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Stonehaven Inc

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Stonehaven Inc
STONEHAVEN INC.
CASE STUDY

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INTRODUCTION
Stonehaven Inc. Headquartered near
Boston was a manufacturing brand name for non athletic shoes for adults.
Recent changes has made the management to think about bringing necessary improvement to cater the changing demands and tackle the long order-to-delivery lead times.

1.0 What are the daily capacities and manufacturing lead time of cutting, stitching and lasting department considering a
a.100 pair batch
b.10 pair batch?

A. CUTTING
8 hrs/day x 60 min/hr = 480 min/day
Cut Shoe leather = (0.05 x 4)(100) + (5.25 x 4) = 41 min/batch Cut linings = (0.05 x 4)(100) + (5.00 x 4) = 40 min/batch Cut insole = (0.04 x 4)(100) + (4.00 x 4) = 32 min/batch Manufacturing Lead Time (MLT) = 41 min/batch.
Capacity : 480/41=11.7 batches
: 11.70*100= 1170 pairs of shoe/shift

B. STITCHING
8 hrs/day x 60 min/hr = 480 min/day
Prefit = (100/4) x 5.0 = 125 min/batch
Join = (100/3) x 3.0 = 100 min/batch
Ornament = (100/2) x 2.5 = 125 min/batch
Manufacturing Lead Time (MLT) = 5.0 min + 3.0 min
+ 125 min = 133 min/batch.
Capacity : 480/125=11.7 batches
: 1170 pairs of shoe per shift

C. LASTING
8 hrs/day x 60 min/hr = 480 min/day
Staple Insole = 100 x 0.7 = 70 min/batch
Toe and heel seal = 100 x 0.6 = 60 min/batch
Rough Sole, pounds = 100 x 1.0 = 100 min/batch
Cement sole = 100 x 0.9 = 90 min/batch
Inspect, pack = 100 x 0.3 = 30 min/batch
Manufacturing Lead Time (MLT) = 0.7 min + 0.6 min + 1.0 min
+ 0.9 min + 30 min = 33.2 min/batch.
Capacity = 480 min/day ÷ 100 min/batch = 4.8 batches/day x
100 pairs/batch = 480 pairs/day

10 PAIR- A. CUTTING
8 hrs/day x 60 min/hr = 480 min/day
Cut shoe leather = (0.05 x 4)(10) + (5.25 x 4) = 23 min/batch
Cut linings = (0.05 x 4)(10) + (5.00 x 4) = 22 min/batch
Cut insole = (0.04 x 4)(10) + (4.00 x 4) = 17.6 min/batch
Manufacturing Lead Time (MLT) 23 min/batch.
Capacity = 480 min/day ÷ 23 min/batch
= 20.9 batches/day x 10 pairs/batch = 209 pairs/day

B.STITCHING
8 hrs/day x 60 min/hr = 480

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