Third option: Reduce the setup time. Finally, Dewey Johnson has realized that if he could reduce the time it takes to clean and prep the extruder before each batch, he can cut out enough non-value-added time to produce what is needed without any additional wear and tear and without purchasing new equipment. A truly lean-thinking solution! Working with whole batches only (no partial batches allowed), 

what is the required setup time in minutes, rounded to the nearest tenth of a minute, to produce the needed daily demand while keeping only three cutters on the extruder and maintaining a batch size of eight pounds?

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Time per day Time per day Days per week Current Sales Target takt time Setup time (mins) Setup time (seconds) Process time (mins/donut/extruder) Process time (per batch) Setup time + Process time (per batch) Capacity (batches/day) Capacity (donuts/day/machine) Number of machines/cutters Capacity (donuts/day) Dozens cycle time Whole batches/day Capacity (using whole batches) cycle time (using whole batches) 8 hours 480 minutes 7 days 1100 doz/day 13,200 donuts/day 2.18 seconds/donut 2 240.0 15,360.00 Step 1: Batching Step 2: Mixing Step 3: Extruding Step 4: Frying Step 5: Glazing Step 6:Customize 1 15,360.00 1,280.00 1.88 240 15,360.00 1.88 2.5 192.0 12,288.00 2 24,576.00 2,048.00 1.17 192 24,576.00 1.17 Change the values in the green shaded cells to see how each one of these variables affects output. Think about how changing one or more of these will affect the system as a whole. 1.5 90 0.06 1.19 2.69 178.8 3 Batch Size Donut Size Donuts/batch 11,440.55 953.38 2.52 178 11,392.00 2.53 8 lbs 2 oz 64 donuts/batch 1.5 1.5 0.75 0.75 0.029 1.867 257.1 16,457.14 1 16,457.14 1.75 257 16,448.00 1.75 Time per day Time per day Days per week Current Sales Target takt time Setup time (mins) Setup time (seconds) Process time (mins/donut/extruder) Process time (per batch) Setup time + Process time (per batch) Capacity (batches/day) Capacity (donuts/day/machine) Number of machines/cutters Capacity (donuts/day) Dozens cycle time Whole batches/day Capacity (using whole batches) cycle time (using whole batches) 8 hours 480 minutes 7 days 1100 doz/day 13,200 donuts/day 2.18 seconds/donut 2 240.0 15,360.00 Step 1: Batching Step 2: Mixing Step 3: Extruding Step 4: Frying Step 5: Glazing Step 6:Customize 1 15,360.00 1,280.00 1.88 240 15,360.00 1.88 2.5 192.0 12,288.00 2 24,576.00 2,048.00 1.17 192 24,576.00 1.17 Change the values in the green shaded cells to see how each one of these variables affects output. Think about how changing one or more of these will affect the system as a whole. 1.5 90 0.06 1.19 2.69 178.8 3 Batch Size Donut Size Donuts/batch 11,440.55 953.38 2.52 178 11,392.00 2.53 8 lbs 2 oz 64 donuts/batch 1.5 1.5 0.75 0.75 0.029 1.867 257.1 16,457.14 1 16,457.14 1.75 257 16,448.00 1.75