Dore-Dore Q&a
Dore-Dore (Q&A)
1. What is Dore-Dore’s motivation to converting to cells? Should the company continue with its plans for complete implementation of cells in children knit wear? If not, which knitwear products are best made in cells?
Here are the main advantages found converting to cell. * Reducing the throughput time was the main motivation for converting to cells. For Dore-Dore, 3 weeks to 1 day * Defect fixing was local, reducing the cost of defect fixing a lot. In Dore-Dore case, the defect rate was down from 5% to 2.5% * Cell workers tend to help out each other more in cell concept. The members in a cell seemed to work closely and as a team. Members who go out for leaves were really anxious to come back.
Cell concept is more suited to decreasing batch sizes. With this, cell would be good for most areas of knitwear garments. Dore-Dore should plan for complete implementation of cell concept for all knitwear products.
2. Should they implement cells in hosiery production area?
In traditional operation, the total throughput time is 6 weeks, for a 5 day week, that is 30 days
WIP = 30 * 37000 = 11,10,000 pairs
We need to reduce the throughput time to 1 days. Suppose we are going to go for the Enfert’s cell proposal.
In Enfert’s proposal, for TOE CLOSING: he has suggested to use 7 workers per cell. For 7 workers, 1. TOE CLOSING:
Capacity per cell = 7 * 480 = 3360 pairs per cell 2. IRONING:
Labor = 15 sec per pair = 15/60 min per pair
Capacity = 12 * 480 / (15/60) = 23040 which is less than 37000 pairs. We would need multiple cells with more Ironing equipment to achieve the 37000 output
With cell based concept, the equipment costs would be much higher 3. QUALITY CONTROL / PACKING
1-4 min labor content/pair
Batch throughput = 2-3 weeks assume 2.5
Assume labor = 2 min
Enfert’s cell proposal has 6 workers per cell
Capacity = 6 * 480 /2 = 1440
For 37000 pairs, no of cells needed = 26 cells
By implementing cell
1. What is Dore-Dore’s motivation to converting to cells? Should the company continue with its plans for complete implementation of cells in children knit wear? If not, which knitwear products are best made in cells?
Here are the main advantages found converting to cell. * Reducing the throughput time was the main motivation for converting to cells. For Dore-Dore, 3 weeks to 1 day * Defect fixing was local, reducing the cost of defect fixing a lot. In Dore-Dore case, the defect rate was down from 5% to 2.5% * Cell workers tend to help out each other more in cell concept. The members in a cell seemed to work closely and as a team. Members who go out for leaves were really anxious to come back.
Cell concept is more suited to decreasing batch sizes. With this, cell would be good for most areas of knitwear garments. Dore-Dore should plan for complete implementation of cell concept for all knitwear products.
2. Should they implement cells in hosiery production area?
In traditional operation, the total throughput time is 6 weeks, for a 5 day week, that is 30 days
WIP = 30 * 37000 = 11,10,000 pairs
We need to reduce the throughput time to 1 days. Suppose we are going to go for the Enfert’s cell proposal.
In Enfert’s proposal, for TOE CLOSING: he has suggested to use 7 workers per cell. For 7 workers, 1. TOE CLOSING:
Capacity per cell = 7 * 480 = 3360 pairs per cell 2. IRONING:
Labor = 15 sec per pair = 15/60 min per pair
Capacity = 12 * 480 / (15/60) = 23040 which is less than 37000 pairs. We would need multiple cells with more Ironing equipment to achieve the 37000 output
With cell based concept, the equipment costs would be much higher 3. QUALITY CONTROL / PACKING
1-4 min labor content/pair
Batch throughput = 2-3 weeks assume 2.5
Assume labor = 2 min
Enfert’s cell proposal has 6 workers per cell
Capacity = 6 * 480 /2 = 1440
For 37000 pairs, no of cells needed = 26 cells
By implementing cell