Daily Production Requirement

Daily
Batch Size
SN Item Description Type Requiermnet Yeild (Pkts)
( Kg)
(Pkts)
1 White Bread Small Close Top 1800 463 176.82
5 Brown Bread Medium Close Top 4300 212 164.22
4 Brown Bread Small Open Top 1400 398 165.30
6 Brown Super Jumbo Bread Close Top 200 100 165.82
9 Milk Bread Small Close Top 2300 477 195.40
8 Mixed Grain Bread Medium Open Top 1600 250 174.32
7 Mixed Grain Bread Small Open Top 1500 450 174.56
2 White Bread Medium Close Top 5700 257 178.22
3 White Super Jumbo Bread Close Top 350 105 177.47

Total
19150 1572.13
Requirements
nt

Approx
Req. Batches
Batches

3.89 4
20.28 21
3.52 4
2.00 2
4.82 5
6.40 7
3.33 4
22.18 22
3.33 4

69.76 73
 Existing capacity - for Proofing & Baking
SN Bread Size details Trolly Layer Pan per layer

1 small 14 11 20
2 medium 34 11 12
3 Jumbo 10 10 9

Tray & P
Daily
Requier Yeild Batch Req.
SN Item Description Type
mnet (Pkts) Size ( Kg) Batches
(Pkts)
1 White Bread Small Open Top 1800 463 176.82 3.89
4 Brown Bread Small Close Top 1400 398 165.30 3.52
9 Milk Bread Small Open Top 2300 477 195.40 4.82
7 Mixed Grain Bread Small Close Top 1500 450 174.56 3.33
5 Brown Bread Medium Open Top 4300 212 164.22 20.28
8 Mixed Grain Bread Medium Close Top 1600 250 174.32 6.40
2 White Bread Medium Open Top 5700 257 178.22 22.18
6 Brown Super Jumbo Bread Open Top 200 100 165.82 2.00
3 White Super Jumbo Bread Open Top 350 105 177.47 3.33
& Baking
Total Require Diffrence/S
Pan ments hort
3080 7000 -3920
4488 11600 -7112
900 550 350

Tray & Pan

No. of No of layres No. Pans No. of Diffrence/S
Approx
Pan per Pan per pans per Total Pans Requirements
Batches
Trollies trolley Layer Trolley hort

4
4
14 11 20 220 3080 7000 -3920
5
4
21
7 34 11 12 132 4488 11600 -7112
22
2
10 10 9 90 900 550 350
4
 No .of pan No. of extra pans
required per required to
hour complete the cycle

3568 1000

1434 1500

1650 0
 Cooling Capacity
Trolly Adiitiona
SN Cooling capacity space for Existing
l
cooling

1 25 24 10

Existing capa
Bread one layer
SN Trolly Size details Trolly Layer Small medium Jumbo
Bread Bread Bread

1 small Trolly/Bread 13 7 26 20 16
2 Big Trolly /Bread 11 7 57 26 26
3 Avg of both type of Trolley 24 7 41 23 21
 Total Diffrnece Remark

Extra spce is not

34 9
required

Existing capacity for Cooling

One
trolly One trolly One trolly Avg Pcs per Oven Output/per
Total Trolley
Small medium Jumbo Bread
required for
Trolley hour cooling per hour
Bread
Bread
182 140 112 144.66666666667 2400 16.589861751152
399 182 182 254.33333333333 1400 5.5045871559633
290 161 147 199.5 1900 11.047224453558
 No. of extra
No of trolles
trollies required
required for 3 Diffrence
houres of cooling to complete the
cycle

33.141673360673 9.1416733606731 10
 Production
Total Hours
Actual
require for Start Time End time Product Name Req Mix Diff yeild
Mix
production

3.4 5.3 9.1 White Medium 22 22 0 257

1 9.1 10.1 Milk bread small 5 5 0 477
0.4 10.1 10.5 White Jumbo 4 4 0 105
0.2 10.5 11.1 Brown jumbo 2 2 0 100
3.5 11.1 14.4 Brown Medium 21 21 0 212
0.4 14.4 16.2 Brown Bread Small 4 4 0 251
0.4 16.2 17 Mixedgrain Medium 4 4 0 250
0.3 17 17.3 Mixed Grain Bread Small 3 3 0 450
1 17.3 18.3 White Small 4 4 0 463
Production planning
Cooling Trolley Cycle
Total
No. cooling
Total Diffrence of cycle for Capacity Per Trolley
pan aviable Trollies Diffrence
prod pan pan Trolley availabl
required
e

5654 6000 346.00 182.0 31.1 30.0 -1.1

2385 3080 695.00 13.00 290.0 8.2 24.0 15.8
420 900 480.00 290.0 1.4 15.8 14.4
200 480 280.00 290.0 0.7 14.4 13.7
4452 4488.00 36.00 14.00 182.0 24.5 29.0 4.5
1004 3080.00 2076.00 17.40 290.0 3.5 4.5 1.0
1000 2076.00 1076.00 19.20 182.0 5.5 6.0 0.5
1350 2076.00 726.00 20.00 290.0 4.7 5.0 0.3
1852 1730.00 -122.00 20.30 290.0 6.4 7.0 0.6
olley Cycle

