Production Requirement

Daily Requiermnet
SN Item Description Yeild (Pkts)
(Pkts)

1 White Bread Small Open Top 1800 463

5 Brown Bread Medium Open Top 4300 212
4 Brown Bread Small Close Top 1400 398
6 Brown Super Jumbo Bread Open Top 200 100
9 Milk Bread Small Open Top 2300 477
8 Mixed Grain Bread Medium Close Top 1600 250
7 Mixed Grain Bread Small Close Top 1500 450
2 White Bread Medium Open Top 5700 257
3 White Super Jumbo Bread Open Top 350 105

Total
19150 2712
Requirements
rement

Batch Size ( Kg) Req. Batches Approx Batches

176.82 3.89 4
164.22 20.28 21
165.30 3.52 4
165.82 2.00 2
195.40 4.82 5
174.32 6.40 7
174.56 3.33 4
178.22 22.18 22
177.47 3.33 4

1572.13 69.76 73
 Tray & Pan

Daily
Requier Yeild Batch Req. Approx
SN Item Description
mnet (Pkts) Size ( Kg) Batches Batches
(Pkts)

1 White Bread Small Open Top 1800 463 176.82 3.89 4

4 Brown Bread Small Close Top 1400 398 165.30 3.52 4
9 Milk Bread Small Open Top 2300 477 195.40 4.82 5
7 Mixed Grain Bread Small Close Top 1500 450 174.56 3.33 4
5 Brown Bread Medium Open Top 4300 212 164.22 20.28 21
8 Mixed Grain Bread Medium Close Top 1600 250 174.32 6.40 7
2 White Bread Medium Open Top 5700 257 178.22 22.18 22
6 Brown Super Jumbo Bread Open Top 200 100 165.82 2.00 2
3 White Super Jumbo Bread Open Top 350 105 177.47 3.33 4

Existing capacity - for Baking &

Baking
Total
Bread Size details Trolly Layer pan
Pan

small 14 11 20 3080
medium 34 11 12 4488
Jumbo 10 10 9 900

Cooling
Bread one layer One
trolly
Trolly Size details Trolly Layer Small medium Jumbo Small
Bread Bread Bread Bread
small Trolly 13 7 26 20 16 182
Big Trolly 11 7 57 26 26 399

Cooling Capacity
Cooling capacity Trolly of B Layer Small BreaMedium B
28 7 11172 5096
 n

No of
No. Pans No. of Require Diffrence/S
No. of layres Total
per pans per
Trollies per
Layer Trolley
Pans ments hort
trolley

14 11 20 220
3080 7000

-3920

4488 11600
34 11 12 132 -7112
10 10 9 90
900 550
-350

or Baking & Cooling

ng
Require Diffrenc
ments e/Short

7000 -3920
13400 -8912
2350 -1450

ng
Total Total Total
One One bread in bread in bread in
trolly trolly the the the Require Diffrence/Sh
medium Jumbo trolly trolly trolly ments ort
Bread Bread Small medium Jumbo
Bread Bread Bread
140 112 2366 1820 1456 7000 -4634
182 182 4389 2002 2002 13400 -9011
6755 3822 3458 20400 -13645

apacity
Jumbo Bread
5096
 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
 Producti
No of
Jumbo Bread One trolly availabe One trolly Small Bread
Trolly

Small Bread
Jumbo One One Trolly
Trolly Small 112 13 182 Small

jumbo Bread
Bread One Small Bread
Trolly Big 182 11 399 One Trolly Big

Total Hours
Start
require for End time Product Name Req Mix Actual Mix
Time
production

3.4 5.3 9.1 white medium 22 22

1 9.1 10.1 Milk bread small 5 5
0.4 10.1 10.5 white jumbo 2.5 2.5
3.5 10.5 14.4 Brown Med 21 21
1 14.4 15.4 white small 4 4
0.3 15.4 16 Brown jumbo 2 2
0.4 16 16.4 mixedgrain med 4 4
0.4 16.4 17.3 Brown Bread Small 4 4
0.3 17.3 18 Mixed Grain Bread Small 3 3
0.4 18 18.4 white jumbo 2.5 2.5
70 70
Production planning
No of No of
availabe availabe One trolly
Trolly Trolly medium Bread

small Trolly
Medium braed in
13 13 one trolly 140

Big Trolly
Medium in one
11 11 trolly 182

Pan Cycle

require
require Number Number of
pan cycle for of Cooling Trolly Cooling Trolly Short
Diff yeild total prod aviable Diffrence Require for 2 Require for 2 trolly big
pan
Hour duration for Hour duration
Big Trolly for Small
Trolly

0 257 5654 10488 4834.00 10:10 31.1 40.4 -20.1

0 477 2385 3080 695.00 12.4 6.0 13.1 5.0
0 350 875 900 25.00 13.1 4.8 7.8 6.2
0 212 4452 10488.00 6036.00 14 24.5 31.8 -13.5
0 463 1852 3080 1228.00 17.4 4.6 10.2 6.4
0 350 700 900 200.00 18.4 3.8 6.3 7.2
0 250 1000 10488.00 9488.00 19 5.5 7.1 5.5
0 251 1004 1228.00 224.00 19.5 2.5 5.5 8.5
0 450 1350 1852.00 502.00 20.3 3.4 7.4 7.6
0 350 875 900 25.00 21 4.8 7.8 6.2
0 3410 20147
Pan Cycle

When the capacity

Trolly
available Cooling of trolly shot big
trolly and Trolly in cooling as per
small available room for capacity
Time big trolly

-27.4 12.1 25 -6.1

-0.1 14.4 25 19.0
5.2 15.1 25 20.2
-18.8 16 25 0.5
2.8 19.4 25 20.4
6.8 21.4 25 21.2
5.9 22 25 19.5
7.5 21.5 25 22.5
5.6 22.3 25 21.6
5.2 23 25 20.2
 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
 Propose Plan - For Optimised 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
ources
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