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

Station Capacity
(orders per hour)
(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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