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We begin by stating assumptions, and then we will explain how we calculated the figures
mentioned in above table.
Assumptions:
• For custom shirts, the time for new cutting machine is 2.5 minutes; this includes the roll
out time and cutting time.
• We are taking the assumption that they are doing no rework.
We will now explain each calculation, how we calculated cycle time, Manufacturing lead
time (MLT), WIP inventory etc.
Actual Cycle Time (min/shirt):
In order to calculate cycle time, we know that cycle time of a process is the cycle time of
its bottleneck operation. In the current process we are using a batch size of 60 and we are
provided with the cycle time of each operation in the case (Exhibit-3). We can get the
cycle time of each operation by dividing the time taken to complete one batch by the
number of batches simultaneously worked upon in each operation (Detailed explanation
given in Exhibit-1). This will give us the cycle time in minutes per shirt. Then...