Question

Better Bagels, Inc. manufactures a variety of bagels, which are frozen and sold in grocery stores. The production process consists of the following steps.

1. Ingredients, such as flour and raisins, are received and inspected. Then they are stored until needed.
2. Ingredients are carried on hand carts to the mixing room.
3. Dough is mixed in 40-pound batches in four heavy-duty mixers.
4. Dough is stored on large boards in the mixing room until a bagel machine is free.
5. A board of dough is carried into the bagel room. The board is tipped, and the dough slides into the hopper of a bagel machine. This machine pulls off a small piece of dough, rolls it into a cylin-drical shape, and then squeezes it into a doughnut shape. The bagel machines can be adjusted in a setup procedure to accommodate different sizes and styles of bagels. Workers remove the uncooked bagels and place them on a tray, where they are kept until a boiling vat is free.

6. Next the trays of uncooked bagels are carried into an adjoining room, which houses three 50-gallon vats of boiling water. The bagels are boiled for approximately one minute.
7. Bagels are removed from the vats with a long-handled strainer and placed on a wooden board. The boards full of bagels are carried to the oven room, where they are kept until an oven rack is free. The two ovens contain eight racks which rotate but remain upright, much like the seats on a Ferris wheel. A rack full of bagels is finished baking after one complete revolution in the oven. When a rack full of bagels is removed from the oven, a fresh rack replaces it. The oven door is opened and closed as each rack completes a revolution in the oven.
8. After the bagels are removed from the oven, they are placed in baskets for cooling.
9. While the bagels are cooling, they are inspected. Misshapen bagels are removed and set aside. (Most are eaten by the staff.)

10. After the bagels are cool, the wire baskets are carried to the packaging department. Here the bagels are dumped into the hopper on a bagging machine. This machine packages a half-dozen bagels in each bag and seals the bag with a twist tie.
11. Then the packaged bagels are placed in cardboard boxes, each holding 24 bags. The boxes are placed on a forklift and are driven to the freezer, where the bagels are frozen and stored for shipment.

Required:
1. Identify the steps in the bagel-production process that fall into each of the following categories: process time, inspection time, move time, waiting time, storage time.
2. List the steps in the production process that could be candidates for non-value-added activities.

Answer 1

	Activity	Category
1	Ingredients such as flour and resing are received, inspected and stored	Inspection/Storage Time
2	Ingredients are carried on hand carts to mixing room	Move Time
3	Dough is mixed in 40 pound batch in 4 heavy duty mixtures	Process Time
4	Dough is stored on a large board in the mixing room	Waiting time
5	A board of dough is carried into bagel room	Move Time
6	Board is tipped and dough slides into the hopper	Process Time
7	The machine squeezes the dough and makes it into doughnut	Process Time
8	Workers remove uncooked bagels and store in a tray	Storage Time
9	Bagels are kept in tray until boiling Vat is free	Waiting time
10	Trays of uncooked bagels are carried to adjoining room	Move Time
11	Bagels are boiled for approximately 1 minute	Process Time
12	Bagels removed and placed on the wooden board	Process Time
13	Board full of bagels are carried to oven room and kept till oven racks are free	Move Time
14	Board full of bagels are kept till oven racks are free	Waiting time
15	Rack full of bagels is finished baking after one complete revolution	Process Time
16	Fresh rack is replaced once a rack completes a revolution	Waiting time
17	After bagels are removed from oven they are plaed in baskets	Storage Time
18	While bagels are cooling they are inspected	Inspection Time
19	Misshappen bagels are kept aside	Inspection Time
20	After bagels are cool Wire baskets are carried to the packaging department	Move Time
21	Bagels are dumped into the hopper in a bagging machine	Process Time
22	Baggaging machine does packaging and seals bag with twist tie	Process Time
23	Packaged bags are placed on the cardboard boxes	Storage Time
24	Boxes are placed on forklift and driven to freezer room	Move Time
25	Bagels are frozen and stored for shipment	Storage Time

	Non Value Added Activities
	Activity	Category
1	Ingredients are carried on hand carts to mixing room	Move Time
2	Dough is stored on a large board in the mixing room	Waiting time
3	Bagels are kept in tray until boiling Vat is free	Waiting time
4	Board full of bagels are kept till oven racks are free	Waiting time
5	After bagels are cool Wire baskets are carried to the packaging department	Move Time
6	Packaged bags are placed on the cardboard boxes	Storage Time