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    Executive Shirts - HBS

    Uploaded by

    Deepika Chainani
    This document compares three different plans - the existing plan, Mike's plan, and Ike's plan - for manufacturing shirts in a garment factory. It provides details on the operations required, labor times, number of workers, production capacity, work-in-progress inventory, labor costs, and other key metrics for each plan. Ike's plan requires the fewest number of workers, has the highest production capacity, and results in the lowest work-in-progress inventory levels of the three options.

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    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd

    Executive Shirts - HBS

    Uploaded by

    Deepika Chainani
    46 views4 pages
    This document compares three different plans - the existing plan, Mike's plan, and Ike's plan - for manufacturing shirts in a garment factory. It provides details on the operations required, labor times, number of workers, production capacity, work-in-progress inventory, labor costs, and other key metrics for each plan. Ike's plan requires the fewest number of workers, has the highest production capacity, and results in the lowest work-in-progress inventory levels of the three options.

    Original Description:

    Executive Shirts - HBS Case Study

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    © © All Rights Reserved

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    This document compares three different plans - the existing plan, Mike's plan, and Ike's plan - for manufacturing shirts in a garment factory. It provides details on the operations required, labor times, number of workers, production capacity, work-in-progress inventory, labor costs, and other key metrics for each plan. Ike's plan requires the fewest number of workers, has the highest production capacity, and results in the lowest work-in-progress inventory levels of the three options.

    Copyright:

    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd
    Download as xlsx, pdf, or txt
    46 views4 pages

    Executive Shirts - HBS

    Uploaded by

    Deepika Chainani
    This document compares three different plans - the existing plan, Mike's plan, and Ike's plan - for manufacturing shirts in a garment factory. It provides details on the operations required, labor times, number of workers, production capacity, work-in-progress inventory, labor costs, and other key metrics for each plan. Ike's plan requires the fewest number of workers, has the highest production capacity, and results in the lowest work-in-progress inventory levels of the three options.

    Copyright:

    © All Rights Reserved
    Download as XLSX, PDF, TXT or read online from Scribd
    Download as xlsx, pdf, or txt
    of 4

    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.

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