Colegio de San Juan de Letran – Calamba

School of Engineering
Industrial Engineering Department

2nd Semester AY 2018 – 2019

IE101L – Production Systems Laboratory

Chapter IV

Submitted by:
Group #4

Avellano, Angel Ann

Catuira, Adrian Lorenzo C.
Neri, Bea Catherine D.
Perez, Jenkins
Terrenal, Erica

Submitted to:
Engr. Ma. Kathleen L. Duran, CIE, AAE, CLSSGB

Date:
April 10, 2019
Operational Plan

As per Canada Business Ontario, in 2015, the foundation of any business begins by
defining objectives and effectively overseeing good and bad times of day by day activities.
These every day exercises make the establishment for an effective business.

Yohei Sushi produces their product on a daily basis. Since the company is targeting to
sell its product within Calamba area, its first store is specifically located in SM City Calamba. It
is reachable and near tricycle terminals, school and residences.

Aside from raw materials, such as the main ingredients of tuyo sushi which are
cucumber, tomato, onions, nori paper, Mindoro rice, Kikkoman sauce and tuyo fish. It also
needs mixing bowl, spoon, and tables to complete the product. It has a clean and peaceful
environment which is ideal to do the business.

Production (Duration per step, per batch)

Project Management (Activity on Node)

ACTIVITY DECRIPTION PREDECESSOR QUANTITY DURATION

Nori Paper – 100
pcs
Tuyo Fish – 40 This must be
Preparing the pcs done before the
A Ingredients - Mindoro Rice – 8 production
kilos
Tomato – 15 pcs
Vinegar Cane –
3 bottles
Onions – 14 pcs
Sugar – 1/4
Kikkoman Sauce
– 1 bottle
Cutting of Tomato – 15 pcs
B tomatoes and A Onions – 14 pcs 10 Minutes
onions
C Frying the Tuyo B Tuyo Fish – 40 25 Minutes
Fish pcs

D Cooking the rice C Mindoro Rice – 8 1 hour & 30

kilos Minutes
Mix the sugar Mindoro Rice – 8
and and pour a kilos
E drop of kikkuman D Sugar – ¼ 25 Minutes
sauce on the rice Kikkoman Sauce
– 1 bottle

F Deboning of E Tuyo Fish – 40 30 Minutes

Tuyo Fish pcs

Nori Paper – 100

pcs
Putting the Tuyo Fish – 40
G ingredients in the F pcs 20 Minutes
sushi rolling mat Mindoro Rice – 8
kilos
Tomato – 15 pcs
Onions – 14 pcs
Rolling and Nori Paper – 100
H cutting the rolled G pcs
Maki Tuyo Fish – 40 1 Hour
pcs
Mindoro Rice – 8
kilos
Tomato – 15 pcs
Onions – 14 pcs
Total time: 260
mins or 4.33 hrs
Table: Project Management
 The precedence diagram method (PDM) is an instrument for planning exercises in a
project plan. It is a strategy for building a venture plan organize graph that utilizes boxes,
referred to as nodes, to represent activities and connects them with arrows that show the
dependencies. It is also called the activity-on-node (AON) method.

Figure: Precedence Diagram (Duration is in minutes)

Calculating the Cycle Time

1 batch = 100 pcs

11 hrs/4.33hrs = 2 batch

100pcs x 2 batch = 200 pcs a day

(11 ℎ𝑟𝑠 − 4.33 ℎ𝑟𝑠)

𝐶𝑌𝐶𝐿𝐸 𝑇𝐼𝑀𝐸 =
200 𝑝𝑐𝑠

Cycle time: 0.0334 hrs or 2.004 mins /pcs

Figure: Master Production Schedule

 𝑭𝑶𝑹𝑬𝑪𝑨𝑺𝑻
𝑴𝑷𝑺 =
𝑷𝑨𝑩
4500
𝑀𝑃𝑆1 = = 214.29
21
4500
𝑀𝑃𝑆2 = = 204.55
22
4545
𝑀𝑃𝑆3 = = 197.61
23
4570
𝑀𝑃𝑆4 = = 228.50
20
4603
𝑀𝑃𝑆5 = = 200.13
23
4651
𝑀𝑃𝑆6 = 22
= 211.41
4692
𝑀𝑃𝑆7 = = 223.43
21
4774
𝑀𝑃𝑆8 = = 207.57
23
4838
𝑀𝑃𝑆9 = = 230.38
21
4898
𝑀𝑃𝑆10 = = 222.64
22
5020
𝑀𝑃𝑆11 = = 251.00
20
5018
𝑀𝑃𝑆12 = = 218.17
23

