Your restaurant’s nasi lemak ayam sambal, nasi lemak ayam goreng and nasi ayam has gained national fame. MAS has approached you and wants you to produce nasi lemak for their in-flight dining and nasi ayam for KLIA’s Golden Lounge. The demand is stable at 10,000 nasi lemak ayam goreng per day, 15,000 nasi lemak ayam sambal per day and 1,000 nasi ayam per day. All of your dishes needs to be flash freezed and this will take 120 seconds per 30 dishes. Once flash freezed, your dish can be stored up to 14 days. You also sell these dishes at your restaurant w demand of 20 per hour (for each dish).
The management has decided to upgrade your facilities. Your rice cooker can cook for 40 people and take only 40 minutes, the process of frying chicken has been improved where you can cook 5 chicken in 5 minutes, and the process of preparing sambal chicken also has been improved where you can prepare 5 chicken in 9 minutes. Changeover time for rice cooker (multiple pot) is 1 minute, changeover time for wok is 3 minutes. MAS is also adamant that condiments is necessary and for this you need a new process (frying condiments has a cycle time of 5 minutes for 10 people), and due to the size of the operation, you need an assembly process where rice, condiments and type of chicken is assembled (Assembly takes 2 minutes per dish).
MAS wants steamed chicken for the nasi ayam and wants chicken stock to be added to the nasi ayam. For this you need to first boil the chicken (30 minutes) in a pot, and 40 dishes can be prepared per pot. And, you also need to prepare the sauce for the chicken rice (5 minutes per batch of 10 chicken). Steaming chicken takes 15 minutes, and you can steam only 3 chickens per steamer. All of your storage has heating facility, which means you can store rice, condiments, and chicken in a heated state for 48 hours. MAS also wants you to incorporate inspection in your processes and this will increase CT by 15%. What do you think is most critical to inspect?
For Nasi Lemak, MAS wants you to deliver the dishes in pallets of 90 dishes – 30 nasi lemak ayam goreng and 60 nasi lemak ayam sambal, but will only accept deliveries during day shift. For Nasi Ayam, MAS wants you to deliver them in pallets of 50 dishes each, and will accept deliveries 24 hours.
Design your operation. Draw your VSM if you work for 8 hours a day (inclusive of 80 minutes of rest), 22 days a month. Worker efficiency is at 85% and NVA makes up 60% of the cycle time. What is your manufacturing efficiency?
