3 Review(s)

Executive Shirt Company, Inc. is well-known for its high-quality, competitively-priced men’sshirts. But a recent dip in the sales has led the company to think on alternatives. Based on thecurrent market trend the General Manager Dwight Collier has decided to go for custom-seizedshirts along with the current production of standard-sized shirts.Considering that the decision is taken prudently, we now shift our focus to the company’sproduction process. The company has been using a batch process to produce standard-sizedshirts.1. Following are the details of the company’s current batch processing. Only a few basic styles and colors constitute the major portion of sales, hence the company hasa limited number of varieties to produce. So, it has large batches of each kind of shirt (size andcolor).It has only one cutting machine, which is computer-controlled and can cut up to 60 layers ofcloth at the same time. Also up to 8 patterns can be cut simultaneously. The cutting process bythe machine takes 30 minutes irrespective of the number of patterns and number of layers.But, the set up time is quite significant. It takes 1.5 minutes to roll out a layer of cloth and so for60 layers; it takes 90 minutes setup time. The machine is being operated by 4 operators and thecompany is using its maximum capacity, i.e. 60 layers and 8 patterns at a time. So,Total number of shirts cut in one run = 60*8 = 480Total time taken by one run = setup time + runtime = 90 + 30 = 120 minutesRegular shirts labor content (minutes per shirt) for cutting = 120 / 480 = 0.25 min / shirtNumber of workers = 4Now, tabulating this data with other the data from other production activities, we getOperationRegular Shirts LaborContent (minutes per shirt)NumberofworkersTimetaken pershirt(minutes)Timetaken perbatch(minutes)1. Cutting 0.25 4 0.06 3.752. Make collar 3.9 8 0.49 29.253. Make cuffs 2 4 0.50 304. Make sleeves 0.65 2 0.33 19.55. Make front 2.5 6 0.42 256. Make back 1.7 4 0.43 25.57. Join shoulders 0.66 2 0.33 19.8