KRISTEN'S COOKIE FLOW CHART

ORDER
RECEIVING
0 MIN

WASH &
MIX
6 MIN

SPOONING
2 MIN

THROUGHPUT TIME :
Is the time the product undergoes through the manufacturing process. It is th

Kristen"s Throughput time includes all value added activities for producing 1 dozen cookies , there
Activity
Mixing
Spooning
Setting & Baking
Cooling
Packing
Total throughput time

Time
6 min
2 min
10 min
3 min
2 min
25 min

CYCLE TIME:
Cycle time is the time from the beginning of the process to the end of the proc
cycle time is the time from when the order is received to the time the custome
the payment.
Kristen"s Cycle time for conversion and production of 1 dozen cookies includes all the activites fro
Activity
Time
Mixing
6 min
Spooning
2 min
Setting & Baking
10 min
Cooling
3 min
Packing
2 min
Payment
1 min
Total Cycle time
26 min

MAXIMUM PRODUCTION:
The maximum capacity is the maximum number of goods that can be produced with the

Kristen"s We will have maximum production if we simultaneously spoon the other dozen while one

SPOONING
2 MIN

OVEN
HEAT
1
MIN

BAKING
9 MIN

COOLING
5 MIN

acturing process. It is the time required to convert the raw material to the finished good.

cing 1 dozen cookies , therefore payment time is not included in throughput because it is a non-value added act

ss to the end of the process. In this case of cookies, the

to the time the customer receives the good and makes

ncludes all the activites from order to cash :

t can be produced with the available resources used to the maximum capacity.

n the other dozen while one dozen is baked in the oven

PACK
2 MIN

hed good.

a non-value added activity

PAY
1 MIN

Answer 1
Activity
Order Receipt
Wash & Mix (1-3 dozen)
Spooning
Set the Oven
Baking
Unload
Cooling
Packing
Payment
Total Time Taken for 1 do

Answer 2
Total Operating Time (Mins)
Step
Step
Step
Step

1
2
3
3

- Mix the dough for 3 dozen cookies

- Spoon 1 dozen cookies
- Load the cookies into oven
completes in the 18th minute

While the cookies being baked the second dozen can be spooned
By the end of 18th minute the second dozen is loaded into the oven
During the second dozen being in the oven, the first dozen is left for cooling and packed by
By the end of 28th minute the second dozen has been baked and the first dozen is ready fo
By the end of 33rd minute the second dozen has cooled down
By the end of 35th minute the second dozen has been packed
Payment and pickup takes place at the end of 36 minutes for 2nd order
Time taken to process an order of 2 dozen cookies end to end is 36 mins
Bottlenecks- setting the oven thermostat for baking
Time for second dozen = Time for first dozen + bottleneck
Time taken for the 2 dozen for production is 36 mins
Time for the third dozen=Time taken for first dozen+2*bottlenecks
General equation for nth dozen= 26+(n-1)*bottleneck
This general equation should be less then equal to the time constraing of 240 mins (4hrs)
Equation = 16 + 10n <=240
Therefore n = 22

Answer 3
Kristen's job = Washing, Mixing and Spooning
Roommate's job = Set, Pack & Payment collection

Answer 4
1st order

Time consumed by labour for 1 dozen order

6 wash and mix + 2 spoon + 1 set oven + 2 pack time + 1 payment

2nd order Time consumed by labour for 2 dozen order

6 wash and mix + 2*2 spoon + 1*2 set oven + 2*2 pack time + 1 payment
3rd order Time for 3 dozen order
6 wash and mix + 2*3 spoon + 1*3 set oven + 2*3 pack time + 1 payment
Labor Cost = $10/ hours assumption
Labor cost / min
No. of Dozens
1 dozen
2 dozen
3 dozen
Labor Cost = $15/ hours assumption
Labor cost / min
No. of Dozens
1 dozen
2 dozen
3 dozen

Answer 5
0 additional mixers required since 1 sits ideal for a long time during baking and cooling
2 more baking trays require

