You can find more information at

Capacity

Unlimited

Unlimited

b

1.5 Minutes

C

You can find more information at

Capacity

Unlimited

Unlimited

b

.75 min

Customization

You can find more information at

3.5 Sec

b

There is no shortage of doughnuts

c

Doughnuts total in one minute

3rd Bottle Neck

According to the above, the Extrusion process is the first bottleneck in manufacturing and reduces the doughnut production per day to 11440 Units. Fraction shall not be considered.

Additionally, the batching unit is the 2nd bottleneck. This limits the production to 15360 units per day which is far less than the average daily demand.

The analysis is therefore limited to the 1st Bottleneck of the manufacturing.

Accordingly, the overall system can only produce 11440 units. This assumes that the process is continuous. There has been product at each stage since the manufacturing began.

Alternatives

There are several options available to get around the bottleneck. These alternatives are detailed below.

Double the batch weight to 16 lbs

According to the first proposal, Mr. Dewey could double the batch size. This will allow the company to meet its demand. However, prematurity may be diminished as the report reveals.

Here is the detailed calculation.

Doubling Batch Size up to 16 lbs

Sl No

Particulars

Information

In 8 hours, no more doughnuts

Comment

Shift

Single

Time

8 Hours

7 days

Batching Capacity

You can find more information at

2 Minutes

b

Size range

2 lb – 20 lb

c

Batch Size

16 lb

D

Cookies and doughnuts required

e

Batch(c*16/d); No number of doughnuts

f

No doughnuts per Minute (e/a).

3rd Bottle Neck

You can find more information at

Number

b

c

Number of doughnuts made per 2.5 Minutes

D

No doughnuts per Minute (c/b).

4th Bottle Neck

Production

A

Extrusion

You can find more information at

Number

b

No batch of doughnuts

c

Time needed to bake 54 doughnuts

1 minute

D

Time taken to make 64 doughnuts

e

Cleaning Time

1.5 minutes

f

g

No Doughnuts per Minute

1st Bottle Neck

B

Frying

You can find more information at

Capacity

Unlimited

Unlimited

b

1.5 minutes

C

You can find more information at

Capacity

Unlimited

Unlimitable

b

.75 min

Customizing

You can find more information at

3.5 Sec

b

There is no shortage of doughnuts

c

Doughnuts total in one minute

2nd Bottle Neck

It can be seen that the first bottleneck has been identified at 15874 Units of doughnuts (Fraction was ignored).

Thus, the company will be able satisfy its demand requirements and so the alternative steps shall be able provide the solution.

The solution will not last long as sales continue to rise, and the problem will recur again. However, it comes at no additional cost to the company.

8.2 lb. batch size and shorter extrusion set up time

Another alternative is to reduce extrusion time in order to meet the demand.

Here’s a breakdown of how to reduce the required time:

Batch Size 8 lb and shorter Extrusion Set Up Time

Sl No

Particulars

Information

In 8 hours, no more doughnuts

Comment

Shift

Single

Time

8 Hours

7 days

Batching Capacity

You can find more information at

2 Minutes

b

Size range

2 lb – 20 lb

c

Batch Size

8 lb

D

Cookies and doughnuts required

e

Batch(c*16/d), No number of doughnuts

F

No doughnuts per Minute (e/a).

3rd Bottle Neck

You can find more information at

Number

b

c

Number of doughnuts made per 2.5 minutes

D

No doughnuts per Minute (c/b).

4th Bottle Neck

Production

A

Extrusion

You can find more information at

Number

b

No batch of doughnuts

c

Time needed to bake 54 doughnuts

1 minute

D

Time taken to make 64 doughnuts

e

Cleaning Time

f

g

No Doughnuts per Minute

1st Bottle Neck

B

Frying

You can find more information at

Capacity

Unlimited

Unlimited

b

1.5 Minutes

C

You can find more information at

Capacity

Unlimited

Unlimited

b

.75 min

Customization

You can find more information at

3.5 Sec

b

No Doughnuts

c

Doughnuts total in one minute

2nd Bottle Neck

Time taken to set up

Sl No

Particular

Short

No Doughnuts Required

Work hours

Doughnuts required every minute

Donut Batch Size

Time available (4/3)

Cutter takes time

Schedule Time (5-6)

After looking at the above, one can infer that the first bottleneck is 13200 units of doughnuts (Fraction was ignored).

Thus, the company will be able satisfy its demand requirements and so the alternative steps shall be able provide the solution.

However, this solution is temporary because sales will increase and the problem will reappear. It is however not at any extra cost to the company.

Batch Size of 8 lbs, and an Increase in Cutters to 6 at 3

To meet the demand, the third alternative is to increase cutter numbers to 6.

Here’s a more detailed explanation of how the same can be calculated.

Batch Size: 8 lbs. Cutters increased up to 6

Sl No

Particulars

Information

In 8 hours, no more doughnuts

Comment

Shift

Single

Time

8 Hours

7 days

Batching Capacity

You can find more information at

2 Minutes

b

Size range

2 lb – 20 lb

c

Batch Size

8 lb

D

Cookies and doughnuts required

e

Batch(c*16/d), No number of doughnuts

f

No doughnuts per Minute (e/a).

3rd Bottle Neck

You can find more information at

Number

b

c

Number of doughnuts made per 2.5 Minutes

D

No doughnuts per Minute (c/b).

4th Bottle Neck

Production

A

Extruding

You can find more information at

Number

b

No batch of doughnuts

c

Time needed to bake 108 doughnuts

1 minute

D

Time it took to bake 64 doughnuts

e

Cleaning Time

f

g

No number of doughnuts per Minute

1st Bottle Neck

B

Frying

You can find more information at

Capacity

Unlimited

Unlimited

b

1.5 Minutes

C

You can find more information at

Capacity

Unlimitted

Unlimited

b

.75 min

Customizing

You can find more information at

3.5 Sec

b

No doughnuts

c

Doughnuts total in one minute

2nd Bottle Neck

On examining the above, one can infer that the first bottleneck lies at 14680Units doughnuts (Fraction was ignored).

Thus, the company should be able satisfy its demand requirements and so the alternative option shall be able provide the solution.

This solution requires an additional expense for three cutters.

Best Solution

In the present situation, Mr. Dewey Johnson will choose proposal one because it provides a better solution than any other two for the following reasons.

You don’t need to make any additional expenditures

1stbottleneck exceeds the demand

It is able to idle.

Four scenarios were used to base the analysis:

Refer to

Examples of Company Bottlenecks.

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