Stonehaven Case Analysis

Cutting Department
Setup Time (Min.)
Run Time/Piece (Min.)

Batch
Size
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95

6.85
0.06

6.75
0.07

5.25
0.08

Machine 1
Cycle Time
Operating at
Capacity
(Min/batch)
28.60
29.80
31.00
32.20
33.40
34.60
35.80
37.00
38.20
39.40
40.60
41.80
43.00
44.20
45.40
46.60
47.80
49.00
50.20

Machine 2
Cycle Time
Operating at
Capacity
(Min/batch)
28.40
29.80
31.20
32.60
34.00
35.40
36.80
38.20
39.60
41.00
42.40
43.80
45.20
46.60
48.00
49.40
50.80
52.20
53.60

Machine 3
Cycle Time
Operating at
Capacity
(Min/batch)
22.60
24.20
25.80
27.40
29.00
30.60
32.20
33.80
35.40
37.00
38.60
40.20
41.80
43.40
45.00
46.60
48.20
49.80
51.40

Cutting Dept.
Cycle Time
Operating at Cutting Dept. Cutting Dept.
Capacity
Capacity
Capacity
(Min/batch) (Batches/day) (Pairs/day)
28.60
16.78
83.92
29.80
16.11
161.07
31.20
15.38
230.77
32.60
14.72
294.48
34.00
14.12
352.94
35.40
13.56
406.78
36.80
13.04
456.52
38.20
12.57
502.62
39.60
12.12
545.45
41.00
11.71
585.37
42.40
11.32
622.64
43.80
10.96
657.53
45.20
10.62
690.27
46.60
10.30
721.03
48.00
10.00
750.00
49.40
9.72
777.33
50.80
9.45
803.15
52.20
9.20
827.59
53.60
8.96
850.75

100

51.40

55.00

53.00

55.00

8.73

872.73

Kitting Department
Run Time/Pair (Min.)

Stitching Department
Number of Workers
Run Time/Pair (Min.)

0.10
Kitting
Cycle Time
Operating at
Kitting
Capacity
Capacity
(Min/batch) (Batches/day)
0.50
960.00
1.00
480.00
1.50
320.00
2.00
240.00
2.50
192.00
3.00
160.00
3.50
137.14
4.00
120.00
4.50
106.67
5.00
96.00
5.50
87.27
6.00
80.00
6.50
73.85
7.00
68.57
7.50
64.00
8.00
60.00
8.50
56.47
9.00
53.33
9.50
50.53

Kitting
Capacity
(Pairs/day)
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00
4,800.00

4
3.80

6
4.20

7
5.30

Prefit
Joining
Ornamenting
Cycle Time Cycle Time Cycle Time
Operating at Operating at Operating at
Capacity
Capacity
Capacity
(Min/batch) (Min/batch) (Min/batch)
4.75
3.50
3.79
9.50
7.00
7.57
14.25
10.50
11.36
19.00
14.00
15.14
23.75
17.50
18.93
28.50
21.00
22.71
33.25
24.50
26.50
38.00
28.00
30.29
42.75
31.50
34.07
47.50
35.00
37.86
52.25
38.50
41.64
57.00
42.00
45.43
61.75
45.50
49.21
66.50
49.00
53.00
71.25
52.50
56.79
76.00
56.00
60.57
80.75
59.50
64.36
85.50
63.00
68.14
90.25
66.50
71.93

10.00

48.00

4,800.00

95.00

70.00

75.71

Lasting Department
Run Time/Pair (Min.)
Stitching Dept.
Cycle Time
Operating at Stitching Dept. Stitching Dept.
Capacity
Capacity
Capacity
(Min/batch) (Batches/day)
(Pairs/day)
4.75
101.05
505.26
9.50
50.53
505.26
14.25
33.68
505.26
19.00
25.26
505.26
23.75
20.21
505.26
28.50
16.84
505.26
33.25
14.44
505.26
38.00
12.63
505.26
42.75
11.23
505.26
47.50
10.11
505.26
52.25
9.19
505.26
57.00
8.42
505.26
61.75
7.77
505.26
66.50
7.22
505.26
71.25
6.74
505.26
76.00
6.32
505.26
80.75
5.94
505.26
85.50
5.61
505.26
90.25
5.32
505.26

Station 1
0.90

Station 2
0.65

Lasting Dept.
Cycle Time
Operating at Lasting Dept.
Capacity
Capacity
(Min/batch) (Batches/day)
8.28
57.97
12.88
37.27
17.48
27.46
22.08
21.74
26.68
17.99
31.28
15.35
35.88
13.38
40.48
11.86
45.08
10.65
49.68
9.66
54.28
8.84
58.88
8.15
63.48
7.56
68.08
7.05
72.68
6.60
77.28
6.21
81.88
5.86
86.48
5.55
91.08
5.27

Station 3
0.75

Lasting Dept.
Capacity
(Pairs/day)
289.86
372.67
411.90
434.78
449.78
460.36
468.23
474.31
479.15
483.09
486.37
489.13
491.49
493.54
495.32
496.89
498.29
499.54
500.66

Station 4
0.92

95.00

5.05

505.26

95.68

5.02

501.67

Average WIP Calculations

Station 5
0.85
Assumes all WIP leaves the department when the process is done
Factory
Cycle Time
Operating at
Factory
Factory
Capacity
Capacity
Capacity
(Min/batch) (Batches/day) (pairs/day)
28.60
16.78
83.92
29.80
16.11
161.07
31.20
15.38
230.77
32.60
14.72
294.48
34.00
14.12
352.94
35.40
13.56
406.78
36.80
13.04
456.52
40.48
11.86
474.31
45.08
10.65
479.15
49.68
9.66
483.09
54.28
8.84
486.37
58.88
8.15
489.13
63.48
7.56
491.49
68.08
7.05
493.54
72.68
6.60
495.32
77.28
6.21
496.89
81.88
5.86
498.29
86.48
5.55
499.54
91.08
5.27
500.66

Average
Cutting
Dept. WIP
(Batches)
1.00
1.00
1.00
1.00
1.00
1.00
1.00
0.94
0.88
0.83
0.78
0.74
0.71
0.68
0.66
0.64
0.62
0.60
0.59

Average
Kitting
Dept. WIP
(Batches)
0.02
0.03
0.05
0.06
0.07
0.08
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10
0.10

Average
Stitching
Dept. WIP
(Batches)
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00
34.00

Average
Steaming
Dept. WIP
(Batches)
12.59
12.08
11.54
11.04
10.59
10.17
9.78
8.89
7.99
7.25
6.63
6.11
5.67
5.29
4.95
4.66
4.40
4.16
3.95

Average
Lasting
Dept. WIP
(Batches)
0.29
0.43
0.56
0.68
0.78
0.88
0.98
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00

95.68

5.02

501.67

0.57

0.10

34.00

3.76

1.00

Total
Average
WIP in all
Departments
(Batches)
47.89
47.55
47.15
46.78
46.45
46.14
45.85
44.94
43.96
43.17
42.51
41.96
41.49
41.08
40.72
40.40
40.12
39.87
39.65

Total
Average
WIP
Average Raw
Average
Between
Material
Finished Goods
Departments Inventory
Inventory
(Batches)
(Batches)
(Batches)
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00
18.00
20.00
8.00

Average
Batch
Throughput Time
1,884.58
1,953.28
2,032.58
2,111.88
2,191.18
2,270.48
2,349.78
2,547.64
2,793.34
3,039.04
3,284.74
3,530.44
3,776.14
4,021.84
4,267.54
4,513.24
4,758.94
5,004.64
5,250.34

39.44

18.00

20.00

8.00

5,496.04