Current

Man
Power

Units
Minutes
Produced Per Shirt

Time

Time Per
Batch

Prepare Cutting Table

Cutting

4
4

90.00
30.00

480
480

0.1875
0.0625

Make Collar
Make Cuf
Make Sleeves
Make Front
Make Back
Join Shoulder
Attach Collar
Attach Sleeve
Stitch down Sleeve
Sew Side Seam
Attch Cuf
Hem Bottom

8
4
2
6
4
2
4
4
2
4
4
4

3.90
2.00
0.65
2.50
1.70
0.66
1.65
1.55
0.65
1.80
1.55
1.70

8
4
2
6
4
2
4
4
2
4
4
4

0.4875
0.5000
0.3250
0.4167
0.4250
0.3300
0.4125
0.3875
0.3250
0.4500
0.3875
0.4250

29.2500
30.0000
19.5000
25.0000
25.5000
19.8000
24.7500
23.2500
19.5000
27.0000
23.2500
25.5000

Inspect
Iron
Fold & Package

4
4
4

1.50
1.95
1.75

4
4
4

0.3750
0.4875
0.4375
0.5000

22.5000
29.2500
26.2500
30.0000

Process Cap

120 Shirts Per Hour

960 Shirts Per Day
19200 Shirts Per Month

Capacity Ut 0.833333
wip

11760
Direct Labo
30720
Utilization 0.690365

wip*cylc time / total time in

3264
4.08

12.25

Ike Plan
Custom
Labour
Content
minutes /
Shirt

Man
Power

Units
Minutes
Produced Per Shirt

Time

0.7500
0.2500

1
1

2.5

0.5

3.9000
2.0000
0.6500
2.5000
1.7000
0.6600
1.6500
1.5500
0.6500
1.8000
1.5500
1.7000

1
1
1
1
1
1
1
1
1
1
1
1

3.90
2.00
0.65
2.50
1.70
0.66
1.65
1.55
0.65
1.80
1.55
1.70

1
1
1
1
1
1
1
1
1
1
1
1

3.90
2.00
0.65
2.50
1.70
0.66
1.65
1.55
0.65
1.80
1.55
1.70

1.5000
1.9500
1.7500

1
1
1

1.50
1.95
1.75

1
1
1

1.50
1.95
1.75
3.90
26.0100

26.5100
Process Capacity

15.384615 Shirts Per Hour

123.07692 Shirts Per Day
2461.5385 Shirts Per Month

Capacity Uti

21208

ip*cylc time / total time in day

0.8125

Direct Labo
7680
Utilization 0.3386719

2601

Ikea Plan

Mikes Plan

Normal

Man
Power

Units
Minutes
Produced Per Shirt

Time
4
4

90.00
30.00

480
480

0.1875
0.0625

0.75
0.25

7
3
1
5
3
1
3
3
1
3
3
3

3.90
2.00
0.65
2.50
1.70
0.66
1.65
1.55
0.65
1.80
1.55
1.70

0.5571
0.6667
0.6500
0.5000
0.5667
0.6600
0.5500
0.5167
0.6500
0.6000
0.5167
0.5667

3.9000
2.0000
0.6500
2.5000
1.7000
0.6600
1.6500
1.5500
0.6500
1.8000
1.5500
1.7000

3
3
3

1.50
1.95
1.75

7
3
1
5
3
1
3
3
1
3
3
3
0
0
3
3
3

0.5000
0.6500
0.5833
0.6667

1.5000
1.9500
1.7500
0.0000
26.5100

Process Cap

90 Shirts Per Hour

720 Shirts Per Day
14400 Shirts Per Month
Shortfall
1600 Per Month
Overtime 17.777778 Hours
Sho
WIP

Man hours
Per Shirt

9060

Direct Labo
23520
Utilization 0.8115306

19087.2

810
831

818

831

7753.8462
7290

7200
13.33

Prepare Cutting Table

Cutting
Make Collar
Make Cuf
Make Sleeves
Make Front
Make Back
Join Shoulder
Attach Collar
Attach Sleeve
Stitch down Sleeve
Sew Side Seam
Attch Cuf
Hem Bottom
Inspect
Iron
Fold & Package

