| CRISPIVORE BEEF FREEZE-DRY TRIAL — WORK SCHEDULE | |||||
| Job Number: ST104323 | Start Date: 7/1/2025 | Trial Duration: 4 Weeks (28 Days) | |||||
| PROJECT SCOPE & TARGETS | |||||
| Parameter | Value | Unit | Source / Notes | ||
| Production Target (Bulk Output) | 250000 | lbs | Task requirement — minimum 250,000 lbs | ||
| Output per Freeze Dryer Cycle | 4620 | lbs | Product Specification: 7,680 lbs raw → 4,620 lbs finished... | ||
| Raw Input per Freeze Dryer Cycle | 7680 | lbs | Product Specification: full batch size per dryer | ||
| Number of Freeze Dryers | 2 | units | Plan & Establish: 2 dryers available | ||
| Freeze Dry Cycle Time | 15 | hours | Product Specification: 15-hour drying cycle per batch | ||
| Shift Length | 12 | hours | Plan & Establish: 12-hour shifts | ||
| Shifts per Day | 2 | shifts | Plan & Establish: 24/7 production (2 shifts/day) | ||
| Employees per Shift | 20 | persons | Plan & Establish: 20 personnel per 12-hr shift | ||
| Total Employees per Day | =B13*2 | persons | Calculated: 2 shifts × 20 employees | ||
| Trial Duration | 28 | days | Task requirement: four weeks | ||
| Start Date | 7/1/2025 | date | Plan & Establish reference | ||
| Raw Waste / Shrinkage Rate | 0.02 | % | Product Specification: average 2% raw waste | ||
| Finished Waste / Shrinkage Rate | 0.02 | % | Product Specification: average 2% finished waste | ||
| Realistic Cycles per Dryer per Day | 1 | cycles | Operational assumption: 1 full batch per dryer per day (a... | ||
| CALCULATED METRICS & FEASIBILITY | |||||
| Total Cycles Required (Target) | =B6/B7 | cycles | Production Target ÷ Output per Cycle | ||
| Cycles per Dryer Required | =B22/B9 | cycles | Total Cycles Required ÷ Number of Dryers | ||
| Theoretical Max Cycles per Day (per dryer) | =24/B10 | cycles | 24 hours ÷ Freeze Dry Cycle Time | ||
| Realistic Cycles per Day (per dryer) | =B19 | cycles | Operational assumption (prep + packaging + 15-hr cycle) | ||
| Total Cycles Possible (Trial) | =B25*B9*B15 | cycles | Realistic Cycles/Day × Dryers × Days | ||
| Total Output Possible (Trial) | =B26*B7 | lbs | Total Cycles Possible × Output per Cycle | ||
| Target Achieved? | =IF(B27>=B6,"YES — EXCEEDED","NO — NOT MET") | Compares Total Output Possible vs Production Target | |||
| Margin Above Target | =B27-B6 | lbs | Total Output Possible minus Production Target | ||
| Margin Above Target (%) | =B29/B6 | % | Margin ÷ Production Target | ||
| Total Raw Input Required | =B22*B8 | lbs | Total Cycles Required × Raw Input per Cycle | ||
| Total Labor Hours per Cycle | =20*4 | hrs | 20 employees × avg 4 hrs active per cycle (prep + pack + ... | ||
| Total Labor Hours over Trial | =B26*B32 | hrs | Total Cycles Possible × Labor Hours per Cycle | ||
| Average Daily Output | =B27/B15 | lbs/day | Total Output Possible ÷ Trial Duration | ||
| Required Daily Output to Meet Target | =B6/B15 | lbs/day | Production Target ÷ Trial Duration | ||
| EQUIPMENT CAPACITY SUMMARY | |||||