Bill of Materials (Raw Materials)

Raw Prospective

Materials Sources Volume Costs Picture

Nori Paper Grocery 100 pcs PHP

Stores 700.00
 Public
Tuyo Fish Marker & 40 pcs PHP
Grocery 150.00
Stores

Public
Mindoro Marker & 8kg PHP
Rice Grocery 510.00
Stores
Public
Tomato Marker & 15 pcs PHP
Grocery 83.6
Stores

Public
Vinegar Marker & 3 bottles PHP
Cane Grocery 370.14
Stores

Public
Onions Marker & 14pcs PHP
Grocery 32.56
Stores

Public
Sugar Marker & 1/4 sugar PHP
Grocery 18.00
Stores
 Kikkoman Grocery 2 bottles PHP
Sauce Stores 98.00

Public
Cucumber Marker & 2 pcs PHP
Grocery 30.93
Stores

Figure: BOM Chart

Production Technique

The production technique for our business is batch production. Batch production is a
technique used in manufacturing, in which the object in question is created stage by stage over
a series of workstations, and different batches of products are made.

Yohei Sushi will open in SM Calamba at 10:00AM and will close at 9:00PM with a total of
11 hrs working day. The production will produce 200 pieces per day assuming that the workers
has already mastered the process, the equipment that will use are chopping board, cooking
knife, frying pan, LPG Gas, spatula, rice cooker, gas stove, bowl, spoon, plate, sushi rolling mat,
tables.
Production Cost

A. Machinery and equipment

Machinery Specifications Costs Origin of the Machinery

& Equipment
Used for placing
Chopping Board the ingredients for PHP 549.75 Local
chopping
Used for cutting
Cooking Knife ingredients PHP 400.00 Local

Frying Pan Used for frying PHP 899.75 Local

To make sure that
LPG Gas there are enough PHP 800.00 Local
gas for cooking
Used to mix tuyo
Spatula fish PHP 216.00 Local

Rice Cooker To cook rice PHP 900.00 Local

Used for cooking
Gas Stove the ingredients PHP 800.00 Local
Used for mixing
Bowl the rice PHP 349.75 Local

Spoon For mixing rice PHP 260.00 Local

Used for dividing
Plate the ingredients PHP 350.00 Local
For rolling the
Sushi Rolling Mat sushi PHP 381.00 Local
Table: Machinery and Equipment
 B. Furniture

Furniture Specifications Costs Origin of the machinery

For creating Maki

PHP
Tables and preparing the Furniture Shop
3,000.00
ingredients
Table: Furniture

The table shown below is the production costs on a monthly basis. The costs include the Raw
Materials, Labor Cost, and Overhead Cost that includes (Utilities, Packaging, and Store Rental).
Utilities consist of electricity and water.

Costs: (Raw Materials, Machinery and equip) PHP 10,899.48

Labor Cost

Wage – PHP 10,071

PHP 11,571
Benefits – PHP 1,500

Overhead Cost

Store Rental – PHP 10,500

Water – 600

Electricity – 3,000 PHP 13,400

Packaging – PHP 2,000

Total Cost per Month PHP 58,963.84

Cost per Pack (4 pcs) PHP 59.00

Table: Cost
Quality Control

Quality control in the food business is underlining the controllable components that
influence the nature of the completed item, including the choice of raw materials, processing
methods, packaging, storage, and distribution.

Yohei Sushi came up with the following:

• Ensuring that all the workers are clean and healthy.

• Guarantee that only the highest quality ingredients are used.
• Use appropriate equipment for the production
• Maintain high standards for hygiene and sanitation

Customer Service

To have a good customer service, the staff ought to welcome the client with way and
positive way. It is additionally critical to accomplish the consumer loyalty and an increasingly
charming background for them. It is essential that the staff know to impart to the client to urge
them to buy and return once more. Great client satisfaction can enable our business to develop.
We ensure that the team listens to customer’s demands and suggestions and reaches them
dozens of time.

Inventory Control

Yohei Sushi will use the inventory control which is the minimum stock levels. With this
form of control, additional stock gets ordered when the existing stock has reached a certain
level.

