National Cranberry Cooperative

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1. Problems facing receiving plant No. 1 (RP1)
The problems that The National Cranberry Cooperative is facing with are described in the table below. Mostly they are related to the problem of capacity.

Problem | Implications|
Presence of bottlenecks in the stages of drying and separating of berries.| Excessive overtime costs.| | Overcapacities in other stages of processing of berries.|

2. Process Flow Diagram
From 8-10 min to few hours

400*3= 1200 bbls/h

1500*3 = 4500 bbls/h

1500 bbls/h

Separators
Dry bins 1-16-(24)

Dry
Delivery

Dechaffing
Destoning

Wet Bins (17)-25-27

Wet Delivery

Dechaffing
Drying
Sorting & Shipping

200*3 = 600 bbls/h
1500*2 = 3000 bbls/h

From 8-10 min to fewhours

Peak harvest day:
18.000 barrels unloaded in 12 hours. Arrival rate from 7 AM to 7 PM is 1500 bbls/h. Wet harvested: 50%

Delivered| 18,000|  |  |  |
Wet| 9,000| 7:00-13:00| 4,500| 750 bbls/h|
| | 13:00-19:00| 4,500| 750 bbls/h|
Dry| 9,000| 7:00-13:00| 4,500| 750 bbls/h|
| | 13:00-19:00| 4,500| 750 bbls/h|

3. Inventory build-up diagram
When observing our process flow, we identified two bottlenecks: (1) drying for wet cranberries and (2) separation of both dry and wet berries. According to the data provided, there is 50 % of incoming berries which were wet harvested. In the absolute terms, this amounts to 750 bbls/h. The three drying machines can only handle 600 bbls/h altogether, meaning that 150 bbls of berries have to be stored in the bins each hour while waiting for the drying process. The second bottleneck is “located” at the separators. The three separating lines have the capacity to separate 1200 bbls/h, while there are 1350 bbls/h ready to be separated. Therefore, 150 bbls of dry berries have to be stores each hour.

At the end of the day (7 PM) there are 2400 bbls wet berries waiting for drying and separating, while also 2400 bbls of dry berries still have to go...
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