| Equipment | Capacity | Cycle Time | Operating Window | Stagger Strategy | |
| Freeze Dryer 1 | 7,680 lbs raw / 4,620 lbs output | 15 hours | 24/7 | Starts Day 1 06:00 | |
| Freeze Dryer 2 | 7,680 lbs raw / 4,620 lbs output | 15 hours | 24/7 | Starts Day 1 13:30 (7.5-hr stagger) | |
| Packaging Line | 6 totes per dryer cycle | ~2.5 hrs | Post-dryer | Runs after each dryer unload | |
| Freezer Staging | Full batch (480 trays) | As needed | Pre-dryer | Holds prepped trays before dryer loading | |
| CRISPIVORE BEEF FREEZE-DRY TRIAL — PRODUCTION ASSIGNMENTS | |||||
| Job Number: ST104323 | 20 Personnel per 12-Hour Shift | 40 Total Personnel per Day (2 Shifts) | |||||
| Role | # per Shift | Shift Coverage | Primary Responsibilities | Key Tasks | Notes |
| Supervisor | 1 | Both (rotates weekly) | Overall production oversight, shift coordination, safety ... | • Leads shift handoff meetings • Approves batch records a... | 1 per shift; may work overtime during critical load/unloa... |
| Lead | 2 | Both (1 per dryer area) | Assist Supervisor in directing floor activities, troubles... | • Directs tray prep and loader teams • Coordinates dryer ... | 2 per shift; ideally 1 dedicated to each dryer zone |
| Tray Prep / Tray Loader | 6 | Both (rotates) | Prepare trays, portion meat onto trays, weigh, load onto ... | • Inspect and clean trays • Load 16 lbs of raw beef per t... | 6 per shift; batch size = 480 trays per dryer (7,680 lbs ... |
| Freeze Dryer Operator | 2 | Both (1 per dryer) | Operate and monitor freeze dryers, manage load/unload seq... | • Load full trolleys into dryer • Set/verify cycle parame... | 2 per shift; 1 operator assigned to each dryer for contin... |
| Packaging Operator | 7 | Both (rotates) | Inspect finished product, perform metal detection, bulk-p... | • Inspect finished product (texture, color, moisture) • M... | 7 per shift; supports 6 totes per dryer cycle (3 totes pe... |
| QA Technician | 1 | Both (rotates) | Quality assurance sampling, traceability verification, do... | • Collect samples for testing (Salmonella, Listeria, CFU/... | 1 per shift; critical path for batch release |
| Maintenance | 1 | Both (on-call + rounds) | Preventive and corrective maintenance on freeze dryers, p... | • Pre-shift equipment inspections • Respond to breakdowns... | 1 per shift; cross-trained on both dryers |
| TOTAL PER SHIFT | =SUM(B5:B11) | Replicated for Shift 2 | |||
| DAILY LABOR SUMMARY (24-HOUR COVERAGE) | |||||
| Role | # per Day | Shift 1 (06:00–18:00) | Shift 2 (18:00–06:00) | Overlap / Handoff | |
| Supervisor | =B5*2 | 1 | 1 | 30-min overlap at shift change for handoff | |
| Lead | =B6*2 | 2 | 2 | 30-min overlap at shift change | |
| Tray Prep / Tray Loader | =B7*2 | 6 | 6 | Staggered start based on dryer schedule | |
| Freeze Dryer Operator | =B8*2 | 2 | 2 | Continuous coverage; handoff at mid-cycle if needed | |
| Packaging Operator | =B9*2 | 7 | 7 | Shift based on dryer unload timing | |
