Operation Cutting Set up for cutting Make Collar Make cuffs Make sleeves Make front Make back

Join shoulders Attach collar Attach Sleeves Stitch down sleeves Sew side seam Attach cuffs Hem bottom Inspect Iron Fold, Package

Regular shirts labour content min/shirt 30 1.5 3.9 2 0.65 2.5 1.7 0.66 1.65 1.55 0.65 1.8 1.55 1.7 1.5 1.95 1.75 25.51 Direct labour excluding cutting

No. workers 4 4 8 4 2 6 4 2 4 4 2 4 4 4 4 4 4 64 No. of workers No. of machines 1 48 4

Individual capacity shirts/day 1920 985 960 1477 1152 1129 1455 1164 1239 1477 1067 1239 1129 1280 985 1097 960 Capacity of the plant

Individual cycle time mins/shirt 0.250 0.488 0.500 0.325 0.417 0.425 0.330 0.413 0.388 0.325 0.450 0.388 0.425 0.375 0.488 0.438 0.5 Cycle time of the plant

Type of operation Cutting Sewing Inspection Ironing Packaging

No. of workers 4 48 4 4 4

Average WIP 16 144 12 12 12 196

Overall Capacity Demand Actual cycle time Cycle time of bottle neck WIP (Shirts) Manufacturing lead time Capacity utilization Direct labour content required Total labour minutes available Direct labour utilization Direct labour cost (DLC) DLC at full capacity

960 800 0.6 0.5 11760 14.7 83.33 26.51 38.4 69.04 3.84 3.2

shirts/day shirts/day mins/shirt mins/shirt shirts days percent mins/shirt mins/shirt percent $/shirt $/shirt

Current Production 16000 Shirts / month 20 days /month 800 shirts / day Bottle neck

Operation Cutting Set up for cutting New Machine cutting Make Collar Make cuffs Make sleeves Make front Make back Join shoulders Attach collar Attach Sleeves Stitch down sleeves Sew side seam Attach cuffs Hem bottom Inspect Iron Fold, Package

Regular shirts labour content min/shirt 30 1.5 2.5 3.9 2 0.65 2.5 1.7 0.66 1.65 1.55 0.65 1.8 1.55 1.7 1.5 1.95 1.75 25.51 Direct labour excluding cutting

No. workers 4 4 1 8 4 2 6 4 2 4 4 2 4 4 4 4 4 4 65 No. of workers No. of machines 2 48 4

Individual capacity shirts/day 1920 960 985 960 1477 1152 1129 1455 1164 1239 1477 1067 1239 1129 1280 985 1097 960 Capacity of the plant

Individual cycle time mins/shirt 0.250 0.500 0.488 0.500 0.325 0.417 0.425 0.330 0.413 0.388 0.325 0.450 0.388 0.425 0.375 0.488 0.438 0.5 Cycle time of the plant

Type of operation Cutting Sewing Inspection Ironing Packaging

No. of workers 5 48 4 4 4

Average WIP 36 288 24 24 24 396

Overall Capacity Demand Actual cycle time Cycle time of bottle neck WIP (Shirts) Manufacturing lead time Capacity utilization Direct labour content required Total labour minutes available Direct labour utilization Direct labour cost (DLC)

960 900 0.53 0.5 1980 2.2 93.75 27.01 34.67 77.91 3.47

shirts/day shirts/day mins/shirt mins/shirt shirts days percent mins/shirt mins/shirt percent $/shirt

DLC at full capacity

3.25 3120

$/shirt

Current Production 16000 Shirts / month 20 days /month 800 Bottle neck 2000 20 100 Shirts / month days /month shirts / day shirts / day

Operation Cutting Set up for cutting Make Collar Make cuffs Make sleeves Make front Make back Join shoulders Attach collar Attach Sleeves Stitch down sleeves Sew side seam Attach cuffs Hem bottom Inspect Iron Fold, Package

Regular Shirts Regular shirts No. labour content workers min/shirt 30 4 1.5 4 3.9 2 0.65 2.5 1.7 0.66 1.65 1.55 0.65 1.8 1.55 1.7 1.5 1.95 1.75 25.51 Direct labour excluding cutting 7 3 1 5 3 1 3 3 1 3 3 3 3 3 3 49 No. of workers No. of machines 1 36 3

Individual capacity shirts/day 1920 862 720 738 960 847 727 873 929 738 800 929 847 960 738 823 720 Capacity of the plant

Individual cycle time mins/shirt 0.250 0.557 0.667 0.650 0.500 0.567 0.660 0.550 0.517 0.650 0.600 0.517 0.567 0.500 0.650 0.583 0.667 Cycle time of the plant

Type of operation Cutting Sewing Inspection Ironing Packaging

No. of workers 4 36 3 3 3 Regular Shirts

Average WIP 16 108 9 9 9 151

Overall Capacity Demand Actual cycle time Cycle time of bottle neck WIP (Shirts) Manufacturing lead time Capacity utilization Direct labour content required Total labour minutes available Direct labour utilization

720 800 0.60 0.667 9060 12.58 111.11 26.51 29.40 90.17

shirts/day shirts/day mins/shirt mins/shirt shirts days percent mins/shirt mins/shirt percent

Direct labour cost (DLC) DLC at full capacity Overtime details 1 hour overtime for the workers Cost incurred is

2.94 3.27

$/shirt $/shirt

441 2352 768 3561

$/day

Operation

Custom Shirts Regular shirts No. workers labour content min/shirt

Individual capacity shirts/day

Individual cycle time mins/shirt

New Machine cutting Make Collar Make cuffs Make sleeves Make front Make back Join shoulders Attach collar Attach Sleeves Stitch down sleeves Sew side seam Attach cuffs Hem bottom Inspect Iron Fold, Package

2.5 3.9 2 0.65 2.5 1.7 0.66 1.65 1.55 0.65 1.8 1.55 1.7 1.5 1.95 1.75 25.51 Direct labour excluding cutting No. of workers 1 12 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 16 No. of workers No. of machines 1 12 1

960 123 240 738 192 282 727 291 310 738 267 310 282 320 246 274 123

0.500 3.900 2.000 0.650 2.500 1.700 0.660 1.650 1.550 0.650 1.800 1.550 1.700 1.500 1.950 1.750 3.900

Capacity of Cycle time the plant of the plant Average WIP 5 36 3 3 3 50

Type of operation Cutting Sewing Inspection Ironing Packaging Custom Shirts Overall Capacity Demand Actual cycle time Cycle time of bottle neck WIP (Shirts) Manufacturing lead time Capacity utilization Direct labour content required Total labour minutes available Direct labour utilization

123 100 4.80 3.9 50 0.5 81.25 26.01 76.80 33.87

shirts/day shirts/day mins/shirt mins/shirt shirts days percent mins/shirt mins/shirt percent

Direct labour cost (DLC) DLC at full capacity

7.68 6.24

$/shirt $/shirt

Current Production 16000 Shirts / month 20 days /month 800 shirts / day

2000 20 100

Shirts / month days /month shirts / day