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    Capacity Planning and Scheduling: Name - Abhinav Singh DFT 5

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    Monaal Singh
    Abhinav Singh was tasked with capacity planning and scheduling for 5 production orders (styles 1A through 5E). The document provides production cycle times, a calendar, and daily reports of cutting, sewing, and finishing output. Abhinav was to assign completion dates, record actual output, calculate utilization rates, and analyze any issues. Their analysis found average utilization rates were low across processes. Several orders were not completed by deadlines, and some days had no production. Errors in documentation were also observed.

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    Capacity Planning and Scheduling: Name - Abhinav Singh DFT 5

    Uploaded by

    Monaal Singh
    154 views5 pages
    Abhinav Singh was tasked with capacity planning and scheduling for 5 production orders (styles 1A through 5E). The document provides production cycle times, a calendar, and daily reports of cutting, sewing, and finishing output. Abhinav was to assign completion dates, record actual output, calculate utilization rates, and analyze any issues. Their analysis found average utilization rates were low across processes. Several orders were not completed by deadlines, and some days had no production. Errors in documentation were also observed.

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    03 ABHINAV

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    Abhinav Singh was tasked with capacity planning and scheduling for 5 production orders (styles 1A through 5E). The document provides production cycle times, a calendar, and daily reports of cutting, sewing, and finishing output. Abhinav was to assign completion dates, record actual output, calculate utilization rates, and analyze any issues. Their analysis found average utilization rates were low across processes. Several orders were not completed by deadlines, and some days had no production. Errors in documentation were also observed.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    154 views5 pages

    Capacity Planning and Scheduling: Name - Abhinav Singh DFT 5

    Uploaded by

    Monaal Singh
    Abhinav Singh was tasked with capacity planning and scheduling for 5 production orders (styles 1A through 5E). The document provides production cycle times, a calendar, and daily reports of cutting, sewing, and finishing output. Abhinav was to assign completion dates, record actual output, calculate utilization rates, and analyze any issues. Their analysis found average utilization rates were low across processes. Several orders were not completed by deadlines, and some days had no production. Errors in documentation were also observed.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
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    of 5

    NAME - ABHINAV SINGH

    DFT 5

    Capacity Planning and Scheduling


    On the ‘Production Order Control Record’ you will find the entry of five cutting orders,
    mentioned as style 1A, 2B….5E, where order quantity and delivery date for each style is
    mentioned. For example order quantity and delivery for style 1A is 2600 pieces and 26th
    October respectively. You have to calculate the deliverables based on the following
    parameters.

    ● Production Cycle Times


    Complete cutting 4 days after cut issue
    Complete sewing 9 days after complete cutting
    Complete finishing 4 days after complete sewing

    ● Calendar

    ● Garments received into warehouse are considered ready for delivery.


    ● Working days are from Monday to Friday.

    Assignment Output (Deliverables)


    1. Assign the planned completion date for the following steps for each order:
    a. Complete cutting
    b. Complete sewing
    c. Complete finishing - into warehouse.

    2. Each day the Planning department receives information on the garments completed in three
    main departments; cutting sewing & finishing. An extract of ‘actual’ daily
    Cutting / Sewing / Finishing reports for 5 styles are enclosed. Based on daily reports:
    a. Enter the information on the 'Production Order Control Record'.
    b. If the daily capacity of cutting/sewing/finishing is 3000 garments per day, then what
    is average utilization of cutting, sewing and finishing capacity during above period?
    c. Write down your observations regarding problems in the factory.

