Essay About Executive Shirt Company And B1Make Collar

Executive Shirts Company Case Study
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OPERATIONS MANAGEMENTCASE 1: EXECUTIVE SHIRT COMPANY, INC.GROUP 11Savitra Bhagwat | 1914010Naman Jhamaria | 1914029Debapriya Majumdar | 1914041Atul Mishra | 1914047Anshuman Tiwari | 1914069Executive Shirt Company, Inc. is known for high quality and competitively priced men’s shirts. A recent dip in sales has led general manager Dwight Collier to explore the alternatives. According to him, the market provides tremendous opportunity for Custom-sized dress shirt. He plans to introduce customized shirts in his current production facility as these shirts can fetch almost 75% more than regular standard shirts. For that, Mr. Collier introduced a change in manufacturing process by integrating a ‘low ply’ Laser Cutting Machine for customized shirts.Characteristics of the new machineSmall: can cut only 1 shirt pattern at a time out of up to 5 layers of clothExtremely fast: Laying out pattern and cutting took only 2.5 minutesHigher Scrap rate: material costs 10% higher than for standard sized shirtsNew workers needed to operate the new machinePlanning the Custom Shirt Line: Constraints by Mr. CollierManufacturing lead time for the custom shirts to be less than 5 working daysThe production volume to be same for standard-sized shirts at 16000 per monthAllow for production of 2000 custom shirts per monthLarge capital expenditures not to be madeCompany’s Current batch processing mechanismThe firm is manufacturing the standard-sized shirts using a batch process. Since few basic styles and colors contribute to a major portion of the sales, the firm has limited variety to produce. Hence, it has large batches of each kind of shirt (size and color).The firm has five departments, as follows: (Table 1)Type of OperationNumber of WorkersNumber of MachinesAverage WIP (number of 60 shirt-batches)Cutting4116Sewing4848144Inspection412Ironing4412Packaging412Total6453196It has one computer controlled cutting machine that can cut up to 60 layers of cloth (up to 8 patterns) at the same time. This process takes 30 minutes irrespective of the number of layers and pattern. Setup time is 1.5 minutes for each layer and 60 layers take total 90 minutes. The machine is operated by 4 workers, and is fully utilized.Number of shirts cut at a time = 60×8 = 480 ShirtsTotal time = setup time + runtime = 90 + 30 = 120 minutesStandard shirt cutting time = 120/480 = 0.25 minutes/shirtNumber of workers = 4(Table 2)S.No.OperationRegular Shirts Labor Content (minutes/Shirt)Number of WorkersTime taken per shirtTime taken per batchACutting                                                                                     0.25 4                                 0.06           3.75 B1Make Collar                                                                                     3.90 8                                 0.49         29.25 B2Make Cuffs                                                                                     2.00 4                                 0.50         30.00 B3Make Sleeves                                                                                     0.65 2                                 0.33         19.50 B4Make Front                                                                                     2.50 6                                 0.42         25.00 B5Make Back                                                                                     1.70 4                                 0.43         25.50 B6Join Shoulders                                                                                     0.66 2                                 0.33         19.80 B7Attach Collar                                                                                     1.65 4                                 0.41         24.75 B8Attach Sleeves                                                                                     1.55 4                                 0.39         23.25 B9Stitch down sleeves                                                                                     0.65 2                                 0.33         19.50 B10Sew side seam                                                                                     1.80 4                                 0.45         27.00 B11Attach cuffs                                                                                     1.55 4                                 0.39         23.25 B12Hem Bottom                                                                                     1.70 4                                 0.43         25.50 B13Inspect                                                                                     1.50 4                                 0.38         22.50 B14Iron                                                                                     1.95 4                                 0.49         29.25 B15Fold, Package                                                                                     1.75 4                                 0.44         26.25 Total                                                                               25.76 64                                 6.23      374.05