Executive Shirt Company Case Analysis

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OPERATIONS MANAGEMENT

EXECUTIVE SHIRT COMPANY CASE

PGP1 – Section A

Group 13

Manohar Vankadara

Darshan Karkera

Sukvinder Singh

Sunil Kumar

A Touseefullah Siddiqui

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 taken per | | |per shirt) |workers |shirt (minutes) |batch (minutes) | |1. Cutting |0.25 |4 |0.06 |3.75 | |2. Make collar |3.9 |8 |0.49 |29.25 | |3. Make cuffs |2 |4 |0.50 |30 | |4. Make sleeves |0.65 |2 |0.33 |19.5 | |5. Make front |2.5 |6 |0.42 |25 | |6. Make back |1.7 |4 |0.43 |25.5 | |7. Join shoulders |0.66 |2 |0.33 |19.8 | |8. Attach collar |1.65 |4 |0.41 |24.75 | |9. Attach sleeves |1.55 |4 |0.39 |23.25 | |10. Stitch down sleeves |0.65 |2 |0.33 |19.5 | |11. Sew side seam |1.8 |4 |0.45 |27 | |12. Attach cuffs |1.55 |4 |0.39 |23.25 | |13. Hem bottom |1.7 |4 |0.43 |25.5 | |14. Inspect |1.5 |4 |0.38 |22.5 | |15. Iron |1.95 |4 |0.49 |29.25 | |15. Fold, package |1.75 |4 |0.44 |26.25 | |Total |25.76 |64 |6.27...
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