Cutting

Assumptions
Die Change time
Batch Size
Number of components
components / machine
Run in Parallel
WIP

4
100
1200
400
1

Cut Shoe Leather

Die Change time
Stamp time
Process Time (minutes)
Idle Time

11.25
0.1
85
0

Cut Linings
Die Change time
Stamp time
Process Time (minutes)
Idle Time

9
0.08
68
17

Cut Insoles
Die Change time
Stamp time
Process Time (minutes)
Idle Time

8
0.06
56
29

Capacity (batches)
Capacity (pairs)
Cycle time (minutes)
Lead time

5.65
564.71
85
85

Cutting Process time

85
WIP

Whole System
Total WIP
LT = CT X WIP
In Hours

40.64
8940
149

In Days

6.21

Solve for an optimum batch size

Cutting is limited by Stitching
4(11.25 + 0.1x) = 2.2x

minimum batch size that affects cutting capacity but does n

Kitting
Assumptions
20 minutes for 100 kits
WIP

Kitting Process time

20
WIP

System capacity is limited by the cycle time of stitching. Every department cannot run at
It would be physically impossible for the product to flow at different (average) rates.

atch size that affects cutting capacity but does not affect the whole system

Stitching
Assumptions
Prefit Workers
Join Workers
Ornament Workers
Run In parallel
WIP

4
3
2
18

Prefit
Run Time / Pair
Pair/Worker
Process Time

8.8
2.2
220

Join
Run Time / Pair
Pair/Worker
Process Time
Idle time

6
2
200

Ornament
Run Time / Pair
Pair/Worker
Process Time
Idle Time

5.3
2.65
265

Capacity (batches)
Capacity (pairs)
Cycle time (minutes)
Lead time

2.18
218.18
220
3960

Stitching Process Time

220
WIP

me of stitching. Every department cannot run at their maxium speed. We must look at the system a
product to flow at different (average) rates.

affect the whole system

Steaming
Assumptions
Enough Space for all
WIP

1.64

Steaming Time

360
WIP

eir maxium speed. We must look at the system as a whole

Lasting
Assumptions
Run in Succession
WIP

1) Staple Insoles
2) Toe and heel seat lasts
3)Rough sole, pound
4) Cement sole, pull last
5) Inspect, pack

1.2
1
1.5
1.3
0.7

30

Capacity (batches)
Capacity (pairs)
Cycle time (minutes)
Lead time

Throughput Time

4.53
452.83
1.5
106

Cutting
Assumptions
Die Change time
Batch Size
Number of components
components / machine
Run in Parallel
WIP
Machine Number

4
25
300
100
1
3

Cut Shoe Leather

Die Change time
Stamp time
Process Time (minutes)
Idle Time

11.25
0.1
55
0

Cut Linings
Die Change time
Stamp time
Process Time (minutes)
Idle Time

9
0.08
44
11

Cut Insoles
Die Change time
Stamp time
Process Time (minutes)
Idle Time

8
0.06
38
17

Capacity (batches)
Capacity (pairs)
Cycle time (minutes)
Lead time

8.73
218.18
55
55

Cutting Process time

55
WIP

Whole System
Total WIP
LT = CT X WIP
In Hours

40.64
2235
37.25

In Days

1.55

Solve for an optimum batch size

Cutting is limited by Stitching
4(11.25 + 0.1x) = 2.2x
x = 25

minimum batch size that affects cutting capacity but does n

Kitting
Assumptions
20 minutes for 100 kits
WIP

Kitting Process time

20
WIP

System capacity is limited by the cycle time of stitching. Every department cannot run at
It would be physically impossible for the product to flow at different (average) rates.

atch size that affects cutting capacity but does not affect the whole system

Stitching
Assumptions
Prefit Workers
Join Workers
Ornament Workers
Run In parallel
WIP

4
3
2
18

Prefit
Run Time / Pair
Pair/Worker
Process Time

8.8
2.2
55

Join
Run Time / Pair
Pair/Worker
Process Time
Idle time

6
2
50

Ornament
Run Time / Pair
Pair/Worker
Process Time
Idle Time

4.2
2.1
52.5

Capacity (batches)
Capacity (pairs)
Cycle time (minutes)
Lead time

8.73
218.18
55
990

Stitching Process Time

55
WIP

me of stitching. Every department cannot run at their maxium speed. We must look at the system a
product to flow at different (average) rates.

affect the whole system

Steaming
Assumptions
Enough Space for all
WIP

1.64

Steaming Time

360
WIP

eir maxium speed. We must look at the system as a whole

Lasting
Assumptions
Run in Succession
WIP

1) Staple Insoles
2) Toe and heel seat lasts
3)Rough sole, pound
4) Cement sole, pull last
5) Inspect, pack

Capacity (batches)
Capacity (pairs)
Cycle time (minutes)
Lead time

Throughput Time

1.2
1
1.5
1.3
0.7

16.55
413.79
1.5
29 lead time = (n+6)

n= batch