The document contains information about current and proposed production plans for regular and custom shirts. The current plan has 64 workers across cutting, sewing, inspection, ironing and packaging operations to produce 196 shirts per day. The Mike plan proposes changes to produce both regular and custom shirts with a total of 64 workers and 396 shirts per day. The Ike plan proposes changes for regular shirts only with 151 minutes per shirt and custom shirts with one worker allocated to each operation. Key metrics like capacity, utilization and cost structure are also presented.

1. current plan - regular shirt
Number of Number of Av WIP (60 shirt Cutting
type of operation workers machines batch) time Shirts cut
Cutting 4 1 16 120 480
Sewing 48 48 144
Inspection 4 12
Ironing 4 4 12
Packaging 4 12
64 196
Mike Plan - Reg & Custom Shirt
Number of Number of Av WIP (5 shirt
type of operation workers machines batch)
Cutting 5 2 36 m/c 1
Sewing 48 48 288 m/c 1
Inspection 4 24 m/c 1
Ironing 4 4 24 m/c 1
Packaging 4 24 m/c 1
396 m/c 1
m/c 1
m/c 2
Ike Plan - RegularShirt
Number of Number of Av WIP (60 shirt Cutting
type of operation workers machines batch) time Shirts cut
Cutting 4 1 16 120 480
Sewing 36 36 108
Inspection 3 9
Ironing 3 3 9
Packaging 3 9
151
Ike Plan - Custom Shirt
Number of Number of Av WIP (60 shirt
type of operation workers machines batch)
Cutting 1 1
Sewing 12 12
Inspection 1
Ironing 1 1
Packaging 1
Actual Cycle time Min/Shirt time interval between two items output
WIP Shirts Sum WIP * 60
Manf Lead Time Cycle time * WIP
Munf. Lead time days three weeks lead time

2. Little's Law = Av. Inv = Av Flow Time * flow rate Flow rate = 1/ Cycle time
Production Capacity
Cap Util
c utting efforts Min / Shirt = 4 worker, 120 min batch, 480 shirts o/p
Direct labor content Min / Shirt
Total availble Labour Sewing Ops
Labour on on cutting
Total aval Labour capacity
User direct labour Direct Labour Content x 800 shirt per day
Labour Utilization %
Labour cutting Min/shirt
Direct Labour cost ($/shirt) dollars Capacity * Rate (Not to use Utilization)
Reg Shirt Lab Number of Available capacity Avl per Max used
Operation Min/shirt workers (min) day O/p Capacity
Make coller 3.90 8 3840 985 960
make cuffs 2.00 4 1920 960 960
make sleeves 0.65 2 960 1477 960
make front 2.50 6 2880 1152 960
make back 1.70 4 1920 1129 960
join shoulders 0.66 2 960 1455 960
attach collar 1.65 4 1920 1164 960
attach sleeves 1.55 4 1920 1239 960
stitch down sleeves 0.65 2 960 1477 960
sew side seam 1.80 4 1920 1067 960
attach cuffs 1.55 4 1920 1239 960
hem bottom 1.70 4 1920 1129 960
inspect 1.50 4 1920 1280 960
iron 1.95 4 1920 985 960
fold, package 1.75 4 1920 1097 960
25.51 60 28800 28800
Cost Structure
Raw materials 7.00
total labour 4.50
other indirect cost 4.50
total manu cost 16.00
wholesale price 25.00
retail price 50.00

3. Current production20 days Per day max 960
Max prod cap 19200
Used cap 16000
Util % 83.33

4. Cycle time
Avl per day Max used for 60 shirts
O/p Capacity Util % batch
1920 960 50 120
1218.6
90
117
105
Minuts 1650.6
Days 3.43875
Avl per day Max used
batch size Cutting time Shirts cut O/p Capacity Util % Min/Shirt
5 37.5 40 512 800 156 0.9375
10 45 80 853 800 94 0.5625
15 52.5 120 1097 800 73 0.4375
20 60 160 1280 800 63 0.375
25 67.5 200 1422 800 56 0.3375
30 75 240 1536 800 52 0.3125
60 120 480 1920 800 42 0.25
5 2.5 5 960 100 10 0.5
Cycle time
Avl per day Max used for 60 shirts
O/p Capacity Util % batch
1920 960 50 120
Mike
Regular 5 10 15 20 25 30
0.6 0.53 0.53 0.53 0.53 0.53 0.53
11760 1980 3960 5940 7920 9900 11880
7056 1056 2112 3168 4224 5280 6336
14.7 2.2 4.4 6.6 8.8 11 13.2

5. 960 960 960 960 960 960 960
83.33% 93.75% 93.75% 93.75% 93.75% 93.75% 93.75%
1 3.39 2.06 1.61 1.39 1.26 1.17
26.51 28.90 27.57 27.12 26.90 26.77 26.68
28800 28800 28800 28800 28800 28800 28800
1920 2400 2400 2400 2400 2400 2400
30720 31200 31200 31200 31200 31200 31200
21208 26009 24809 24409 24209 24089 24009
69.04 83.36 79.52 78.23 77.59 77.21 76.95
38.40 34.67 34.67 34.67 34.67 34.67 34.67
3.84 3.47 3.47 3.47 3.47 3.47 3.47
this should
Batch time be less then
Mins (60 Total cycle
Util % Shirts) time 0.6
98 234 0.4875
100 120 0.5 Giving bottleneck
65 39 0.325
83 150 0.41666667
85 102 0.425
66 39.6 0.33
83 99 0.4125
78 93 0.3875
65 39 0.325
90 108 0.45
78 93 0.3875
85 102 0.425
1218.6 #DIV/0!
75 90 0.375
98 117 0.4875
88 105 0.4375
312.00 0.42516667

7. Big m/c 5 layer cutting time
1.066667
0.9375
Big m/c 10 layer cutting time
1.777778
Cycle time 0.5625
Combine Cycle
time with M/c
2
3.39
2.06
1.61
1.39
1.26
1.17
0.94
60
0.53
23760
12672
26.4

8. 960
93.75%
0.94
26.45
28800
2400
31200
23809
76.31
34.67
3.47