    Daily Cutting report

    Daily Sewing report

    Daily Finishing Report


    PRODUCTION ORDER CONTROL RECORD
    Quantity Complete Cutting Complete Sewing Complete Finishing Ready for
    Style Date costumer
    Plan Actual Plan Actual Plan Actual
    No. Issued Cut Issued Delivery
    Date Qty. Date Date Qty. Date Date Qty. Date
    1A 2600 2600 1.10 1-10 400 3-10 5-10 960 18-10 18-10 800 24-10 26-10
    To To To
    4-10 800 4-10 17-10 1600 19-10 23-10 1760 26-10
    1400 5-10 40 22-10 40 29-10
    2560
    2B 800 790 2.10 2-10 290 4-10 8-10 790 17-10 19-10 160 23-10 25-10
    To To To 20 24-10
    5-10 600 5-10 18-10 24-10 600 25-10
    780
    3C 2600 2740 2.10 2-10 940 8-10 8-10 2000 24-10 19-10 1500 30-10 26-10
    To 1100 10-10 To 720 26-10 To 1000 31-10
    5-10 700 11-10 18-10 24-10 150 1-11 0
    4D 3000 2980 3.10 3-10 480 9-10 9-10 1900 22-10 22-10 2400 1-11 26-10
    To To 600 25-10 To
    8-10 2500 10-10 19-10 490 29-10 25-10 480 2-11
    0
    5E 2200 2150 4.10 4-10 1150 8-10 10-10 1000 22-10 23-10 1900 5-11 10-11
    To To 500 23-10 To 150 7-11
    9-10 1000 10-10 22-10 650 24-10 26-10 100 9-11
    2150

    *starting the work from issued date only.

    UTILIZATION:

    Cutting:
    Date Garments cut(x) Utilization{(x/3000)x100}
    2-Oct 0 0%
    3-Oct 400 13.33%
    4-Oct 1090 36.33%
    5-Oct 2000 66.67%
    8-Oct 2090 69.67%
    9-Oct 480 16%
    10-Oct 4600 153.33%
    11-Oct 700 23.33%
    Average Utilization=47.33%
    Sewing
    Date Garments Sewed(x) Utilization{(x/3000)x100}
    17-Oct 790 26.33%
    18-Oct 960 32%
    19-Oct 1600 53.33%
    22-Oct 2940 98%
    23-Oct 500 16.67%
    24-Oct 2650 88.33%
    25-Oct 600 20%
    26-Oct 720 24%
    29-Oct 490 16.33%
    Average Utilization=41.67%

    Finishing
    Date Garments finished(x) Utilization{(x/3000)x100}
    23-Oct 160 5.33%
    24-Oct 820 27.33%
    25-Oct 600 20%
    26-Oct 1760 58.67%
    29-Oct 40 1.33%
    30-Oct 1500 50%
    31-Oct 1000 33.33%
    1-Nov 2550 85%
    2-Nov 480 16%
    5-Nov 1900 63.33%
    6-Nov 0 0%
    7-Nov 150 5%
    8-Nov 0 0%
    9-Nov 100 3.33%
    Average Utilization=26.33%

    Observations:

    ● For garment 1A factory was unable to complete the goal of manufacturing 2600
    issued quantity of garments and was able to manufacture 2560 number of garments
    (40 less than the required) till the day of delivery, but these numbers of garments can
    be delivered to the costumer and rest 40 can be delivered later.
    ● Similarly factory made 20 garments less of kind 2B and 50 garments less of kind 5E
    and manufactured garments can be delivered to the customer and remaining can be
    delivered later.
    ● Factory was unable to finish any garment of type 3C and 4D till the day of delivery, in
    this situation customer can be requested to extend the time for delivery.
    ● Factory was not even close to their planned dates and days like 2nd October, 6th
    November & 8th November were totally wasted as there was no production in those
    days and hence utilization was also 0 on those days.
    ● For garment type 1A factory cut 100 garments more than the issued number, this
    could be due to human error or communication error or due to any other cause.
    ● Average utilization was very less for all the processes and was way less for finishing.
    ● Utilization in all these processes on various days varied with high ratios (e.g.: In
    cutting, one day it was 69.67% and the other day it was 13.33%. The reason for it
    could be absenteeism or any other reason.
    ● Utilization in the cutting process on 10th October was 153.33%, which is not possible
    and this could be due to error in documentation or anything else.

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