Executive Shirt Case Questions

Current Process

a$.$ Draw the process flow diagram for the current production process.

b$.$ What is the current flow rate of shirts at Executive Shirt $[$per hour, per day$]?$

c$.$ What is the average amount of WIP in the shirt production process?

d$.$ What is the current production time for each shirt $($hours$,$ days of work, weeks of

work$)?$

e$.$ What is the daily capacity of the production process?

f$.$ What is the bottleneck?

g$.$ What is the current level of utilization?

Mike's Plan

a$.$ Draw the process flow diagram for Mike's revision to the production process to

include customer shirts.

b$.$ What is the desired flow rate of shirts to meet Collier's criterion $($per hour, per day$]?$

c$.$ Is this possible with the sewing operation?

d$.$ What is the new WIP associated with Mike's plan?

e$.$ Assume capacity is sufficient to meet Collier's flow rate. What is the production

time for each shirt in Mike's plan? Does this meet Collier's requirements?

f$.$ What is the capacity?

g$.$ What is the associated utilization?

Ike's Plan

a$.$ Draw the process flow diagram for lke's revision to the production process.

b$.$ What is the capacity of the production process for standard shirts given Ike's staffing

changes? How can we still produce $800$ shirts per day on the regular production line

with this plan?

c$.$ What is the WIP on the regular production line? What is the associated lead time for

a standard shirt?

d$.$ What is the capacity of the custom shirt line? What is the bottleneck?

e$.$ How can we compare Mike's and Ike's plans given these results?