Question: Time per day 8 hours Batch Size 8 lbs Time per day 480 minutes Donut Size 2 oz Days per week 7 days Donuts/batch 64
Time per day 8 hours Batch Size 8 lbs Time per day 480 minutes Donut Size 2 oz Days per week 7 days Donuts/batch 64 donuts/batch Current Sales 1100 doz/day Target 13,200 donuts/day takt time 2.18 seconds/donut Step 1: Batching Step 2: Mixing Step 3: Extruding Step 4: Frying Step 5: Glazing Step 6:Customize Setup time (mins) 1.5 Setup time (seconds) 90 Process time (mins/donut/extruder) 2 2.5 0.06 1.5 0.75 0.029 Process time (per batch) 1.19 1.5 0.75 1.867 Setup time + Process time (per batch) 2.69 Capacity (batches/day) 240.0 192.0 178.8 257.1 Capacity (donuts/day/machine) 15,360.00 12,288.00 16,457.14 Number of machines/cutters 1 2 3 1 Capacity (donuts/day) 15,360.00 24,576.00 11,440.55 16,457.14 Dozens 1,280.00 2,048.00 953.38 cycle time 1.88 1.17 2.52 1.75 Whole batches/day 240.0 192.0 178.0 257.0 Capacity (using whole batches) 15,360.00 24,576.00 11,392.00 16,448.00 cycle time (using whole batches) 1.88 1.17 2.53 1.75
Second option: Add cutters to the extruder. Johnson also considered adding an additional three cutters to the extruder. He knew this would increase the rate at which donuts could be cut and shaped, but he also knew that it would add to the cleaning and setup which had to be performed prior to each step and that it would cost him to purchase and install the new cutters...making this, again, not the ideal option - but a feasible one. In order to make an informed decision, he needs to know this: Working with whole batches only (no partial batches allowed), what is the maximum setup time in minutes, rounded to the nearest tenth of a minute, that could be allowed for each batch if he were to add an additional three cutters without changing the current batch size of eight pounds?
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