Question

The pizza-making process at Mama’s is outlined in the table below. The shop is open 8 hours a day to fulfill a typical daily demand of 40 pizzas. Sketch the process and balance the assembly to answer the questions below.

Task	Predecessor	Minutes
A. Roll Dough	--	12
B. Spread Sauce	A	4
C. Prepare Toppings	--	7
D. Put Toppings on Pizza	B,C	3
E. Sprinkle Cheese	D	2
F. Bake Pizza	E	10

1. What is the maximum cycle time? (in minutes)

2. What is the theoretical minimum number of workstations? (round appropriately)

3. How many workers (actual workstations) are needed?

4. What is the idle time per cycle? (in minutes)

5. What is the efficiency? (nearest whole number)

Answer 1

Answer 1: cycle time= 8 hours/40pizzas= 8*60/40= 12 mins

Answer 2: Theoretical no. of workstations= sum of task times/cycle time= 38/12 = 3.16~4 workstations

Answer 3: Actual no. of workstation= 4 only

Workstation	Task	Explanation	Idle time
1	A	12=12, no space for other tasks	0
2	B, C	Because the sum time taken by all mentioned process is less than cycle time, 11<12	1
3	D, E	5<12	7
4	F	10<12	2

Answer 4: total idle time = 10 mins, average idle time= 10/4= 2.5 mins

Answer 5: percentage of idle time = idle time/ no. of workstation* cycle time = 10/(4*12)=0.208 i.e 20.8%

Efficiency = 1-idle %= 1-0.208= 79.2%

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