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OM 1

Jigar Jain

Executive Shirt Company

Process Flow Diagram


90
Raw
Material

30

Make
Cuffs

Laying
Sheets

19.5

Make
Sleeves

23.25
Attach
Sleeves

30
Cutting
Sheets

29.25

Make
Collar

24.75
Attach
Collars

25

25.5

Make
Front

Make
Back

18
Join
Shoulder

19.5
Stitch
Sleeves
23.25
Attach
Cuffs
25.5

Hem
Bottom

27
Sew Side
Seam
25.5

Inspect
Shirts

29.25

Iron
Shirts

26.25

Fold
Package

Objective
Current
Process

Mikes Plan

Ike - Regular

Ike - Custom

Cycle Time
(mins)

0.6

0.53

0.67

4.8

MLT (days)

14.7

2.2

12.58

0.45

11760

1980

9060

45

Prod Cap
(shirts / day)

960

960

720

123

Cap Utilization
(%)

0.83

0.94

0.81

DL Content
(Mins)

26.51

27.01

26.51

26.01

DL Utilization
(%)

0.69

0.78

0.81

0.33

DL Cost ($)

3.84

3.46

3.49

7.68

WIP Inv
(shirts)

Calculations

Actual Cycle Time

Manufacturing Lead Time

WIP * Cycle Time

Work In Process

480 (Minutes Available Per Day) / Production Per day

No. of WIP Batch * Batch Size

Production Capacity

480 (Minutes Available Per Day) / Theoretical Cycle Time


(Calculated from Bottleneck)

Calculations

Capacity Utilization

Direct Labor Content

Total time taken for a shirt in entire process

Direct Labor Cost

Production Per Day / Production Capacity

Total Employee * Wage Rate * Hours per Day / Production per Day

Direct Labor Utilization

Direct Labor Content / Minutes Available Per Shirt (= Employees *


Hours Per Day * Batch Size / Production)

I Cant Cope

Mr Sane
Activity

Activity Time (Seconds)

Immediate Predecessor

30

None

50

None

40

50

20

10

10

4,5

20

10

10

40

11

20

12

30

13

50

14

50

10

15

10

11

16

40

8,12

Mr Sane - Grouping
Activity

Activity Time (Seconds)

Immediate Predecessor

1, 3

30 + 40 = 70

None, 1

2, 5

50 + 20 = 70

None, 2

4, 8

50 + 20 = 70

1, 2

6, 9, 13

10 + 10 + 50 = 70

3, 6, 9

7, 10, 11

10 + 40 + 20 = 70

4, 5, 9, 7

14, 15

50 + 10 = 60

10, 11

12, 16

30 + 40

7, 8, 12

With New Order

Requirement = 420 units / day


Available Time = 7 hours
Required Cycle Time = 7 * 60 / 420 = 60
seconds
Existing Cycle Time = 70 seconds
New process Grouping Requirement:

1 person = 60 seconds
2 persons = 120 seconds
And so on

New Grouping 8 people


Activity

Activity Time (Seconds)

Immediate Predecessor

1, 2, 3

30 + 50 + 40 = 120 (2 people)

None, None, 1

4, 5, 6, 7, 8, 9

50 + 20 + 10 + 10 + 20 + 10 =
120 (2 people)

1, 2, 3, 4, 5, 6

10, 11, 14, 15

40 + 20 + 50 + 10 = 120 (2
people)

9, 7, 10, 11

12, 13, 16

30 + 50 + 40 = 120 (2 people)

7, 9, 8, 12

Total

8 People

** There are other groupings possible

Uma
Activity

Activity Time (Seconds)

Immediate Predecessor

40

None

50

None

70

20

50

40

B, c

60

30

D, f, g

Mr Sane - Grouping
Activity

Activity Time (Seconds)

Immediate Predecessor

A, b, c, d

40 + 50 + 70 + 20 = 180

None, none, a, a

E, f, g, h

50 + 40 + 60 + 30 = 180

A, b, c, e, d, f, g

With New Order

Requirement = 210 units / day


Available Time = 7 hours
Required Cycle Time = 7 * 60 / 210 = 120
seconds
Existing Cycle Time = 180 seconds
New process Grouping Requirement:

1 person = 180 seconds


2 persons = 90 seconds
And so on

New Grouping 8 people


Activity

Activity Time (Seconds)

Immediate Predecessor

A, b

40 + 50 = 90 (1 people)

None, None

C, d

70 + 20 = 90 (1 people)

E, f

50 + 40 = 90 (1 people)

A, b, c

G, h

60 + 30 = 90 (1 people)

E, d, f, g

Total

4 People

** There are other groupings possible

Thank You