(Solved Homework): Dave’s Sub Shop makes custom submarine sandwiches to order. The general process flow is…

Dave’s Sub Shop makes custom submarine sandwiches to order. The general process flow is shown below. A different person works each station.

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Order Essay

Take Order

1 Min/order

Slice Bun & Add Meat Cheese

3 Min/order

Add Toppings & Condiments

4 min/order

Bag the Order

2 Min/Order

Fill in the following table. Don’t forget the units.

Station	Capacity	Utilization	Slack
Take Order
Slice Bun and Add Meat/Cheese
Add Toppings and Condiments
Bag the Order

Where is the bottleneck?

What is the system capacity?

Where should you add capacity and how much? Why should you add it there? What is the benefit of adding capacity?

What is the flow time?

What is the cycle time?

Is there a benefit if we shift 1 minute of work from Condiments to Bagging? (Assuming we have not added capacity)

Expert Answer

Answer

Station	Capacity (orders per hour)	Utilization (%)	Slack (%)	Slack (orders per hour)
Take Order	60	25%	75%	45
Slice Bun and Add Meat/Cheese	20	75%	25%	5
Add Toppings and Condiments	15	100%	0%	0
Bag the Order	30	50%	50%	15

The bottleneck is “Add Toppings and Condiments” as it has least capacity.
System capacity = min(60, 20, 15, 30) = 15 sandwiches per hour
Capacity should be added to the bottleneck and the amount should be up to the next minimum i.e. that of slicing Bun and adding Meat/Cheese (20 per hour). So, we can add 5 orders per hour of capacity in the 3rd station.
Flow time = 1+3+4+2 = 10 minutes
Cycle time = max(1, 3, 4, 2) = 4 minutes
The capacity becomes –

Station	Capacity (orders per hour)
Take Order	60
Slice Bun and Add Meat/Cheese	20
Add Toppings and Condiments	20
Bag the Order	20

System capacity = min(60, 20, 20, 20) = 20 sandwiches per hour (benefit of 5 units of capacity will be observed)

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