Stoneheaven

1. Cutting

During cutting process 3 machines are working on 4 diff. pieces each parallelly

And next batch is taken in only after the first one goes out. So the slowest of the three machines will give the capacity of the department. All the time shown is in minutes & x is size of batch (Given 100). Therefore:

Cutting

Operation Set Up Time / Per die change Run Time / piece Total time per Batch

(5.25 *4+.05*100*x) Capacity/hr. (Batch)

60/max. time reqd. in the deptt.

M/c 1 5.25 0.05 41 1.46

M/c 2 5 0.05 40

M/c 3 4 0.04 32

2. Kitting

Here kits are being manufactured out of pieces from cutting process & diff materials reqd. for assy.

Kitting

Operation Run time / batch Capacity/hr. (Batch)

=60/Run time per batch

Kit making 10 6.00

3. Stitching

In the stitching process every worker is working on one full kit (which is our batch). Since the no. of workers are more than one so it is a parallel line & the capacities of each process can be summed up. After that the least capacity process will be the bottleneck of the dept. & hence the capacity of the process.

Stitching

Operation No. of workers Run time / pair Total time per Batch per worker Individual Capacity/hr. (Batch)

=60*no. of workers/total time per batch per worker Capacity of stitching/ hr. (Batches)

Prefit 4 5 500 0.48 0.48

Join 3 3 300 0.60

Ornament 2 2.5 250 0.48

4. Steaming

Here the shoe uppers are steamed. Since it is mentioned that the oven capacity is not a bottleneck so we are assuming that the capacity is more than whatever is slowest capacity of the sytem.

Steaming

Operation Run time Total time per Batch Capacity of stitching/ hr. (Batches)

Steaming in an oven 360 360 Excess Capacity so not a bottleneck

5. Lasting

Here the process breaks from batch to sequential Production & hence the total capacity of the line will be the because of the slowest process in the deptt.

Lasting

Operation Run Time / pair Total time per Batch Capacity/hr. (Batch)

=60/Max. total time per batch

St.1 -Staple Insole 0.7 70 0.60

St.2 - Toe & heel Seat Lasts 0.6 60

St. 3- Rough Sole Pound 1 100

St. 4- Cement Sole, Pull Last 0.9 90

St.5- Inspect, Pack 0.3 30

a) Factory's Daily Capacity:

From the above tables we choose the lowest capacity across the system which is going to be the capacity of the plant.

So we see the bottleneck process is stitching with a