# (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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 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)

 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
1. The bottleneck is “Add Toppings and Condiments” as it has least capacity.
2. System capacity = min(60, 20, 15, 30) = 15 sandwiches per hour
3. 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.
4. Flow time = 1+3+4+2 = 10 minutes
5. Cycle time = max(1, 3, 4, 2) = 4 minutes
6. 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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