Start Next
End Time
Time Cycle

13.00 16.00 16.00

16.00 19.00 19.0
16.1 19.1 19.1
19.4 22.4 22.4
19.2 22.2 22.2
20 23 23.0
20.3 23.3 23.3
21.3 24.3 24.3
 Propo
Standard Pla
Small
Factor UOM Mix Pcs
Sifting Fixed Kg/Hour NA 2000
Mixing Fixed No / Hour 8 3520
Cutting Fixed No / Hour 8 3520
Moulding Fixed No / Hour 8 3520
Proofing Variable Trolley / 2 hour 20 Trolley 4400
Baking Fixed Pans / hour 2605 Pan / Hr 2605
Cooling Variable 25 Trolley/2.5 hour 13 small + 11 Big Trolley 6755
Slicing Fixed Pcs / Hour / 2 machine 2100 Pcs / 1 machine 4200
Packing Fixed Pcs / Hour 3600 pcs / 1 machine 3600
 Proposed Plan - For Optimal Use Of Resources
Standard Plan Actu
Average
Medium Jumbo Small
Mix Pcs Mix Pcs Mix
NA 2000 NA 2000 2000 400
6 1438 6 615 1858 7 4
6 1438 6 615 1858 7 4
6 1438 6 615 1858 7 4
20 Trolley 2640 20 Trolley 1800 2947 4
1485 Pan / Hr 1485 1300 Pan /Hr 1300 1797 1788 pan / Hr
13 small + 11 Big Trolley 3822 13 small + 11 Big Trolley 3458 4678 4
2100 Pcs / 1 machine 4200 2100 Pcs / 1 machine 4200 4200 2100
3600 pcs / 1 machine 3600 3600 pcs / 1 machine 3600 3600 3600
urces
Actual Plan Proposed Plan
Average Average
Small Medium Jumbo Small Medium Jumbo
Pcs Mix Pcs Mix Pcs Mix Pcs Mix Pcs Mix Pcs
400 400 600 600 600 600
1788 4 956 2.5 256.25 1000 4 6 2682 6 1434 6 613 1576
1788 4 956 2.5 256.25 1000 4 6 2682 6 1434 6 613 1576
1788 4 956 2.5 256.25 1000 4 6 2682 6 1434 6 613 1576
1788 4 956 2.5 256.25 1000 2947 2682 2947 1434 2947 613 1576
1788 956 pan / hr 956 410 Pan / hr 256.25 1000 1797 2682 1797 1434 1797 613 1576
1788 4 956 2.5 256.25 1000 4678 2682 4678 1434 4678 613 1576
1788 2100 956 2100 256.25 1000 4200 2682 4200 1434 4200 613 1576
1788 3600 956 3600 256.25 1000 3600 2682 3600 2682 4200 613 1992
Average

6
6
6
2947
1797
4678
4200
3800
 Standard

No of Mix Kg 178
Capacity
Activity name Start time End time Time (Min) Manpower
Std per hour

2000 per
Shifter 05:00:00 AM 05:02:00 AM 2.00 hour

Mixing 5:02 5:17 15 1424

Cutting 5:18 5:26 8.00 1335

Moulding 5:20 5:27 7 1467

Proofing 5:37 7:37 120 2 3080 pan (14 Trolly of 11 layer

Baking 7:37 8:17 40 2 2605 per hour

Cooling 8:17 10:47 150 6 2366 - small Trol

4389 pcs in big Tro

Slicing 4200 pcs

Packaging 10:47 10:47 60 8 4200 pcs

Note 178 is the average weight from each batch 1980

1188

No of Mix Kg 172
Activity name Start time End time Time (Min) Manpower
Std per hour

2 700 per hour

Shifter 05:00:00 AM 05:02:00 AM
2
15 1376
Mixing 5:02 5:17

10 1032
Cutting 5:18 5:26
7
7 1263.33
Deviding 5:20 5:27

120 2 2640 pan (20 Trolly of 11 layer w

Proofing 5:37 7:37

40 2 1485 per hour

Baking 7:37 8:17
big trolly 1820 pcs
150 6
Cooling 8:17 10:47 Small trolly - 1540 pc

Slicing 4200 pcs

60 8 4200 pcs
Packaging 10:47 11:47
Note 178 is the average weight from each batch
701 is the average weight of medium bread\
20 trolly capacity of Proofer
10 in the cutting is consder as an time taken for complete

No of Mix Kg 171
Activity name Start time End time Time (Min) Manpower
Std per hour
Shifter 05:00:00 AM 05:02:00 AM 2 700 per hour
2
Mixing 5:02 5:17 15 1368
Cutting 5:18 5:26 10 1026
7
Deviding 5:20 5:27 7 1482.78

120 2 900 pan (10 Trolly of 10 layer w

Proofing 5:37 7:37
Baking 7:37 8:17 40 2 1300 per hour

2002 - big trolly.

