S.

No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

Operation
Cutting***
Make Collar
Make Cuff
Make Sleeves
Maek Front
Make Back
Join Shoulders
Attach collar
Attach sleeves
Stich down sleeves
Sew Side seam
Attach cuff
Hem Bottom
Inspect
Iron
Fold, Package

Regular Labour
content(minutes/s
hirt)

No of
workers

Capacity

1
3.9
2
0.65
2.5
1.7
0.66
1.65
1.55
0.65
1.8
1.55
1.7
1.5
1.95
1.75
26.51
20

4
8
4
2
6
4
2
4
4
2
4
4
4
4
4
4
64

1920.00
984.62
960.00
1476.92
1152.00
1129.41
1454.55
1163.64
1238.71
1476.92
1066.67
1238.71
1129.41
1280.00
984.62
1097.14

No of labours

64

65

65

Labour cost/hr

$6.00

Working Days in Month

Existing Plan
Ordered qty
Working minutes per Day

16000

Batch Size

480

Required no Of Shirts(per day)

800

Mike's Plan
18000
480

900

No of
worker
5
8
4
2
6
4
2
4
4
2
4
4
4
4
4
4
65

Capacity
2880.00
984.62
960.00
1476.92
1152.00
1129.41
1454.55
1163.64
1238.71
1476.92
1066.67
1238.71
1129.41
1280.00
984.62
1097.14

No of
worker
4
7
3
1
5
3
1
3
3
1
3
3
3
3
3
3
49

No of
workers in Capacity
custom line
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
16
Existing
Method
Mike's
Method

Ike's Plan
16000

2000

800

100

1920.00
861.54
720.00
738.46
960.00
847.06
727.27
872.73
929.03
738.46
800.00
929.03
847.06
960.00
738.46
822.86

*** Regular Labor Content

is Different for all the
Methods. Referencing is
used for that from WIP
Ike's Method Tables presented in the
End.

Actual Cycle Time(Required)

Manufacturing lead time
WIP
Prodn Capacity
Capacity Utilization(in %)
Direct labour content
Direct labour content(ava)
direct lab utilization
Direct Labour Cost
existing plan
WIP
Cutting
Sewing
Inspection
Iron
Packaging

0.60
14.70
11760
960.0
83.33
26.51
38.4
69.04
3.84

0.53
2.2
1980
960.0
93.75
26.45
34.67
76.31
3.47

0.67
12.58
9060
720
111.11
26.51
29.40
90.17
3.43
Batch of 60

4
48
4
4
4

1
48

16
144
12
12
12
196
WIP Inventory
Batch of 5

Mike's Plan
WIP
Cutting
Sewing
Inspection
Iron
Packaging

5
48
4
4
4

2
48
4

IKE's Plan

11760
Cutting
time/batch
2.5

36
288
24
24
24
396
WIP Inventory

Regular

4.80
0.5
50
123
81.25
26.01
76.80
33.87
7.68

Batch of 60

1980

Cutting
time/labour
0.5

WIP
Cutting
Sewing
Inspection
Iron
Packaging

4
36
3
3
3

1
36
3

16
108
9
9
9
151
WIP Inventory

WIP custom
Cutting
Sewing
Inspection
Iron
Packaging

1
12
1
1
1

1
12
1
1
1

Cutting
time/batch
2.5

9060

5
36
3
3
3
50
WIP Inventory

50

Cutting
time/labour
0.625
Cutting
time/batch
2.5

Cutting
time/labour
0.5

Capacity
custom line
960.00
123.08
240.00
738.46
192.00
282.35
727.27
290.91
309.68
738.46
266.67
309.68
282.35
320.00
246.15
274.29

*** Regular Labor Content

is Different for all the
Methods. Referencing is
used for that from WIP
Tables presented in the
End.