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Type of Number of Number of Average WIP (number

Operation workers Machines of 60-shirt batches


Cutting 4 1 16
Sewing 48 48 144
Inspection 4 12
Ironing 4 4 12
Packaging 4 12
Total WIP
(shirts): 11760
Regular Shirts Labor Content Number of
Operation (Minutes per shirt) Workers
Cutting Operation 1 4
1. Make Collar 3.90 8
2. Make cuffs 2.00 4
3. Make sleeves 0.65 2
4. Make front 2.50 6
5. Make back 1.70 4
6. Join shoulders 0.66 2
7. Attach collar 1.65 4
8. Attach sleeves 1.55 4
9. Stitch down sleeves 0.65 2
10. Sew side seam 1.80 4
11. Attach cuffs 1.55 4
12. Hem bottom 1.70 4
13. Inspect 1.50 4
14.Iron 1.95 4
15. Fold, Package 1.75 4

Regular Shirts
Actual Cycle Time(min./shirt)*
Manufacturing Lead Time(days)
WIP Inventory(shirts)
Production Capacity(shirts/day)**
Capacity Utilization
Direct Labor Content(min./shirt)
Direct Labor Utilization
Direct Labor Cost($/shirt)
Total Labor Capacity of shirt Capacity of shirt Used labor No. of labors No. of
Content/day production/day production/month capacity (%) needed surplus labor
Regular Shirts Labor Content
Operation (Minutes per shirt)
Cutting Operation-regular shirts 1.5
Cutting Operation-customized shirts 0.5
1. Make Collar 3.90
2. Make cuffs 2.00
3. Make sleeves 0.65
4. Make front 2.50
5. Make back 1.70
6. Join shoulders 0.66
7. Attach collar 1.65
8. Attach sleeves 1.55
9. Stitch down sleeves 0.65
10. Sew side seam 1.80
11. Attach cuffs 1.55
12. Hem bottom 1.70
13. Inspect 1.50
14.Iron 1.95
15. Fold, Package 1.75
27.51

Type of Operation Number of workers


Cutting-regular shirts 4
Cutting-customized shirts 1
Sewing 48
Inspection 4
Ironing 4
Packaging 4

Regular Shirts
Actual Cycle Time(min./shirt)* 0.5
Manufacturing Lead Time(days) 2.000
WIP Inventory(shirts) 1920
Production Capacity(shirts/day)** 960.0
Capacity Utilization 93.8%
Direct Labor Content(min./shirt) 27.01
Direct Labor Utilization 77.59%
Direct Labor Cost($/shirt) 3.47
Total Labor Capacity of shirt Capacity of shirt Used labor
Number of Workers Content/day production/day production/month capacity (%)
4 1920 1280.0 28160.0 63%
1 480 960.0 21120.0 10%
8 3840 984.6 21661.5 91%
4 1920 960.0 21120.0 94%
2 960 1476.9 32492.3 61%
6 2880 1152.0 25344.0 78%
4 1920 1129.4 24847.1 80%
2 960 1454.5 32000.0 62%
4 1920 1163.6 25600.0 77%
4 1920 1238.7 27251.6 73%
2 960 1476.9 32492.3 61%
4 1920 1066.7 23466.7 84%
4 1920 1238.7 27251.6 73%
4 1920 1129.4 24847.1 80%
4 1920 1280.0 28160.0 70%
4 1920 984.6 21661.5 91%
4 1920 1097.1 24137.1 82%
65 31200 20073.3111493187 441612.845285012

Average WIP
(number of 5-
Number of Machines shirt batches batch
1 24
1 6
48 288
24
4 24
24
Total WIP (shirts): 1950

Customized Shirts
0.5
1.91
1830
960.0
93.8%
26.01
77.59%
3.47
No. of labors No. of surplus
needed labor
3 1
1 0
8 0
4 0
2 0
5 1
4 0
2 0
4 0
3 1
2 0
4 0
3 1
4 0
3 1
4 0
4 0