| QA Technician | =B10*2 | 1 | 1 | Continuous coverage for batch release | |
| Maintenance | =B11*2 | 1 | 1 | On-call + rounds during both shifts | |
| TOTAL DAILY LABOR | =SUM(B16:B22) | 20 | 20 | ||
| CRISPIVORE BEEF FREEZE-DRY TRIAL — PRODUCTION SEQUENCES | |||||||
| Job Number: ST104323 | 2 Dryers | 15-Hour Cycle | 7.5-Hour Stagger | 20 Personnel per Shift | |||||||
| SECTION A: MASTER PRODUCTION SEQUENCE (Single Dryer Batch) | |||||||
| Step # | Sub-Step / Activity | Dryer | Duration | Start (Hrs from Batch Start) | End (Hrs from Batch Start) | Personnel Assigned | Shift / Notes |
| 1 | Tray Prep: Prepare trays, load 16 lbs raw beef, weigh, lo... | — | 2 | 0 | 2 | 6× Tray Prep / Loader | Shift 1 or 2 |
| 2 | Load trolleys into freezer / cold staging | — | 0.5 | 2 | 2.5 | 2× Tray Prep / Loader | Keeps product at ≤ -20°F |
| 3 | Load full trolley into freeze dryer | 1 or 2 | 0.5 | 2.5 | 3 | 2× Freeze Dryer Operator, 1× Lead | Verify probe placement (Top/Middle/Bottom) |
| 4 | Freeze Drying — Monitor temperature, vacuum pressure, cyc... | 1 or 2 | 15 | 3 | 18 | 2× Freeze Dryer Operator | Continuous monitoring; 3–5% atmospheric pressure |
| 5 | Unload dryer / remove dried product trays | 1 or 2 | 0.5 | 18 | 18.5 | 2× Freeze Dryer Operator | End of 15-hr cycle |
| 6 | Unload trays from trolleys; stage for packaging | — | 1 | 18.5 | 19.5 | 6× Tray Prep / Loader, 2× Freeze Dryer Operator | Cross-functional support |
| 7 | Inspection & metal detection | — | 0.5 | 19.5 | 20 | 7× Packaging Operator | Texture, color, metal check |
| 8 | Bulk pack into sacks; place into cardboard tote boxes | — | 1 | 20 | 21 | 7× Packaging Operator | 6 full totes per dryer cycle |
| 9 | Insert corner boards, zip tie sacks, tape tote, label (Pr... | — | 0.5 | 21 | 21.5 | 7× Packaging Operator | Label includes ST104323 |
| 10 | QC check, bag/label/case pack, documentation | — | 0.5 | 21.5 | 22 | 1× QA Technician, 1× Supervisor | Batch record completion |
| 11 | Sample collection & traceability verification | — | 0.5 | 22 | 22.5 | 1× QA Technician | Salmonella, Listeria, CFU/g testing |
| BATCH TOTAL | =SUM(D6:D16) | ||||||
| SECTION B: 24-HOUR CONCURRENT TIMELINE (Dryer 1 + Dryer 2... | |||||||
| Time of Day | Dryer 1 Activity | Dryer 2 Activity | Shift on Duty | Personnel Deployed | Dryer 1 Step Ref | Dryer 2 Step Ref | Critical Notes |
| 06:00 – 08:00 | Tray Prep (Steps 1–2) | Idle / Pre-staging | Shift 1 (06:00–18:00) | 6 Tray Loaders | A1–A2 | — | Dryer 2 pre-staging begins at 13:30 |
| 08:00 – 08:30 | Load Dryer 1 (Step 3) | Idle / Pre-staging | Shift 1 | 2 Operators + 1 Lead | A3 | — | Dryer 1 cycle starts |
| 08:30 – 13:30 | Freeze Dry 1 (Step 4) | Tray Prep (Steps 1–2) | Shift 1 | 2 Operators (Dryer 1); 6 Tray Loaders (Dryer 2) | A4 | A1–A2 | Dryer 2 prep begins at 13:30 |
| 13:30 – 14:00 | Freeze Dry 1 (Step 4) | Load Dryer 2 (Step 3) | Shift 1 | 2 Operators (Dryer 1); 2 Operators + 1 Lead (Dryer 2) | A4 | A3 | Dryer 2 cycle starts; stagger = 7.5 hrs |