Product Development

As per Akrani, G., in 2012, product development is a specialized activity. It is done to

improve the current item or to present another item in the market. It is likewise done to improve
the before highlights or methods or frameworks. The item advancement of the tuyo sushi
incorporates constant improvement of an item or improving a current item by offering inclination
to fulfill the interest of end-client, development of an item to convey better and upgraded
administrations to end-clients and formation of a totally new item or overhauling a current item
by investigating all conceivable outcomes and results.
Location

The location for the production of our tuyo sushi will be on SM Calamba. The said
location is five minutes away from the public market, so accessing different materials and
equipment will not prove to be difficult.

The location that the Researchers pick is near different schools, activity areas, and
subdivision areas wherein our target customers are. Our target customers will be heavily
focused on students especially those who like to eat sushi and those who want to try new
innovative products. Since the market is nearby we’ll make sure that each material will be as
fresh as possible to make a quality product for our customers.

Physical Requirements

Space

Regarding space, since the team is up for kiosk business for the sushi product, 30sqm is
sufficient for the area and space of the company’s business.

Type of building

For the kind of structure of the area where the business ought to be, it ought to be
sufficient space and space for the specialists to rest and create the product. As living spaces go,
a box kiosk is a pretty good deal. A square walled in area with an entryway, a few bits of
equipment from which to hang stuff and perhaps a few tables to where production can be made.

Zoning

The zoning area is adjacent to the road and traffic density nearby. Adjacent to the
highway is suitable zoning, it’s easy to promote and easy to develop the business. The
company would like to be in the residential neighborhood if permitted so.

Access

It is imperative that the area be advantageous to transportation or to suppliers for it very

well may be effectively available by everybody and would encourage each procedure in the
business advancement. Walk-in access is required and suitable for everybody. All simple walk
in procedure are a piece of the way grouping of tracks and are reasonable for individuals of
most ages, versatility and wellness.
 Figure: Yohei Sushi’s Kiosk and Floor Plan

Personnel

As owners, the team wants to be in the business 24/7. Being a hands-on manager is
being actively involved in some work that is similar to that of our employees. The owners are
never completely detached from the day-to-day needs and operations of the business. Being a
hands-on manager, we will take time out to coach our team and associates and is actively
invested in their progress. The owner spends time interacting directly with the employees and
collaborating on projects. They always keep lines of communication open and take an active
part in providing regular feedback and employee mentoring.
Yohei Sushi is looking for a Floor/Kitchen worker to work in our store for the operations
in the kitchen and also in the frontlines. The responsibilities of this job are to ensure that the
quality of the tuyo sushi will be good through food preparation. The worker should be able to
handle every task given without getting flustered. Lastly, the worker should be able to give
quality food with the given amount of time.
 Position Workers Needed Labor Requirement
Can create a good quality
product
Can maintain a good and
clean working area
Floor/Kitchen Worker 2 Knowledge of the food
being prepared
Can work under intense
pressure
Knows how to handle
each other
Table: Workers Needed

Employee No. of Daily Rate Monthly

Employee Salary

Floor/Kitchen Worker 2 Php 385.00 Php11,571.00

Table: Daily Rate and Monthly Salary

Inventory

Without legitimate inventory, the business may not know the measure of item they have
close by and, along these lines, won't be arranged or even have the ability to dispatch orders.
Raw materials are important to any business since you utilize it to create its very own products.
The company's raw materials like dried fish, nori paper, Mindoro rice will be stored. Storing raw
materials can help forecast what will be produce throughout the following quarter. Completed
merchandise stock incorporates any total items that are currently prepared to be showcased
and sold.

Lead time is the entirety of the set up time, handling time, move time and waiting time.
Lead time is the all out time required to finish an order in the wake of getting it from the client. A
lead time can be characterized as the quantity of minutes, hours, or days that must be took into
account the fruition of a task or process, or should pass before an ideal move makes place. In
Yohei Sushi, the lead time will be 1 day, when Yohei Sushi got its request from the client; the
company will quickly process or create the said request of the client.

Suppliers

Tuyo supplier: Trade market

Address: Crossing Calamba, Laguna

The company should just have one supplier in view of the quality and consistency of the
item so it would not change. Deficiency for delivery of the item isn't an issue. It has sufficiently
determined measure of raw materials or ingredients as the production runs. The expense of
supplies may fluctuate; it might go higher or lower depending upon the state of financial status
of the territory. If at any point the expense of supply will go higher, the production may change
some volume or sum in the blend of the tuyo sushi. In any case, this won't be that undeniable to
the clients and the quality and taste will remain.