Executive Shirt Company

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------------------------------------------------- Executive Shirt Company Inc. PREMISE: General Manager Dwight Collier has given the task to Mr. Mike and Mr. Ike to devise a strategy to manufacture regular and custom shirts at ESC’s Pauquet. He specified that the plan devised by both should ensure that 2,000 custom and 16,000 regular shirts are made. Also, no major capital expenditure can be made to execute the works. BUSINESS PROCESS: Question 1: Sl. No | Parameters | Current Process | Mike's Plan | Ike's Plan | | | | | Regular | Custom | | Workers | 68.00 | 69.00 | 53.00 | 16.00 | | Output | 800.00 | 900.00 | 800.00 | 100.00 | | Time | 480.00 | 480.00 | 480.00 | 480.00 | | Batch Size | 60.00 | 5.00 | 60.00 | 60.00 | a | Actual Cycle Time (min/shirt) | 0.60 | 0.53 | 0.67 | 4.80 | | Bottleneck Time | 0.50 | 0.50 | 0.67 | 3.90 | b | Manufacturing Lead Tim (days) | 14.70 | 2.20 | 12.65 | 0.50 | c | WIP Inventory (shirts) | 11,760.00 | 1,980.00 | 9,060.00 | 50.00 | d | Production Capacity (Shirts/day) | 960.00 | 960.00 | 720.00 | 123.08 | e | Capacity Utilization | 83.33% | 83.33% | 111.11% | 81.25% | f | Direct Labor Content (Min/Shirt) | 26.51 | 26.45 | 26.51 | 26.01 | g | Direct Labor Utilization | 64.98% | 71.89% | 83.36% | 33.87% | h | Directed Labor Cost ($/shirt) | 4.08 | 3.68 | 3.71 | 7.68 | Table 1 Question 2: The entire process can be divided in to 3 parts- Laying & Cutting, Sewing and Inspection, Ironing & Packaging. Keeping the same in mind, we can compare the effectiveness of both processes based on the following parameters: COST EFFICIENCY: From the data given in Table 1 the following result can obtained: Mike’s Method’s Total Labor Cost = (65+4)*8*6 = $3,312 Ike’s Method Regular Shirt Labor Cost = 49*(6*8+ (800-720)*0.67/60) = $2,744 Ike’s Method Custom

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