| 14:00 – 18:00 | Freeze Dry 1 (Step 4) | Freeze Dry 2 (Step 4) | Shift 1 | 2 Operators (Dryer 1); 2 Operators (Dryer 2) | A4 | A4 | Both dryers in active cycle |
| 18:00 – 21:00 | Freeze Dry 1 (Step 4) | Freeze Dry 2 (Step 4) | Shift 2 (18:00–06:00) | 2 Operators (Dryer 1); 2 Operators (Dryer 2) | A4 | A4 | Shift change at 18:00; 30-min overlap |
| 21:00 – 21:30 | Unload Dryer 1 (Step 5) | Freeze Dry 2 (Step 4) | Shift 2 | 2 Operators (Dryer 1); 2 Operators (Dryer 2) | A5 | A4 | Dryer 1 cycle ends at 21:00 |
| 21:30 – 23:30 | Unload / Stage Dryer 1 (Steps 6–7) | Freeze Dry 2 (Step 4) | Shift 2 | 6 Tray Loaders + 2 Operators (Dryer 1); 2 Operators (Drye... | A6–A7 | A4 | Dryer 1 product moves to packaging |
| 23:30 – 02:00 | Packaging Dryer 1 (Steps 8–9) | Freeze Dry 2 (Step 4) | Shift 2 | 7 Packaging Operators (Dryer 1); 2 Operators (Dryer 2) | A8–A9 | A4 | Dryer 2 continues drying |
| 02:00 – 03:00 | QC & Docs Dryer 1 (Steps 10–11) | Freeze Dry 2 (Step 4) | Shift 2 | 1 QA + 1 Supervisor (Dryer 1); 2 Operators (Dryer 2) | A10–A11 | A4 | Dryer 1 batch release paperwork |
| 03:00 – 03:30 | Idle / Clean-up Dryer 1 | Unload Dryer 2 (Step 5) | Shift 2 | Maintenance + 2 Operators (Dryer 1); 2 Operators (Dryer 2) | — | A5 | Dryer 2 cycle ends at 03:00 (next day) |
| 03:30 – 06:00 | Prep for next Dryer 1 batch (Steps 1–2) | Unload / Stage Dryer 2 (Steps 6–7) | Shift 2 | 6 Tray Loaders (Dryer 1); 6 Tray Loaders + 2 Operators (D... | A1–A2 | A6–A7 | Continuous cycle; Shift 2 ends at 06:00 |
| 06:00 – 07:00 | Load Dryer 1 (Step 3) | Packaging Dryer 2 (Steps 8–9) | Shift 1 (next day) | 2 Operators + 1 Lead (Dryer 1); 7 Packaging Operators (Dr... | A3 | A8–A9 | Shift 1 resumes; Dryer 2 packaging |
| 07:00 – 09:30 | Freeze Dry 1 (Step 4) | QC & Docs Dryer 2 (Steps 10–11) | Shift 1 | 2 Operators (Dryer 1); 1 QA + 1 Supervisor (Dryer 2) | A4 | A10–A11 | Dryer 2 batch release |
| 09:30 – 10:00 | Freeze Dry 1 (Step 4) | Idle / Clean-up Dryer 2 | Shift 1 | 2 Operators (Dryer 1); Maintenance (Dryer 2) | A4 | — | Dryer 2 ready for next load at 13:30 |
| SECTION C: THROUGHPUT OPTIMIZATION & BOTTLENECK ANALYSIS | |||||||
| Resource | Capacity per Cycle | Utilization | Bottleneck Risk | Mitigation Strategy | |||
| Freeze Dryer 1 | 1 batch / 15 hrs | High | Low | Staggered start prevents queue buildup | |||
| Freeze Dryer 2 | 1 batch / 15 hrs | High | Low | 7.5-hr stagger balances unload/packaging load | |||
| Tray Prep Team (6) | 480 trays / 2 hrs | Medium | Medium | Pre-stage trays; parallel prep if 2nd batch needed | |||
| Packaging Team (7) | 6 totes / 2.5 hrs | Medium | Medium | Overlap packaging with next dryer cycle | |||
| QA Technician (1) | 1 batch release / 0.5 hrs | Low | High | Pre-schedule sampling; use Lead for preliminary checks | |||
| Maintenance (1) | Continuous rounds | Low | Medium | PM schedule during low-activity windows | |||
| Supervisor (1) | Continuous oversight | Low | Low | Digital batch records reduce admin burden | |||