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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