Question 1

According to the given data, the Production cycle times are as follows:
 Complete cutting : 4 days after cut issue
 Complete Sewing : 9 days after complete cutting
 Complete Finishing : 4 days after complete sewing

Style Issue Date Complete Cutting Complete Sewing Complete Finishing

1A 1.10 5.10 18.10 24.10
2B 2.10 8.10 19.10 25.10
3C 2.10 8.10 19.10 25.10
4D 3.10 9.10 22.10 26.10
5E 4.10 10.10 23.10 29.10
Following observations were made from the daily cutting/sewing/finishing reports as well as Production
Order Control record:

Low Efficiency - Extremely Less Capacity Utilization

Reasons:
 Absenteeism
 Poor Work Methods
 Low Operator performance
 Poor operator utilization
 Frequesnt style changes in each department which leads to re-balancing of line each time leading to loss of
output

Remedies:
 Operator Training to increase operator perofrmance
 Carry out method study to develop better procedures
 Correct Line balancing to optmize operator utilization
 Processing single style in a continuous flow to reduce change over times, it’ll further reduce the line balancing
time.

HIGH AMOUNT OF REJECTIONS

Rejections after each department lower the quantity of goods finally produced.
For example, for style 3C, 2740 pieces were cut, 2720 pieces were sewn and finally 2650 pieces were finished.
It is clear from the data that pieces are getting rejected.

Reasons:
 Low Operator Skill
 Poor methods

Remedies:
 Operator Training to increase operator perofrmance
 Carry out method study to develop better procedures

LATE CUTTING START

Cutting started from October 3 while the it was issued on october 1 itself. Cutting could have been started on 1 october
itself without wasting any time. It is possible that at the tie if issue, other orders were in process but then also, the
previous orders must be finished by the time new orders are issued to the cutting department.

SOME DAYS COMPLETELY UNITILIZED

No work is done on October 12, 15, 16 and Novemeber 6, 8. This highly contributes to the poor periodice efficiency.
DELIVERY DATES
Processing of orders is taking time beyond the mentioned delivery dates.
Reasons: This is due to poor production planning
Poor capacity utilization.