150 6
1456 - Small trolly.
Cooling 8:17 10:47
Slicing 4200 pcs
2160 per machine per h
Packaging 10:47 11:47 60 8

1100 jumbo white

1400 super jumbo white
1600 super jumbo brown
1366 average
450.78 is the deviving cups 55X6=330

White Bread Smal 463 Brown Bread Med

Brown Bread Smal 398 Mixed Grain Bre
Milk Bread Small 477 White Bread Med
Mixed Grain Brea 450
447 10
10
Brown Super Jum 100 10
White Super Jumb 105 10
102.5 10
10

Time per hour 6

Mix Require
mix
22 3.67
5 0.83
2.5 0.42
21 3.50
4 0.67
2 0.33
4 0.67
4 0.67
3 0.50
2.5 0.42
70 11.67
 Standard Capacity - Of Machine & Utility

Small Bread

city
er hour Actual

Batch Pcs (Dough) Batch Pcs (Dough)

8.18 3560 712 4.091954023 1780

7.50 3337.5 712 4.091954023 1780

8.24 3667.5 712 4.091954023 1780

0 pan (14 Trolly of 11 layer with 20 Pan) 8

5 per hour 1650 per 42 Min

2366 - small Trolly 1780 pcs

4389 pcs in big Trolly.

4200 pcs
4200 pcs 41 mins for 1780 pcs

11.123595505618

Medium Bread

Capacity
Std per hour Actual

Batch Pcs (Dough) Batch Pcs (Dough)

8 1962.91012838802 688 3.954022988506 981.455064194

6 1472.18259629101 688 3.954022988506 981.455064194

7.34494186046512 1802.18259629101 688 3.954022988506 981.455064194

2640 pan (20 Trolly of 11 layer with 132 Pan) 7

1485 per hour 981

big trolly 1820 pcs

981.455
Small trolly - 1540 pcs

4200 pcs

4200 pcs 41 mins for 1780 pcs

 Jumbo Bread

Capacity
Std per hour Actual
Batch Pcs (Dough) Batch Pcs (Dough)
8 1001.46412884334 688 3.954022988506 981.455064194
6 751.098096632504 688 3.954022988506 981.455064194
8.67122807017544 1085.49048316252 688 3.954022988506 981.455064194

900 pan (10 Trolly of 10 layer with 90 Pan) 11

1300 per hour 1200 per hour

2002 - big trolly.

981.455064194009
1456 - Small trolly.

4200 pcs
2160 per machine per hour
41 mins for 1780 pcs
2160X2 = 4320

212
 250
257
239.666666666667
1
1
1
1
1
1
& Utility

Gaps/Observations

3 bags at each mxiing interval,due to such activity with repeatative interval shifting is not utilizing the
capacity of it.

we have 2 mixing capacity but currenlty only one mixing is under utilization.
If we use two mixing together it will give us an good, efficiency as the Arabic bread line mixing are using it. one after
another no gaps .

only 1 mixing using not 2 mixing together due to this time for the further variable is more & idle time for the 2 mixing
person.
15 minutes of gaps are occuring in betwwen the mixing and cutting after moulding. which result into the idle
manpower.

During the mixing delay result into the, cutting and moulding delay as decribed in the below description.

due to the mixing variable result into the 12 minutes interval 6+6 each time to the cutting operator per mix
of bowl.
So it will goes like this 6 min for the first batch of mix than end of batch and again the second batch mix same
6 min gaps
so, bascially we can consider it as 18 min of gaps between the process from the mixing to the cutting.

moulding takes almost 6 to 7 min for the every batch of dough to reached for the paning :
as it has 5X6 cups with 55 tray capacity so it will be 330.
so it will hold as 330 pcs of dought with respective of dough weight.

proofing capacity is 25 trolly as fullist

active pan & Tray
small we have 14 tray - 14X220= 3080 pan
Medium we have 34 tray - 34X 132= 4488 Pan
Jumbo we have 10 Tray - 900 pan- but we are currenly doing the process as 18 X3 = 54 pan in one trolly ;
because heavy weight observed during the baking process and SS quality for Trolly is bad can't hold the
weight of all 90 pan in one trolly.
Full capacity of baking is 2605 per hours for the small bread, it reaches to the depaning spot.

13 trolly of big with 7 layer in each trolly so bread small will come,
26X7=182 . So 182 X13 trolly = 2366

11 trolly of big we have so capacity is of current scnerio is for small is 57X7-399 pcs ; so 11X399 = 4389 pcs in
big trolly.

2100 pcs of bread per hour ; in one machine.

So basically it will be for 2 machine of cutter is 4200 pcs
2100 per machine per hour.

Gaps/Observations

20X7 140, 140 X 13 -1820 -big trolly.

140X11 --1540 pcs in samll trolly
2100 pcs of bread per hour ; in one machine.
So basically it will be for 2 machine of cutter is 4200 pcs
2100 pcs of bread per hour ; in one machine.
So basically it will be for 2 machine of cutter is 4200 pcs
 Gaps/Observations

18 in one trolly as weight get more and not fesiable for baker to bake in the oven due to this currently using
the 18 per trolly.

2002 - big trolly.

1456 - Small trolly.
245.3638

98.14551