1
90

30
29.25
30

10

19.5
25
25.5
19.8
24.75
23.25

11

12

13

14

15

16

19.5
27
23.25
25.5
22.5
29.25

17

26.25

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

78

79

80

81

82

83

84

85

86

87

88

89

90

91

92

93

94

95

96

97

98

99 100 101 102 103 104 105 106 107 108 109 110

111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127

128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144

145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161

162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178

179 180

800
0.2500

1920.00

0.5571

861.54

0.6667

720.00

0.6500

738.46 830.77

0.5000

960.00

0.5667

810

727.27 818.18

0.5500

872.73

0.5167

929.03

0.6500

738.46 830.77

0.6000

800.00 900.00

0.5167

929.03

0.5000

0.6500

0.5833

2
1600

3
2400

4
3200

5
4000

6
4800

810
810
810
830
738
738

810
1620
810
830
1568
830

810
2430
810
830
2398
830

810
3240
810
830
3228
830

810
4050
810
830
3966
738

810
4860
810
830
4796
830

738
738

1568
830

2398
830

3228
830

3966
738

4796
830

738
738
818
738
738
872
738
738
929
738
738
830
738
738
900
738
738

1568
830
818
1556
818
1744
1556
818
1858
1556
818
830
1556
818
900
1538
800

2398
830
818
2374
818
2616
2374
818
2787
2374
818
830
2294
738
900
2294
756

3228
830
818
3192
818
3488
3192
818
3716
3192
818
830
3124
830
900
3094
800

3966
738
818
3919
727
4360
3919
727
4645
3919
727
830
3862
738
900
3862
768

4796
830
818
4737
818
5232
4737
818
5574
4737
818
830
4692
830
900
4662
800

738
738

1538
800

2294
756

3094
800

3862
768

4662
800

738
738

1538
800

2294
756

3094
800

3862
768

4662
800

738
738

1538
800

2294
756

3094
800

3862
768

4662
800

738
738
738
738

1476
738
1476
738

2215
738
2215
738

3046
831
3037
822

3784
738
3784
747

4615
831
4606
822

847.06

0.6600

0.5667

1
800

847.06 952.94

960.00

738.46 830.77

822.86 925.71

882

7
5600

8
6400

9
7200

10
8000

11
8800

12
9600

13
10400

14
11200

15
12000

810
5670
810
830
5626
830

810
6480
810
830
6456
830

810
7290
810
830
7194
738

720
8010
720
830
7932
738

810
8820
810
830
8762
830

810
9630
810
830
9592
830

810
10440
810
830
10422
830

810
11250
810
830
11160
738

810
12060
810
830
11990
830

5626
830

6456
830

7194
738

7932
738

8762
830

9592
830

10422
830

11160
738

11990
830

5626
830
818
5555
818
6104
5555
818
6503
5555
818
830
5522
830
900
5462
800

6456
830
818
6373
818
6976
6373
818
7432
6373
818
830
6352
830
900
6262
800

7194
738
818
7191
818
7848
7191
818
8361
7191
818
830
7182
830
900
7062
800

7932
738
818
7918
727
8720
7918
727
9290
7918
727
830
7918
736
900
7862
800

8762
830
818
8736
818
9592
8736
818
10219
8736
818
830
8656
738
900
8656
794

9592
830
818
9554
818
10464
9554
818
11148
9554
818
830
9486
830
900
9456
800

10422
830
818
10372
818
11336
10372
818
12077
10372
818
830
10316
830
900
10256
800

11160
738
818
11099
727
12208
11099
727
13006
11099
727
830
11054
738
900
11054
798

11990
830
818
11917
818
13080
11917
818
13935
11917
818
830
11884
830
900
11854
800

5462
800

6262
800

7062
800

7862
800

8656
794

9456
800

10256
800

11054
798

11854
800

5462
800

6262
800

7062
800

7862
800

8656
794

9456
800

10256
800

11054
798

11854
800

5462
800

6262
800

7062
800

7862
800

8656
794

9456
800

10256
800

11054
798

11854
800

5446
831
5428
822

6184
738
6184
756

7015
831
7006
822

7846
831
7828
822

8584
738
8584
756

9415
831
9406
822

10246
831
10228
822

10984
738
10984
756

11815
831
11806
822

16
12800

17
13600

18
14400

19
15200

20
16000

810
12870
810
830
12820
830

810
13680
810
830
13650
830

810
14490
810
830
14480
830

810
15300
810
830
15218
738

720
16000
700
830
16000
782

12820
830

13650
830

14480
830

15218
738

16000
782

12820
830
818
12735
818
13952
12735
818
14864
12735
818
830
12714
830
900
12654
800

13650
830
818
13553
818
14824
13553
818
15793
13553
818
830
13544
830
900
13454
800

14480
830
818
14371
818
15696
14371
818
16722
14371
818
830
14371
827
900
14254
800

15218
738
818
15189
818
16568
15189
818
17651
15189
818
830
15189
818
900
15154
900

16000
782
818
16000
811
17440
16000
811
18580
16000
811
830
16000
811
900
16000
846

12654
800

13454
800

14254
800

15154
900

16000
846

12654
800

13454
800

14254
800

15101
847

16000
899

12654
800

13454
800

14254
800

15101
847

16000
899

12646
831
12628
822

13384
738
13384
756

14215
831
14206
822

15046
831
15028
822

16000
954
16000
972

18

13

16

13

13
2

76