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Dore Dore Case Study

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    *Q1. * Evaluate the changes Dore-Dore made in its children’s knitwear division. How does the traditional operation & cellular manufacturing system differ? Solution: * {draw:g} CHILDREN KNITWEAR TRA*DITIONAL SETUP (PRODUCT –FOCUSED LAYOUT) {draw:frame} {draw:g} CHILDREN KNITWEAR CELLULAR SETUP (PROCESS- FOCUSED LAYOUT) {draw:frame} {draw:frame} *Q2. What is Dore-Dore’s motivation of converting to cells? Should the company continue with the plan for complete implementation of cells in children knitwear? *If not, which* knitwear products *(if* any) *should be manufactured in cells?

    Solution: The various reasons which motivated Dore – Dore to convert to cells are as follows: The high discrepancy between the actual labour time and average throughput time of various operations. Reduction in average throughput time of an operation by converting to cellular manufacturing system. Example: The average sewing throughput time of a garment dropped from 15 working days to 1 working day by converting sewing department setup from traditional to cellular. Reduction in WIP by converting to cellular manufacturing system.

    Example: The WIP of Sewing department reduced from 720 to 48 by converting from traditional to cellular setup. Increase in value added time. Example: The labour value added time in sewing operation increased by 14 times by converting from traditional to cellular setup. Reduced labour idle time and hence increase in labour utilization Increase in machine utilization. EVALAUTION OF PLAN FOR COMPLETE CONVERSION OF SEWING DEPARTMENT TO CELLS The various operations which different knitwear products undergo are as follows: Sweaters {draw:g} {draw:g} Sweatshirts {draw:g} Dresses

    Skirts {draw:g} {draw:g} Trousers Shorts {draw:g} T-Shirts {draw:g} {draw:rect} Sewing Operations: Features of a Work-Cell An ideal cell manufactures a narrow range of highly similar products. Cellular layouts organize departments around a product or a narrow range of similar products. Once processing begins, they move directly from process to process (or sit in mini-queues). The result is very fast throughput. Communication is easy since every operator is close to the others. This improves quality and coordination. Simplicity is an underlying theme throughout cellular design.

    Considering the above stated features of the cell, the following conversion plan of the Sewing Department can be considered: Shorts and Trousers can be produced together in a common cell as they have the same basic operations. Skirts have the least no. of sewing operations so they can be produced in an individual cell. Sweaters also have simple sewing operations, so they can be produced in an individual cell. Also the Sweatshirt style which has sewing operations similar to sweaters can be produced in the same cell. T-shirts can also be produced in individual cells

    Both Sweatshirts and dresses can have a variety of styles (and high demand, as the demand for fashionable garments is more), so it is better to produce both of these products on the traditional line. {draw:frame} {draw:frame} {draw:frame} {draw:frame} {draw:frame} EVALUATION OF PLAN FOR COMPLETE IMPLEMENTATION OF CELLS IN CHILDREN KNITWEAR: Knitting Department: {text:list-item} {text:list-item} {text:list-item} {draw:g} {draw:g} Cutting Department: {text:list-item} {text:list-item} {text:list-item} {text:list-item} {text:list-item} {text:list-item} {text:list-item} {draw:frame} {draw:frame} {draw:frame} {draw:frame}

    Sewing and Finishing Department: {text:list-item} CONCLUSION: Benefits of complete conversion of the knitwear division to cells: Decrease in WIP, cycle time and hence the inventory holding cost. Reduction in defects and hence quality improvement. Increase in labour efficiency and machine utilization Flexibility to meet varying demands and hence better customer responsiveness. Product flexibility i. e. easier introduction of new and similar product in cells than in traditional line.

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