Natural Blends Case Study
Natural BlendsNatural BlendsNatural BlendsNatural BlendsNatural BlendsNatural BlendsNatural BlendsNatural BlendsNatural BlendsNatural BlendsNatural BlendsNatural BlendsNatural BlendsNatural Blends
Part B
4a. How often during an 8-hour workday would you have a setup change in the extraction process (e.g., how often would you changeover to another size orange)?
Since we also need to replace the filter every 90 minutes which adds another 30 minutes to overall downtime, it makes sense then to try to minimize as much idle time as possible by coordinating when the bin has to be changed at EXTRACTION with the filter change at FILTRATION. In order to meet the processing requirements; each orange size must be processed at least once per day, and all three sizes must be processed equally during the week. If we change the bin (4) times each day with one size twice per day for the 6 days, we can satisfy both requirements. What’s more since we are limiting the total downtime by coordinating each bin change every 90 minutes with every filter change, we maintain the (2) hour downtime with no difference in processing time each week.
Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Bin Change Sequence {S,M,L,S} {M,L,S,M} {L,S,M,L} {S,M,L,S} {M,L,S,M} {L,S,M,L}
Using the sequence above, we are changing bins sizes (4) times per day. If we coordinate all (4) of our bin changes at 90 minute intervals with each filter change at the same time interval, we spend 20 minutes changing the bin to a different size, at the same time the filter is being changed. What happens here is that our EXTRACTION downtime is 20 minutes + 10 minute idle time (while we wait for the filter to be changed) over 30 minutes.
EXTRACTION
FILTRATION Time: 90 minute run-time Downtime + (idle): 20 minutes + 10 minutes Total time: 120 minutes Time: 90 minute run-time Downtime: 30 minute Total Time: 120 minutes
Since we’ve maintained a 6-hour run-time, our production rate also remained the same at 18,000 pounds per hour.
Part B
4a. How often during an 8-hour workday would you have a setup change in the extraction process (e.g., how often would you changeover to another size orange)?
Since we also need to replace the filter every 90 minutes which adds another 30 minutes to overall downtime, it makes sense then to try to minimize as much idle time as possible by coordinating when the bin has to be changed at EXTRACTION with the filter change at FILTRATION. In order to meet the processing requirements; each orange size must be processed at least once per day, and all three sizes must be processed equally during the week. If we change the bin (4) times each day with one size twice per day for the 6 days, we can satisfy both requirements. What’s more since we are limiting the total downtime by coordinating each bin change every 90 minutes with every filter change, we maintain the (2) hour downtime with no difference in processing time each week.
Day 1 Day 2 Day 3 Day 4 Day 5 Day 6 Bin Change Sequence {S,M,L,S} {M,L,S,M} {L,S,M,L} {S,M,L,S} {M,L,S,M} {L,S,M,L}
Using the sequence above, we are changing bins sizes (4) times per day. If we coordinate all (4) of our bin changes at 90 minute intervals with each filter change at the same time interval, we spend 20 minutes changing the bin to a different size, at the same time the filter is being changed. What happens here is that our EXTRACTION downtime is 20 minutes + 10 minute idle time (while we wait for the filter to be changed) over 30 minutes.
EXTRACTION
FILTRATION Time: 90 minute run-time Downtime + (idle): 20 minutes + 10 minutes Total time: 120 minutes Time: 90 minute run-time Downtime: 30 minute Total Time: 120 minutes
Since we’ve maintained a 6-hour run-time, our production rate also remained the same at 18,000 pounds per hour.