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Question: Scenario 1: BBCC Revisit Billy Bob’s Campus cookies (BBCC) discussed in the assigned reading, “Process Analysis: Definitions, Tools, and Insights”. (Assume no parallel processing takes place). 1. Since the cookie sheets can hold exactly 1 dozen cookies, BBCC will produce and sell cookies by the dozen. How much time will it take to fill an order of 2, 3, or 4 dozen cookies? 2. Assuming each order is for 2 dozen cookies, what is the production capacity and takt time of this process? 3. What is the WIP inventory level if demand is from customers ordering 1 dozen at a time if the system consists of 2 ovens and Billy working alone? (Assume that there is a backlog of orders so the bottleneck is always in the production. process).

Scenario 1: BBCC Revisit Billy Bob’s Campus cookies (BBCC) discussed in the assigned reading, “Process Analysis: Definitions, Tools, and Insights”. (Assume no parallel processing takes place). 1. Since the cookie sheets can hold exactly 1 dozen cookies, BBCC will produce and sell cookies by the dozen. How much time will it take to fill an order of 2, 3, or 4 dozen cookies? 2. Assuming each order is for 2 dozen cookies, what is the production capacity and takt time of this process? 3. What is the WIP inventory level if demand is from customers ordering 1 dozen at a time if the system consists of 2 ovens and Billy working alone? (Assume that there is a backlog of orders so the bottleneck is always in the production. process).

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1. Since the cookie sheets can hold exactly 1 dozen cookies, BBCC will produce and sell cookies by the dozen. How much time will it take to fill an order of 2, 3, or 4 dozen cookies?

Cycle time for 2 dozen cookies = 6 mins to mix + 4 mins to spoon + 20 total baking mins + 10 mins to cool + 4 mins to pack + 1 min to receive payment = 45 mins

Cycle time for 3 dozen cookies = 6 mins to mix + 6 mins to spoon + 30 total baking mins + 15 mins to cool + 6 mins to pack + 1 min to receive payment = 64 mins

Cycle time for 4 dozen cookies = 12 mins to mix + 8 mins to spoon + 40 total baking mins + 20 mins to cool + 8 mins to pack + 1 min to receive payment = 89 mins

2. Assuming each order is for 2 dozen cookies, what is the production capacity and takt time of this process?

Billy = 10 mins

Bob = 7 mins

Oven = 20 mins

Takt time is 20 mins per order based on the time in the oven. This equates to 3 orders per hour for capacity.

3. What is the WIP inventory level if demand is from customers ordering 1 dozen at a time if the system consists of 2 ovens and Billy working alone? (Assume that there is a backlog of orders so the bottleneck is always in the production. process).

WIP = CT * R. Two ovens reduces the CT by 10 mins on the baking time and we can reasonably assume another 5 mins is saved by letting both dozen cool as the same time. This brings CT to 30 mins. Takt time becomes 12 mins with Billy working alone. WIP = 30 mins * 2 dozen / 12 mins = 5 dozen.

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