OPERATIONS MANAGEMENT

1. Correct diagram (110 points)

1.1: Receiving and testing: 14 points

1.2: Dumping: 9 points

1.3: Temporary storage: 21 points

1.4: Dechaffing / destoning / drying: 12 points

1.5: Separation / quality grading: 24 points

1.6: Bulking and bagging: 30 points

2. Neat, professional, easy-to-follow diagram (40 points)

1.

2.

2.1. Your name, section name at the top of the page: 2 points

2.2. Course name, assignment name at the top of the page: 2 points

2.3. Dotted-line boundaries around each process stage: 6 points

2.4. Correctly and legibly labeled boxes and arrows: 10 points

2.5. Clear indication of process start and end: 8 points

2.6. Properly aligned boxes, diamonds, inverted triangles and arrows: 12 points

Introduction:

Oh My God Cherries Inc. (OMGCI) – a North Carolina-based processor of cherries has a cherry processing plant located in Florida. This plant, called FL-1, receives both fresh (dry harvested) and process cherries (water harvested / wet) during each harvesting season. The handling process for cherries is highly mechanized at FL-1. The process consists of several operations: receiving and testing, dumping, temporary storage, destoning, dechaffing, drying, separation, and bulking / bagging. The objective of the entire process is to gather bulk cherries and prepare them for storage / further processing.

Process stages:

1. Receiving and testing:

Trucks arrive at FL-1 loaded with dry or wet cherries. When the truck arrives, its gross and empty weights are recorded in one step. Then, prior to unloading the cherries (achieved through dumpers, described in the next step), three separate samples are taken at the same time to determine the following:

· The percentage of the truck’s net weight that is made up of clean cherries

· The percentage of unusable (poor / smaller / frosted) cherries in the truck

· The color grade of the cherries in the truck

2. Dumping:

After a truckload of cherries is weighed and sampled, the truck moves to one of the seven HH301 dumpers. The dumpers empty the truck content onto one of the seven rapidly moving belt conveyors. Each of the seven conveyors takes the cherries to the second level of the plant for storage in one of the 30 transient storage bins (TSBs).

3. Temporary storage:

TSBs 1-20 can hold 250 barrels each, and TSBs 21-30 can hold 400 barrels each. TSBs 1-15 are used for dry cherries only, and TSBs 26-30 are used for wet cherries only. TSBs 16-25 can be used for either wet or dry cherries (however, dry and wet cherries are never combined in any TSB). Wet cherries from these bins are directly taken to one of the five dechaffing units. The dry cherries are routed through one of the four destoning units capable of processing 1500 barrels per hour each, before going through a dechaffing unit.

4. Dechaffing / Destoning / Drying:

The dechaffing units can process up to 1500 barrels of cherries per hour each. Only the first two dechaffing units are used to process the wet cherries at any time. After dechaffing, the wet cherries are taken to one of the six drying units before being taken to the quality grading area. The drying units process wet cherries that come out of dechaffing area at the rate of 200 barrels per hour each. After drying, the wet cherries are taken to the quality grading area (as explained in the next paragraph). The dry cherries first go through destoning, then dechaffing (only the last three dechaffing units are used for the dry cherries), and then finally move to the quality grading area as explained below.

5. Separation / quality grading:

After destoning, dechaffing, and drying (as applicable), the cherries are transported to one of the two large take-way conveyors that take the cherries to the jumbo separators. Each of the two large take-way conveyors is able to process 500 barrels of cherries per hour, and is attached to twelve jumbo separators that separate the cherries into three groups – 1st quality, potential 2nd quality, and unacceptable cherries. The first quality cherries are taken to the shipping area (as explained in the next paragraph). The unacceptable cherries fall through waste chutes into water-filled waste flumes, and float off to the disposal area. The potential 2nd quality cherries fall into the Bailey mill that separate the cherries into 2nd quality cherries and unacceptable cherries. Unacceptable cherries coming out of the Bailey mill also fall through waste chutes into water-filled waste flumes, and float off to the disposal area.

6. Bulking and bagging:

Five conveyors (four from the jumbo separators and one from the Bailey mill) transport separated (1st and 2nd quality) cherries to the shipping building. Each of the five conveyors can feed cherries to any of the three main flexible conveyors in the shipping area. These flexible conveyors can route the cherries to any of the five bagging stations, any of the three bulk bin stations, or to any of the six bulk truck stations.

From the bulk truck stations, the cherries leave the FL-1 plant in bulk trucks for shipment directly to the finish processing plant.

From the bagging stations as well as bulking stations, the cherries leave the FL-1 plant as described below:

· In bins for storage at freezers with bulk bin storage capability

· In bags for storage in freezers that could handle only bagged cherries

· In bins / bags for storage in freezers that could handle both bins and bags.

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