Executive Shirt Company

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The executive shirt company is a well known brand in apparel industry having varieties of high quality standard size readymade shirts which were competitively priced also. Foreseeing the tremendous opportunity in custom shirt market, the general manager Mr. Dwight Collier decides to venture in to this new product segment. As the existing custom sized dress shirt market commanded a substantial high price of 75% more w.r.t similar off-the-shelf shirt and also the delivery time was more than 6 weeks. So Mr. Dwight collier decided to start production of a line of custom made dress shirt which will be moderately priced and at the same time will be delivered within 10 working days after customer places the order. So Mr. Dwight ordered a new “low-ply” laser cutting machine for the purpose and also planned to hire a new worker to operate the same. Before starting production Mr. Dwight wanted to study several options for designing the manufacturing process for custom shirt line. So he endowed the task to two of his managers Mike and Ike to envisage him a plan for incorporating production of custom shirts into the existing manufacturing process. Taking into consideration the following conditions: * Manufacturing lead time for the custom shirts <= 5 working days. * 2000 no. of custom sized shirts to be produced per month. * The factory will continue producing 16000 standard size readymade shirts per month, which it is producing at present. * Refrain from any large capital expenditure.

The existing ECS Production facility
ECS’s current process is designed to make large volume of shirts with limited product variety and more or less constant volume. Following are the features of the present production unit which is located at Pauquet, Mississippi: * Make to stock process

* Job Shop manufacturing process
* Product layout arrangement of shop floor.
* Total...
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