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lean operations, Supply Chain Management

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Kateville Textile Printing Company Ltd
Introduction
Kateville Textile Printing Company Ltd. design company which produces design fashion products and distribute to all branches of Stockwell Supermarket Chain Stores Ltd. The company’s currently functional layout in the shop floor has some operational problems which forced production to use large batch quantities due to the high set up times resulting in high build up in-process stock.
The company is looking to improve their competitiveness through the implementation of lean concepts to improve the manufacture of well designed men’s and women’s wears as well as children’s wear for an overseas market.
Customer Report:
Customer requirement: One daily shipment of 600 units to Stockwell Supermarket Chain Stores Ltd. The buyer, Kateville Textile Printing Company Ltd places weekly orders to Gennie Fabrics Ltd., the supplier by fax for 1,200units inventory to be supplied direct to production site.

Production Control Department:
I. Receives Stockwell Supermarket Chain Stores Ltd. 800 daily forecast and enter them into the MRP system
II. Issue weekly orders to supplier, Kay Fabrics
III. Secure 1,500 unit raw materials delivery by weekly fax order release
IV. Generate weekly department MRP requirement based upon customer order, WIP, F/G inventory levels and anticipate scrap and down tme.
V. WIP between cutting and screen print = 600units
VI. WIP between screen print and sewing = 1,600units
VII. Finished Goods Inventory = 2,500units
VIII. Manual daily directives from Production Supervisor

Based on the week forecasts, production department releases daily manual information through the Factory Supervisor to the shop floor.
Additional Information:
• Movement of production materials through the process is by push system
• Supplier delivery takes 3 days and hold ups between cutting and screen print takes 2 days.
• Queuing between screen print and sewing takes 2 days whilst finish goods remain at the warehouse five days before shipment to Kateville Textile Printing Company Ltd.

Process Information
A. Cuttings
i. 5 operators
ii. Cycle time = 4mins
iii. Changeover time = 65mins
iv. Uptime = 85%
v. 2 Shifts


B. Screen Print
i. 3 operators
ii. Cycle time = 14mins
iii. Changeover = 65mins
iv. Uptime= 80%
v. 3 Shifts

C. Sewing
i. 15 operators
ii. Cycle time= 18mins
iii. Changeover = 35mins
iv. Uptime = 95%
v. 1 shift

D. Shipping Department
Remove sewed dresses from finished goods warehouse and stages them for truck shipment to customer.

Requirement:
Question 1
From the above information create and comment on the current state map of Kateville Textile Printing Company Ltd. (14marks)
Question 2
From Q1 design to improve the manufacturing systems at a cell level using lean techniques to create a future state map and comment with justification any actions taken in arriving at your decision. (15marks)

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