Assignment 1

1. The bread-making process of Panadería Josmar consist mainly of three lines of products,
croissant-rolls-making process involving two dependent parallel lines, one for the preparation
of the premium croissant and one for the bread rolls made with a similar dough but with a
different bread preparation, one being a classic croissant and the other a roll. The third line is
a wholemeal bread which involves less sophisticated preparation steps compared to the other.
The process starts at station 1 where the flour is processed with some ingredients to produce
the raw dough, then individual portions for the different types of bread are dossed. This
station has a production rate of 230 portions per hour. The processing times and resources
utilized for the rest of the stations are given in the table below. After station 1 85% of the
produced portions are sent to station 2 for the production lines of croissants and rolls. The
remaining 15% are sent to the production line of wholemeal breads. The sequence for the
croissant production line goes through stations 1, 2 and 4. For the rolls the sequence involves
stations 1, 2, 5, 7. Finally for the wholemeal bread the sequence is stations 1, 3, 6, 8.

Station Task Time Machines Workers Workers Station that must

Available required Available precede
1 230 units/hour 2 4 8 -
2 0,5 min/unit 3 2 6 1
3 0,7 min/unit 1 2 2 1
4 75units/hour 4 2
5 0,6 min/unit 1 1 1 2
6 0,4 min/unit 1 1 1 3
7 75units/hour 2 5
8 75units/hour 1 6

The entire operation works shifts of 8 hours but there is a lunch pause of half an hour given to all
workers at which all stations are shutdown. Station 1 process the flour to produce the dough and then
the raw portions for the breads, a special type of machine is used here that requires 4 operators.
Stations 2 correspond to the flattening and rolling of each portion to produce the croissants, which
also includes an inspection to ensure the quality. Historically, 5% of the portions are discarded here.
Station 4 corresponds to the baking process. After going through the inspection at Station 2, 20% of
the rolls that do not meet the requirements for croissants are processed at Station 5, transformed into
cinnamon rolls, and then baked at Station 7. Station 3 adds nuts to the wholemeal portions and
inspects them, where historically 5% of the portions are discarded. To this station arrives 15% of the
portions prepared at Station 1. Station 6 add a special coating to the breads and then they are baked
at Station 8. All of the ovens used at Stations 4, 7 and 8 require a 30 minutes maintenance every day.
a) Draw the flow chart for the bread-production operation described. (10% of the grade)
b) Perform a capacity analysis for this operation and determine whether it is balanced to meet
the current weekly demands of 18000 croissants, 5000 rolls and 3000 wholemeal breads?
Explain. (20% of the grade)
 c) Determine what changes in the current configuration of this operation would be required to
meet the weekly demand levels of 18000 croissants, 5000 rolls, and 3000 wholemeal breads?
Explain. (20% of the grade)

2. For a five year planning horizon with forecasted demands as shown in the following
table, what would be the requirements in terms of machines and persons for the
bread production operation using the following resources:

Croissant machine à Capacity 234000 units/year, there are currently 2 machines available,
and 4 workers are required to operate 1 machine. The company have currently 8 workers at
its disposal.

Rolls machine à Capacity 260000 units/year, there is currently 1 machine available, and 1
worker are required to operate 1 machine. The company have currently 1 worker at its
disposal.

Wholemeal bread machine à Capacity 156000 units/year, there is currently 1 machine

available, and 2 workers are required to operate 1 machine. The company have currently 2
workers at its disposal.

The demands for the three types of bread for the five-year planning horizon are shown in
the table below.

Demands for the next 5 years

Product Year 1 Year 2 Year 3 Year 4 Year 5
Croissant 923500 934000 1060000 950000 1040000
Rolls 241800 293800 269000 327600 387500
Wholemeal Bread 181500 189000 201000 174000 158000

d) Assuming the firm requires 1 bags of 25 kgs of flour to produce 5000 units of bread, how
many bags should they plan to purchase for the planning horizon sales? (10% of the grade)
e) What is the configuration of the system (machines and operators) required to meet the
demand forecasts for the planning horizon? (20% of the grade)
f) What capacity is required to meet 150 percent of expected demand? (20% of the grade)