Executive Shirts

In: Business and Management

Submitted By Benerio
Words 2825
Pages 12
Prepared by: Executive Shirt Company Inc. March 22, 2012

Question 1: Compute the following quantities for the current production process as well as for Mike’s and Ike’s plans, assuming the plans are implemented as described in the case.

Cutting:
Time required = (90 mins + 30 mins) / (60 layers x 8 patterns) = 0.25 mins / shirt for 1 cutting machine.

(TABLE: CURRENT PRODUCTION PROCESS) Operation:Current Production Process | Regular Shirts Labor Content(mins/shirt) | Number of Workers | Time required =Labor content / # Workers(mins/worker/shirt) | 1. Make collar | 3.90 | 8 | 0.488 | 2. Make cuffs | 2.00 | 4 | 0.500 | 3. Make sleeves | 0.65 | 2 | 0.325 | 4. Make front | 2.50 | 6 | 0.410 | 5. Make back | 1.70 | 4 | 0.420 | 6. Join shoulders | 0.66 | 2 | 0.330 | 7. Attach collar | 1.65 | 4 | 0.410 | 8. Attach sleeves | 1.55 | 4 | 0.390 | 9. Stitch down sleeves | 0.65 | 2 | 0.320 | 10. Sew side seam | 1.80 | 4 | 0.450 | 11. Attach cuffs | 1.55 | 4 | 0.390 | 12. Hem bottom | 1.70 | 4 | 0.420 | 13. Inspect | 1.50 | 4 | 0.380 | 14. Iron | 1.95 | 4 | 0.490 | 15. Fold, package | 1.75 | 4 | 0.420 |

Current Production Process | Calculation Explanation | Value | a. Actual Cycle Time | = 1 / flow rate | = 1 / (800 shirts / 480 mins) = 1 / 1.667) = 0.60 min / shirt | b. Manufacturing Lead Time | = WIP / flow rate | = 11,760 / 800 = 14.70 days | c. WIP Inventory | = Total WIP x batch size | = (16 + 144 + 12 + 12 + 12) x 60= 196 x 60 = 11,760 shirts | d. Production Capacity | Bottleneck | = (60 layers x 8 patterns) / 0.500= 960 shirts / day | e. Capacity Utilization | = Flow ratea / Production capacity | = 800 / 960 = 83.33% | f. Direct Labor Content | = Direct labor time / unit= Cutting + Operation process time | = (0.25 mins x 4 machines) + 25.51 mins = 26.51 mins / shirt | g. Direct Labor Utilization | = Labor used / labor availableb | =…...

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Executive Shirt Case Analysis

...OPERATIONS MANAGEMENT EXECUTIVE SHIRT COMPANY CASE Q.1) Compute the following quantities for the current production process as well as for Mike’s and Ike’s plans, assuming the plans are implemented as described in the case. Solution: Current batch processing Sales for the Executive Shirt Company are constituted of only a few basic styles and colours. Hence the company has a limited number of varieties to produce. So, it has large batches of each kind of shirt (size and color). It has only one cutting machine, which is computer-controlled and can cut up to 60 layers of cloth at the same time. Also up to 8 patterns can be cut simultaneously. The cutting process by the machine takes 30 minutes irrespective of the number of patterns and number of layers. But, the set up time is quite significant. It takes 1.5 minutes to roll out a layer of cloth and so for 60 layers; it takes 90 minutes setup time. The machine is being operated by 4 operators and the company is using its maximum capacity, i.e. 60 layers and 8 patterns at a time. So, Total number of shirts cut in one run = 60*8 = 480 Total time taken by one run = setup time + runtime = 90 + 30 = 120 minutes Regular shirts labor content (minutes per shirt) for cutting = 120 / 480 = 0.25 min per shirt Number of workers = 4 |Operation |Regular Shirts Labor Content (minutes |Number of |Time taken per |Time......

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