Dore Dore

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Dore Dore Case study - Solutions:

1. Evaluate the Changes Dore Dore has made in its Children’s Knitwear division.

* Children Knitwear Traditional setup (Product – Focused Layout) * Children Knitwear cellular setup (Process – Focused Layout)

Traditional Operations:

Yam & Fabric supplier – 2.5 months – average lead time
Knitting – throughput time – 80 hrs
Dyeing – 5 weeks – average lead time
Cutting – 40 hrs – throughput time
Sewing and finishing – 120 hrs – throughput time
Lead time & Throughput time – batch size = 200 units
Bottle neck operation is sewing & finishing.

Work in progress calculations:

Units progress / day = 2000 units
Through put time = 15 days
WIP = 2000 *15=30000 Units
No of workers = 42
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What changes are required to ensure successful implementation of cellular manufacturing?

One problem with cellular operations is lowered machine utilisation and increased capital.

Moreover to ensure supervisors to perform in this process also.

4. What is Dore-Dore’ motivation for converting to Cells?

The various reasons which motivated Dore – Dore to convert to cells are as follows:

* Improved quality of the products due to reduced defects * Designs can be easily adapted to market trends due to decrease throughput time.
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. * Results in low inventory and in turn low cost of inventory management freeing idle capital. * Workers in cellular operations are more flexible due to cross training. * Wait time between each operation is reduced. * Can plan for more than two annual collections * Stocks can be supplied to wholesalers on a daily basis to reduce burden * Reduction in WIP by converting to
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