Labor content Capacity

No of Cycle Time
Operation
Min/shirt workers min/shirt Shirts/day

Cutting 1 4 0.25 1920

1. Make Collar 3.9 8 0.49 985

2. Make 4 0.50 960
Cuf 2
3. Make 2 0.33 1477
Sleeve 0.65
4. Make 6 0.42 1152
Front 2.5
5. Make 4 0.43 1129
Back 1.7
6. Join 2 0.33 1455
Shoulder 0.66
7. Attach
4 0.41 1164
coller 1.65
8. Attache 4 0.39 1239
Sleeve 1.55
9. Stich
down 2 0.33 1477
sleeve 0.65
10. Sew side 4 0.45 1067
seem 1.8
11. Attach 4 0.39 1239
cuf 1.55
12. Hem 4 0.43 1129
bottom 1.7

13. Inspect 4 0.38 1280

1.5
14. Iron 1.95 4 0.49 985
15. 4 0.44 1097
Packaging 1.75
Labour
content 26.51
Capacity
Utilization Per day
production 800

0.42 minutes
avaliable per
day 480
0.81

0.83

0.54

0.69

0.71

0.55

0.69

0.65

0.54

0.75

0.65

0.71

0.63

0.81

0.73
Bottleneck Make cuffs
Bottleneck Production
Capacity(shirts/day) 960

Bottleneck Cycle Time(min/shirt)

0.5

Actual Production
Rate(shirts/day) 800

Actual Cycle Time(min./shirts)

480/800 0.6

Capacity Utilization
0.83

WIP Inventory(shirts)
196*60 11760

Manufacturing Lead Time(days)

11760/800 or CT*WIP per da 14.7

Direct Labor
Content(min./shirts) 26.51
Direct Labor Utilization 26.51*800/ 64*8*60

Direct Labor Cost($/shirts)

64*8*6/800 3.84
 Labor
Cycle Time Capacity Capacity
Operation content No of workers min/shirt
Min/shirt Shirts/day Utilization
New Cutting m/c 2.5 1 0.4 960 0.1
1. Make collar 3.9 1 0.2564102564 123 0.81
2. Make Cuf 2 1 0.5 240 0.42
3. Make Sleeve 0.65 1 1.5384615385 738 0.14
4. Make Front 2.5 1 0.4 192 0.52
5. Make Back 1.7 1 0.5882352941 282 0.35
6. Join Shoulder 0.66 1 1.5151515152 727 0.14
7. Attach coller 1.65 1 0.6060606061 291 0.34
8. Attache Sleev 1.55 1 0.6451612903 310 0.32
9. Stich down sl 0.65 1 1.5384615385 738 0.14
10. Sew side se 1.8 1 0.5555555556 267 0.38
11. Attach cuf 1.55 1 0.6451612903 310 0.32
12. Hem bottom 1.7 1 0.5882352941 282 0.35
13. Inspect 1.5 1 0.6666666667 320 0.31
14. Iron 1.95 1 0.5128205128 246 0.41
15. Packaging 1.75 1 0.5714285714 274 0.36
28.01 16
Per day production 800
minutes avaliable per day 480
 Cycle
Labor content No of Time
Operation
Min/shirt workers min/shi
rt
New Cutting m/c 2.5 / 5 0.5 1 0.5

Cutting 120* 4 / 480 1 4 0.25

1. Make coller 3.9 3.9 8 0.4875

2. Make Cuff 2 2 4 0.5

3. Make Sleeve 0.65 0.65 2 0.325

4. Make Front 2.5 2.5 6 0.4167

5. Make Back 1.7 1.7 4 0.425

6. Join Shoulder 0.66 0.66 2 0.33

7. Attach coller 1.65 1.65 4 0.4125

8. Attache Sleeve 1.55 1.55 4 0.3875

9. Stich down sleeve 0.65 0.65 2 0.325

10. Sew side seem 1.8 1.8 4 0.45

11. Attach cuff 1.55 1.55 4 0.3875

12. Hem bottom 1.7 1.7 4 0.425

13. Inspect 1.5 1.5 4 0.375

14. Iron 1.95 1.95 4 0.4875
15. Packaging 1.75 1.75 4 0.4375
27.01
Capacity Capacity
Shirts/day Utilization 900
960 0.94 480 Bottleneck
Bottleneck
Production
1920 0.47 Capacity(shirts/da
y)

Bottleneck Cycle
985 0.91 Time(min/shirt)
960 0.94

Actual Prodcution
1477 0.61 Rate(shirts/day)

Actual Cycle
1152 0.78 Time(min./shirt)
0.5
1129 0.80
Capacity
1455 0.62 Utilization
1164 0.77
WIP
1239 0.73 Inventory(shirts)

Manufacturing
1477 0.61 Lead Time(days)

1067 0.84
Direct Labor
1239 0.73 Content(min./shir
t)
Direct Labor
1129 0.80 Utilization
Direct Labor
1280 0.70 Cost($/shirt)
985 0.91
1097 0.82
 Make Cuf

960

0.5

=800 regular shirts + 900

100 custom shirts

= based on actual 0.53

capacity (480/900)

900/960 0.94

=396*5 (Exhibit 5) 1980

=0.53*1980 or 2.2
=1980/900

Sum(all Process time) 27.01

0.7791346154 0.7791

3.4666666667 3.466