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(Summary) POM Case 2

Dewey Johnson owns a doughnut shop called Dooly County Doughnuts that has seen increasing sales but long lines. The shop runs on 3-4 employees during peak hours and produces an average of 1,100 dozen doughnuts per day through a four stage process of batching, mixing, extruding, frying, glazing, and customizing doughnuts. However, production cannot keep up with demand, so the shop needs to find a way to increase its doughnut-making capacity such as by increasing batch sizes or modifying equipment.

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Saurabh Sharma
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582 views3 pages

(Summary) POM Case 2

Dewey Johnson owns a doughnut shop called Dooly County Doughnuts that has seen increasing sales but long lines. The shop runs on 3-4 employees during peak hours and produces an average of 1,100 dozen doughnuts per day through a four stage process of batching, mixing, extruding, frying, glazing, and customizing doughnuts. However, production cannot keep up with demand, so the shop needs to find a way to increase its doughnut-making capacity such as by increasing batch sizes or modifying equipment.

Uploaded by

Saurabh Sharma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Overview

• Dewey Johnson owns a “Dooly County Doughnuts” (DCD) shop.


• Been trying to increase sales since the past year.
• Sales have finally increased but now there is a big line outside the shop which extends
well into the parking lot.
• This is a problem and needs to be fixed.

Product Sales

• 8 hour shift per day, 7 days a week


• Process is mostly automated and requires a staff of just 3-4 employees during peak hours
• Average sales: 1,100 dozen doughnuts per day of all varieties (i.e. 13,200 units of each
type of doughnut)
Production
There are four stages: (1) batching, (2) mixing, (3) production, and (4) customizing.
1. Batching:-
• The worker (operator) combines ingredients in a mixing bowl
• Takes 2 minutes to do so
• The equipment can handle batches of dough of various sizes, ranging from just
2lb to over 20lb (pounds).
• Each doughnut requires exactly 2 oz. (ounces) of dough (i.e. 0.06lbs)

2. Mixing:-
• Takes 2.5 minutes per batch
• The store has only 2 mixers

3. Production: Further consists of 3 steps:-


(a) Extruding:-
• After mixing, the dough needs to be cut (extruded) into individual pieces that
would eventually become the finished doughnut.
• The machine has a set of 3 cutters
• Each cutter can extrude dough at a rate of 18 extrusions per minute
• => with 3 cutters, the machine makes 54 doughnuts per minute

• The machine has to be set up before each batch is extruded. This setup time
includes cleaning the machine before a fresh batch can be added.
• The setup takes 1.5 minutes per batch

(b) Frying:-
• After extrusion, the doughnuts are put into a fryer
• The fryer has sufficient space to handle as many doughnuts as the extrusion
machine provides (=> excess capacity)
• The fryer takes 90 seconds to do its job

(c) Glazing:-
• The fried doughnut is cooled on a conveyor before it is put into the glazing
machine
• The cooling process takes 45 seconds
• Same as the fryer, the conveyor runs continuously and has sufficient space to
handle as many doughnuts as the extrusion machine provides. (so the
extrusion machine is the bottleneck?)

4. Customising:-
• The doughnuts have to be customised to either be sold at the counter or be boxed
for specific orders
• This step involves adding different toppings
• 1 employee is needed to handle this
• On an average, 2 doughnuts are processed in 3.5 seconds (1.75 seconds each)
The Problem

• Production cannot keep up with demand, so DCD is unable to service all customers
• Need to find a way to increase capacity.
• One possible change is to increase the batch size. The standard size which they use is
8lbs, even though the mixer and extruder could handle larger batches.
• The batch size was set at 8lbs out of fear of wearing out the equipment prematurely.
• Secondly, they could keep the same batch size and instead focus on improving some of
the manual steps. (these haven’t been mentioned in the text, need to figure out ourselves)
• Lastly, the extruder could be modified to operate with 6 cutters (currently 3). The trade off
is that the setup time for the extruder (currently 1.5 minutes) would increase (new time is
not mentioned).

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