The year 2020 was tough for everyone – who knew that we would all be wearing masks? – and 2021 wasn’t much better. Due to this unforeseen shortage of masks, Adam and Nandasri decided to get in on the action. They enlisted the help of a number of their classmates to produce masks. The initial batch size is 36 units; the demand rate is 45 units/hr.

Their process has six steps:

Step 1: Sameer sets up the initial cloth pattern for the mask. Laying out the pattern (setup) takes 7 minutes per batch of masks. Cutting each mask takes 44 seconds.

Step 2: The masks are custom embroidered at an embroidery machine. The machine requires a 12-minute setup per batch followed by 90 seconds mask. There are two (2) embroidery machines that can be used in parallel, and each machine has an operator – Bailey and Ishita.

Step 3: The masks go through one of three sewing machines working in parallel to attach the elastic ear bands. This step requires 90 seconds per mask.

Step 4: A second piece of fabric is attached at the next station which requires 2 minutes of setup per batch followed by 58 seconds per mask.

Step 5: Anthony inserts a HEPA filter in the pocket formed by the two pieces of cloth. This requires 48 seconds per mask.

Step 6: The masks are individually bagged by either Dev or Sophia working in parallel. This step takes 60 seconds per mask.

Part 1: For each step calculate the Activity Time (min).

Part 2: For each step calculate the Capacity (units/min).

Part 3: For each step calculate the Capacity (units/hr).

Part 4: For each step calculate the Utilization.

Part 5: Identify whether there is a supply or demand constrain.