Operation Min/Shirt Workers number shirt/worker Total Shirts Type of opertaion

Cutting 1 4 480.00 1920 Cuttting

1 3.9 8 123.08 985 Sewing
2 2 4 240.00 960 Inspection
3 0.65 2 738.46 1477 Ironing
4 2.5 6 192.00 1152 Packaging
5 1.7 4 282.35 1129 Sum
6 0.66 2 727.27 1455
7 1.65 4 290.91 1164
8 1.55 4 309.68 1239
9 0.65 2 738.46 1477
10 1.8 4 266.67 1067
11 1.55 4 309.68 1239
12 1.7 4 282.35 1129
13 1.5 4 320.00 1280
14 1.95 4 246.15 985
15 1.75 4 274.29 1097
Sum 26.51

Bottle Neck Production = 960 shirts

Bottle neck Cycle Time = 0.5 (min/shirt)

Actual Production capacity= 800 shirts

Actual Cycle Time = 0.6 (min/shirt)

WIP Inventory = 11760 Shirt

Manufacturing Lead time = 7056 min

= 14.7 days

Capacity Utilisation = 83.3333 %

Direct Labor content = 26.51 min

Direct labot utilization = 69.04 %

Direct Labor Cost = 3.84 ($/shirt)

N of wokers No of macines Average WIP(60 Shirts)
4 1 16
48 48 144
4 12
4 4 12
4 12
64 196
 Operation Min/Shirt Workers number shirt/worker Total Shirts
Cutting 1 4 480.00 1920 0.94
Cutting 0.5 1 960.00 960
1 3.9 8 123.08 985
2 2 4 240.00 960
3 0.65 2 738.46 1477
4 2.5 6 192.00 1152
5 1.7 4 282.35 1129
6 0.66 2 727.27 1455
7 1.65 4 290.91 1164
8 1.55 4 309.68 1239
9 0.65 2 738.46 1477
10 1.8 4 266.67 1067
11 1.55 4 309.68 1239
12 1.7 4 282.35 1129
13 1.5 4 320.00 1280
14 1.95 4 246.15 985
15 1.75 4 274.29 1097
Sum 26.01

Bottle Neck Production = 960 shirts

Bottle neck Cycle Time = 0.5 (min/shirt)

Actual Production capacity= 900 shirts

Actual Cycle Time = 0.53 (min/shirt)

WIP Inventory = 1980 Shirt

Manufacturing Lead time = 1056 min

= 2.2 days

Capacity Utilisation = 93.7500 %

Direct Labor content = 26.45 min

Direct labot utilization = 75.03 %

Direct Labor Cost = 3.467 ($/shirt)

 Type of opertaion N of wokers No of macines Average WIP(5 Shirts)
Cuttting 5 2 36
Sewing 48 48 288
Inspection 4 24
Ironing 4 4 24
Packaging 4 24
Sum 65 396
Operation Min/Shirt Workers number shirt/worker Total Shirts
Cutting 1 4 480 1920
1 3.9 7 123 862
2 2 3 240 720
3 0.65 1 738 738
4 2.5 5 192 960
5 1.7 3 282 847
6 0.66 1 727 727
7 1.65 3 291 873
8 1.55 3 310 929
9 0.65 1 738 738
10 1.8 3 267 800
11 1.55 3 310 929
12 1.7 3 282 847
13 1.5 3 320 960
14 1.95 3 246 738
15 1.75 3 274 823
Sum 26.51

Bottle Neck Production = 720 shirts

Bottle neck Cycle Time = 0.667 (min/shirt)

Actual Production capacit = 800 shirts

Actual Cycle Time = 0.675 (min/shirt)

WIP Inventory = 9060 Shirt

Manufacturing Lead time = 6115.5 min

= 12.74 days

Capacity Utilisation = 100.0000 %

Direct Labor content = 26.51 min

Direct labot utilization = 80.15 %

Direct Labor Cost = 3.491 ($/shirt)

 Type of opertaion N0 of wokers No of macines Average WIP(5 Shirts)
Cuttting 4 1 16
Sewing 36 36 108
Inspection 3 9
Ironing 3 3 9
Packaging 3 9
Sum 49 151

720 shirts 480 min

800 shirts 533.3333333333 min
OT 54 min
1 hr
Operation Min/Shirt Workers number shirt/worker Total Shirts
Cutting 0.5 1 960 960
1 3.9 1 123 123 Average 3 Shirts Per Work
2 2 1 240 240 WIP
3 0.65 1 738 738
4 2.5 1 192 192
5 1.7 1 282 282
6 0.66 1 727 727
7 1.65 1 291 291
8 1.55 1 310 310
9 0.65 1 738 738
10 1.8 1 267 267
11 1.55 1 310 310
12 1.7 1 282 282
13 1.5 1 320 320
14 1.95 1 246 246
15 1.75 1 274 274
Sum 26.01

Bottle Neck Production = 123 shirts

Bottle neck Cycle Time = 3.9 (min/shirt)

Actual Production capacity = 100 shirts

Actual neck Cycle Time = 4.800 (min/shirt)

WIP Inventory = 50 Shirt

Manufacturing Lead time = 240 min

= 0.50 days

Capacity Utilisation = 81.3008 %

Direct Labor content = 26.01 min

Direct labot utilization = 33.87 %

Direct Labor Cost = 7.680 ($/shirt)

Average 3 Shirts Per Worker+cutting
50