CASE STUDY MANUFACTURE OF COTTON POLO SHIRTS AND JUMPERS

Objective: Explore the manufacturing process of tangüis cotton polo shirts and jumpers from a Peruvian textile company to optimize the process and obtain quality products that can compete in the international market. Theoretical Framework: The forecast demand and forecast control, the required and available capacity of workers and machines for the production process, the aggregate planning of the required workforce, the master production program, and the disaggregation of material requirements with the calculation of the corresponding lead-times. Method : Basic and applied hypothetical case study, transversal and exploratory, non-experimental, where the production process of cotton polo shirts and jumpers is simulated in one year considering their seasonality. Results and Discussion: Proposal for the demand estimation, forecast control, the required and available capacity of workers and machines necessary for the production process, the aggregate planning of the required workforce, the master production program, and the disaggregation of materials with the calculation of the corresponding lead-times. Research Implications: Be able to replicate the case in real situations of companies focused on textile manufacturing to determine their real estimations and propose proposals for continuous improvement. Originality/Value: The contribution to the literature of a case study that can be replicated to the reality of companies oriented to textile manufacturing to optimize their processes and contribute with their proposals for continuous improvement.

Estrutura Teórica: A demanda de previsão e controle de previsão, a capacidade necessária e disponível de trabalhadores e máquinas para o processo de produção, o planejamento agregado da força de trabalho necessária, o programa de produção mestre e a desagregação dos requisitos de material com o cálculo dos lead times correspondentes.
Bases conceptuales: El pronóstico de demanda, el control de pronóstico, la capacidad requerida y disponible de trabajadores y máquinas para el proceso de producción, la planeación agregada de la fuerza de trabajo requerida, el programa maestro de producción y el desagregado de requerimiento de materiales con el cálculo de los lead times correspondientes.
Resultados y discusión: Propuesta de la estimación de la demanda, del control de pronóstico, la capacidad requerida y disponible de trabajadores y máquinas necesarias para el proceso de producción, la planeacion agregada de la fuerza de trabajo requerida, el programa maestro de producción y el desagregado de materiales con el cálculo de los lead times correspondientes.
Originalidad/Valor: La contribución a la literatura de un caso de estudio que se puede replicar a la realidad de empresas orientadas a la fabricación textil para optimizar sus procesos y contribuir con sus propuestas de mejora continua.

COMPLEXITY OF THE ACADEMIC LEVEL
The case is suitable for use in the Operations course of the Undergraduate and Post-Graduate Industrial Engineering programs.It can also be used in elective career courses specialized in the subject.These products have a seasonal behavior, since the poles are consumed more during the spring and summer periods, and the divers are consumed more during the autumn and winter periods.This consumption depends on the acceptance of the products mainly because of the quality of the tangguis cotton and the variety of the models.
You have reviewed the historical data that your company has, extracting the following information: Currently, the company has 34 workers in the plant, each of whom takes an average of 44 minutes to make a cotton polo shirt and 52 minutes to make a cotton diver.Workers have been working with you for a long time, so they already know the process and are increasingly minimizing the number of defective products.
At the beginning of January 20X6, an initial inventory of 100 poles and 120 divers is in stock.The working hours are known to be 8 hours a day (6:00 am to 10:00 pm).It works two shifts per day, 6 days a week, 4 weeks a month.
The following cost information is also available For the calculation of plant capacity, the following average times per operation (per machine) are available: Table 3 Average times per operation An average worker efficiency of 0.8 is considered for each of the operations.
The number of machines for each workstation is: More and more orders are coming from new customers, and to be able to serve them you have to be doing a rescheduling of your production plan continuously.For its elaboration, consider that the demand is evenly distributed during the weeks (for each month).
Currently, for the month of July of the year 20X6, it has the following confirmed orders from its main customers.

Table 6
Confirmed orders for polo shirts and cotton divers 6 The following Operations Diagram of the manufacturing process of the tangguis cotton pole is presented below:  e. Develop the MRP of the tangüis cotton pole for the month of July 20X6, according to the Operations Diagram described above, indicating the calculations for each of the lead times.For its development, consider the MPS found in both Master Production Programs.

TEACHING NOTES
The company is oriented to the textile sector of clothing of polo shirts and tangüis cotton divers located in Lima, Peru.
The case is projected for the estimation of the demand forecast, forecast control, determination of the required and available capacity of workers and machines for the production process, aggregate planning of the required workforce for the manufacture of the poles and divers, the respective master production program and the disaggregation of material requirement with the calculation of the corresponding lead times of the cotton poles for one year.
___________________________________________________________________________ Rev. Gest.Soc.Ambient.| Miami | v.18.n.6 | p.1-9 | e08333 | 2024.3 1.2 DEVELOPMENT You have set up a tangguis cotton polo shirt and scuba diver manufacturing company in Lima, Peru and have been on the market for a few years now.It has been difficult to consolidate in the market at the beginning, but has overcome the initial difficulties and currently has a very good positioning in the sector.By the year 20X6 you need to develop a work strategy and make a whole planning, as you plan to start exporting your products.
Figure 1 Cotton Pole Operations Diagram

Table 1
Historical sales data for polo shirts and cotton divers

Table 5 of machines Place molds and chalk Cut and control quality Join and sew
As a good Engineer, you must anticipate and also prepare the Schedule of your Production Plan for July and August of 20X6, to be able to meet all orders on time.

Table 7
Additional information about tangguis cotton polo shirts and scuba divers