Calculate the system capacity
Frederica’s Fine Frozen Foods has a small manufacturing plant outside of Baltimore. In this facility, they make frozen cheese pizzas for distribution to regional grocery stores. The pizzas are made on a single production line using the seven-station process shown below. Each pizza requires a dough base, to which is then applied a carefully measured .06 gallons of sauce. Fran insists that a mixture of two kinds of cheese (Mozzarella and Romano) is used for the topping. A total of .36 pounds of cheese is applied to the sauced crust with the mixture ratio of Mozzarella to Romano being 2:1. An automatic wrapping machine then applies 2.7 sq. feet of plastic overwrap to the pizza. Finally, the wrapped pizza is inserted into a box and sealed. The measurement of the sauce and the cheese are done during production, since Fran and Fred feel that pre-measured amounts lose their freshness. The following information is available about the entire process:
Station
Description
Capacity
A
Cut dough
200 pizzas / hour
B
Measure sauce
25 gallons / hour
C
Apply sauce
175 pizzas / hour
D
Measure Mozzarella cheese
40 pounds / hour
E
Measure Romano cheese
30 pounds / hour
F
Apply cheese
210 pizzas / hour
G
Apply plastic overwrap
520 sq. feet / hour
H
Insert into carton and seal
250 pizzas / hour
a. A — C —- F —— G —– H
B flows into C and D, E flow into F
What is the system capacity in terms of pizzas per hour? Which department(s) is (are) the bottlenecks? Display your answers to one decimal place.
b. How much slack (i.e. unused capacity) is available in the other departments (in terms of pizzas per hour)? Display your answers to one decimal place.
2. The law firm of L, D & D specializes in the practice of waste disposal law and is interested in analyzing its caseload. Data were collected on the number of cases received in a year the times to complete each case. Calls for their services arrived on average at a rate of one case every 30 days. On average a case takes 25 days to complete. What is the average backlog of cases waiting?
3. A work cell at Chris Ellis Commercial Laundry has a workstation with two machines and each unit produced at the station must be processed by both machines (serial). Each machine has a production capacity of 4 units per hour.
a. What is the flow time for a unit?
b. What is the cycle time for the workstation?
4. Dave’s Sub Shop makes custom submarine sandwiches to order. The general process flow is shown below. A different person works each station.
1. Take order (1min per order)——– 2. slice bun and add meat/cheese (3 min per order)——3. Add toppings and condiments (4minutes per order)——-4. Bag the order (2 minutes per order)
Fill in the following table. Don%u2019t forget the units.
Station
Capacity
Utilization
Slack
Take Order
Slice Bun and Add Meat/Cheese
Add Toppings and Condiments
Bag the Order
Where is the bottleneck?
What is the system capacity?
Where should you add capacity and how much? Why should you add it there? What is the benefit of adding capacity?
What is the flow time?
What is the cycle time?
Is there a benefit if we shift 1 minute of work from Condiments to Bagging? (Assuming we have not added capacity)
