Operational Management – Asaf Bargill, Abhishek Bhattacharya, Gyusub Chung

Part One - Mahou
1.1. What is typical flow at this facility?

1.2. What is the capacity at the various processes? Process Maceration Filtration Boiling Fermentation Maturation Bottling Capacity (L / hour) 150,000 75,000 150,000 335,714 167,857 212,300

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Operational Management – Asaf Bargill, Abhishek Bhattacharya, Gyusub Chung

1.3. Is there a throughput time here? Process Capacity (L / hour) Cycle Time (hours) Maceration Filtration Boiling Fermentation Maturation Bottling 150,000 75,000 150,000 335,714 167,857 212,300 TOTAL 1 2 1 168 336 2.45 1 * 4 batches = 4 2 * 4 batches = 8 1 * 4 batches = 4 168 hours 336 hours 520,000 / 212,300 = 2.45 526.45 (21.93 days) Effective Time (hours)

Note: 4 batches of Maceration, filtration and boiling are used to fill up the tank before the next step (fermentation) can start. So the time taken for 1 batch has been multiplied by 4 for 4 batches. Also, we note there is some time taken to fill up the tanks. We know that each fermentation tank takes up 16 hours to fill up but we don’t have similar data about the pre filling tanks so we have ignored this from our calculation. Our calculations can be further optimized if we receive the tank fill up duration for all the processes. 1.4. What are the inventories held in this facility? The raw materials used in the process – Water, Hops, Malt, Yeast are inventory. WIP is also considered inventory which is when the beer is held in the pre filling tanks. When manufacturing is done, the finished goods are also inventory. 1.5. What does the factory do to improve its quality? Product Quality: The factory has a continuous quality monitoring and evaluation process. The beer is tasted manually by experts at every step of the process to measure the quality of the end product. We also assume that considerable