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
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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