The process flow diagram:

Assumptions and Data: The capacities of the various processes are based on the assumptions or data as shown below: Dumping Capacity Number of Kiwanee Dumpers = 5 Average time taken by truck to load the berries onto Kiwanee Dumpers = 7.5 minutes(Maximum being 10 and minimum being 5 minutes) Average weight of berries in a truck = 75 bbls. Dumping Capacity = 5 * 75 * 60 / 7.5 = 3000 bbls/hr.

Holding Bin Capacities Bin No. 1-16 can hold dry berries only up to 250 bbls per bin. Total capacity of bin numbered 1-24 = 250*16 =4000 bbls Bin 17-24 can hold wet/dry berries so upto 250 bbls so total capacity for 17-24 is=2000(250*8) Bin No. 25-27 can hold berries up to 400 bbls per bin Total capacity of bin numbered 25-27 = 400*3 = 1200 bbls. De-stoning/De-chaffing/Drying Capacity Bin No. 1-16 can hold dry berries only up to 250 bbls per bin. Total capacity of bin numbered 1-16 = 250*16 = 4000 bbls Bin No. 17-24 can hold dry/wet berries up to 250 bbls per bin Total capacity of bin numbered 17-24 = 250*8 = 2000 bbls. Bin No. 25-27 can hold wet berries up to 400 bbls per bin Total capacity of bin numbered 25-27 = 400*3 = 1200 bbls. a. De-stoning Capacity-only for dry berries No. of de-stoning units = 3 Capacity of each unit = 1500 bbls/hr Total de-stoning capacity = 4500 bbls/hr b. De-chaffing Capacity both dry and wet berries No. of de-chaffing units = 3 Capacity of each unit = 1500 bbls/hr Total de-chaffing capacity = 4500 bbls/hr c. Drying only for wet berries No.of drying units = 3 Capacity of each unit = 200bbls/hr (if loading into trucks) Total capacity = 600 bbls/hr Capacity of each unit = 150 bbls/hr (if bagged) Total capacity = 450 bbls/hr Separator Capacity Jumbo Separator and Bailey Mill Lines No. of separator lines = 3 Average capacity of each lines = 400 bbls/hr Total separator capacity = 1200 bbls/hr Bagging Station Capacity Maximum output per day = 8000 bbl Working hours = 12hrs. Capacity = 8000/12 = 667 bbls/hr Bulk Bin Loading Capacity No. of loaders for bulk bin loading = 4 Capacity of each loader = 200 bbls/hr Total bulk bin loading capacity = 4 * 200 = 800 bbls per hr. Bulk Truck Loading Capacity No. of loaders of bulk trucks = 2 Capacity of each loader =1000 bbls/hr Total Capacity Bulk Truck loading Capacity = 2000 bbls/hr

Installing a Light Grading system Total number of berries graded as top quality = 4,50,000 bbls Deserved to be top quality = 50% Premium paid = $.50 Saving from the light grading system : 4,50,000*.50*.50 = $1,12,500 per season One time investment = $10,000 Worker needed at the wage of the chief grading officer = no incremental change in pay Therefore better to install the light grading system. But as the farmers get lesser pay with this method, the grading system can be changed so as to accommodate all types of berries which are better than grade 2B but not than grade 3.

BOTTLENECKS Drying capacity Among the destonig, dechaffing and drying process that takes place before the separator process, drying process takes the maximum time and the yield is very less at it. Hence it forms the bottle neck with capacity = 600 bbls/hr. Separator Capacity Dumping capacity = 3000 bbl/hr Wet berries = .7 * 3000 = 2100 bbls/hr Dry berries = .3 * 3000 = 900 bbls/hr At the separator unit: Wet berries enter at the rate of = 600 bbl/hr (due to the drying process) Dry berries enter at the rate of = 900 bbl/hr (No drying process and the availability of dry berries) Input rate at the separator = 600 + 900 = 1500 bbl/hr Output rate of separator = 1200 bbl / hr Build up rate = 1500 1200 = 300 bbl/hr

Decreasing the truck waiting time Wet berries: Dumpers operate at 1063 bbls/hr (18225*0.7/12) Receiving time for berries = 12 hrs Inventory build up rate is 1063-600 = 463 bbls/hr. (600 is the drying bottle neck) Holding capacity = 2000 +1200 = 3200 bbl. Time to fill up the storage = 3200/463 = 6.911hrs( trucks start waiting after this time) At the end of 12 hours we have 5556 bbls of berries to be stored (463*12) out of which 2356 are waiting in trucks and 3200 are in inventory area. Capacity of one truck = 75bbls Number of trucks needed = 2356/75 = 32 Time taken by the trucks to clear = 2356/463 = 5.08 hrs to clear Total time spent by the truck drivers to clear = 5.08 * 32 = 162.8 hrs Dryer capacity: Wet berries = 18225*0.7 = 12757.5bbl

Time taken = 12757.5/600 = 21.262 hrs Dryers available for 8 hours Overtime for receiving = 21.262-8=13.262hrs Overtime labour cost = 13.262*3.75*1.5*6=$447.6 (6 workers at the receiving assuming to be in the peak period with low volume work force) With one extra dryer Dryer capacity=800bbl/hr Time taken = 12757.5/800 = 15.95 hrs Overtime for receiving = 15.95-8=7.95hrs Overtime labour cost = 7.95*3.75*1.5*6=$268.31 (6 workers at the receiving assuming to be in the peak period with low volume work force) Extra cost of dryer = $25,000 ( one time cost) With one extra dryer Dryer capacity=1000bbl/hr Time taken = 12757.5/1000 = 12.75 hrs Overtime for receiving = 12.75-8=4.75hrs Overtime labour cost = 4.75*3.75*1.5*6=$160.31 (6 workers at the receiving assuming to be in the peak period with low volume work force) Extra cost of dryer = $ 50,000 ( one time cost)

As seen above the recovery period for one dryer is 93.2 days where as for two dryers it is 312 days. Converting the dry bin to wet plus dry bin: If we convert one dry bin to dry + wet bin, then there will be extra capacity in the bins for storage. This is because wet berries form 70 % of input berries. Previously we had 16 dry bins and 8 dry+wet bins which catered to 30% of input. We can reduce the number of dry bins so that the wet berries can be stored more and help save some hours. Solution: Add one dryer because we need to remove the bottleneck. We can convert one or more dry bins to wet bins. But we should not convert many because we cant anyways store the wet berries for more than a day.