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Real Fruit Snack Strips are made from a mixture of dried fruit, food coloring, preservatives, and glucose. The mixture is pressed out into a thin sheet, imprinted with various shapes, rolled and packaged. Since this is a new product to be launched in the market, the production workers in each process are timed with the results of the time study and shown the normal time except operation 40 in the Table 1 below. However, review of the operation no.40 was conducted and showed the five observations conducted by an MBA student was noted and reflected on the table.

The allowance for each process such as this is 10%. The precedence and results of time and motion study for each step in the assembly process are given below.

To meet the demand, Real Fruit needs to produce fruit strips every month for the next year 2020 which has to be determined using the linear projection method as requested by management as described in the production plan in Table 2 running at one-shift operation at 7.5 effective hours. (decimal shall be rounded-off to next number)

Accordingly, as a consultant, you are going to assist the production department to design an assembly line with the fewest number of workstations and resources that will achieve the production demand in the year 2020 without violating precedence constraints. Assume 25 working days for the year 2020. Determine the following items below:

1. Draw the process flow diagram.

2. Given the demand, what is the "takt time" of the production line at the start of January 2020?

3. Determine the normal time of the Operation No. 40. See Table 1

4. Determine the normal time of the entire product line. See Table 1

5. What is the standard time of each process? Operations No. 10, 20, 30, and 40? See Table 1

6. What is the standard time of the entire product line if the allowance is 10%?

7. What is the total product cycle time?

8. What is the design capacity of this process?

9. How many production workers are required to support the plan for 2020?

10. Design and Diagram an appropriate production line to support the plan showing each work stations. Label each production process accordingly.

11. Allocate item (10) resources to your design production system.

12. What is the overall efficiency of the assembly line at minimum workstations?

13. What operations in the process is the bottleneck (operations which has a limited capacity)?

Table 1: Time and Motion Study Data Operation Work Elements Precedence Performa Normal Observations Number No. nce Time Rating (Minutes Cycle Time (Minutes per per Cycle) Cycle) 10 Press out sheet of fruit Cut into strips Outline fun shapes 100% 2 2 3 1.5 1.5 20 30 40 Roll up and package 10 10 20, 30 100% 100% 2 2.2 2 2 1.5 4 4 3.5 3.55 3 4 5 44 4 | 90% 4 Table 2: Production Forecast 2 3 4 Actual Demand in Year 2015 2016 2017 2018 Production Days Actual Demand (units) 5 2019 25 2020 25 25 25 14,000 20,00022,000 25 25 10,000 12,000 Table 1: Time and Motion Study Data Operation Work Elements Precedence Performa Normal Observations Number No. nce Time Rating (Minutes Cycle Time (Minutes per per Cycle) Cycle) 10 Press out sheet of fruit Cut into strips Outline fun shapes 100% 2 2 3 1.5 1.5 20 30 40 Roll up and package 10 10 20, 30 100% 100% 2 2.2 2 2 1.5 4 4 3.5 3.55 3 4 5 44 4 | 90% 4 Table 2: Production Forecast 2 3 4 Actual Demand in Year 2015 2016 2017 2018 Production Days Actual Demand (units) 5 2019 25 2020 25 25 25 14,000 20,00022,000 25 25 10,000 12,000

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