Executive Shirt Case Questions
1. 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?
2. 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?
3. Ike’s Plan
a. Draw the process flow diagram for Ike’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?