Time Taken (Minutes)

0
6
2
1
9
0
5
2
1
26
Assumption - Activities can be performed on parallel
240

ough for 3 dozen cookies

ozen cookies
cookies into oven
n the 18th minute

being baked the second dozen can be spooned

h minute the second dozen is loaded into the oven
dozen being in the oven, the first dozen is left for cooling and packed by the room mate - total production time
minute the second dozen has been baked and the first dozen is ready for delivery
minute the second dozen has cooled down
minute the second dozen has been packed
up takes place at the end of 36 minutes for 2nd order
ess an order of 2 dozen cookies end to end is 36 mins

g the oven thermostat for baking

dozen = Time for first dozen + bottleneck
2 dozen for production is 36 mins
d dozen=Time taken for first dozen+2*bottlenecks
or nth dozen= 26+(n-1)*bottleneck
ion should be less then equal to the time constraing of 240 mins (4hrs)
10n <=240
22 orders can be processed during 240 mins

shing, Mixing and Spooning

Set, Pack & Payment collection

y labour for 1 dozen order

2 spoon + 1 set oven + 2 pack time + 1 payment

12 mins

y labour for 2 dozen order

2*2 spoon + 1*2 set oven + 2*2 pack time + 1 payment

17 mins

2*3 spoon + 1*3 set oven + 2*3 pack time + 1 payment

22 mins

0/ hours assumption
0.1667
Time Taken
12
17
22

Variable Labor Cost

2.00
2.83
3.67

5/ hours assumption
0.25
Time Taken
12
17
22

Variable Labor Cost

3.00
4.25
5.50

s required since 1 sits ideal for a long time during baking and cooling
since 3 dozen is the capacity of the mixer

m mate - total production time 26 mins

ORDER SIZE
1 dozen
2 dozen
3 dozen
4 dozen
5 dozen
6 dozen
7 dozen
8 dozen
9 dozen
10 dozen
11 dozen
12 dozen
13
14
15
16
17
18
19
20
21
22

dozen
dozen
dozen
dozen
dozen
dozen
dozen
dozen
dozen
dozen

COMPLETION TIME
26 min
36 min
46 min
56 min
66 min
76 min
86 min
96 min
106 min
116 min
126 min
136
146
156
166
176
186
196
206
216
226
236

min
min
min
min
min
min
min
min
min
min
min

Variable Labor Cost/Dozen

2.00
1.42
1.22

Material Cost/Dozen
0.70
0.70
0.70

Total Material Cost

0.70
1.40
2.10

Variable Labor Cost/Dozen

3.00
2.13
1.83

Material Cost/Dozen
0.70
0.70
0.70

Total Material Cost

0.70
1.40
2.10

Total Cost
2.70
4.23
5.77

Total Cost/Dozen
2.70
2.12
1.92

Total Cost
3.70
5.65
7.60

Total Cost/Dozen
3.70
2.83
2.53

Cost Saving/Dozen
NA
22%
29%

AVAILABLE FACTS
COST OF IN GRADIENTS
PACKING COST
MIXING TIME

ACTIVITY
ORDER
WASH
SPOONING
OVEN HEAT
BAKING
REMOVE
COOL
PACK
PAY
TOTAL

0.6 PER DOZEN

0.1 PER BOX
6 MIN

RESOURCECUMMULATIVE
0
6
2
1
9
0
5
2
1
26

0
6
8
9
18
18
23
25
26

GANTT CHART FOR 3 BATCHES

TIME IN MINUTES
1

2 3 4 5

Batch 1
ORDER
WASH
SPOONING
OVEN HEAT
BAKING
REMOVE
COOL
PACK
PAY

Batch 2
BAKING
COOL
PACK
PAY

Batch 3
BAKING
COOL
PACK
PAY

PROCESS CONTINUES FOR 240 MINUTES (22 DOZEN)

ES

DOZEN)

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

BAKING

27

28

COOLING
PACKING
PAYMENT

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46