PRODUCTION PLANNING AND CONTROL DEPARTMENT

This department has two parts: production planning and production control.

There are a number of lines and number of machines per line in each of the units. Unit Number of lines 22 9 12 8 8 MACHINES/L INE 42 33 40 45 45

Faridabad Sarai Okhla A-5 E-10

The planning is done for all the lines of all the above units. While planning, they consider a planned efficiency slab for the purpose of estimating output. This efficiency slab is based on the order quantity and is as follows:

Style wise order quantity Efficiency to be considered:

Style wise order quantity 1500-3000 3001-10000 10001-20000 20001-30000 30001-50000 More than 50000

Efficiency to be considered

30% 40% 51% 58% 63% 65%

PRODUCTION CONTROL
For the purpose of production control, there are five teams in this department segregated buyer wise. These people are responsible for the execution of order in the unit. The roles and responsibilities of production control people are: To supervise smooth execution of the order in the unit. Organizing a pre-production meeting prior to production to discuss critical issues. Complete fabric follow up with merchant and the fabric store. Complete accessory follow up with merchant and sub store. Supervising the entire production process to ensure timely execution of the order.

WORKING OF PPCIn order projection a style sheet is received which has a style no., pictures, order quantity, and ex factory. This is received by the product development department. Next, unit is allocated i.e. it is determined in which factory unit, the particular style is going to be made on basis of the order quantity. Also, the ex factory dates are decided. A final chart is prepared and the PD team then divides the order quantity to the production team. A style number is decided upon. This umber is used by the merchant to communicate with buyer. Production team specifies the item number and then the production structure is developed. Final sample received from the buyer and PDS is updated. Next, production team and the merchandiser prepares details about the item. i.e. trims, thread etc. Through movex, any item can be checked by the other department but cannot be altered. Industrial engineering specifies the costing through the run through time. Thus the total cost is achieved. After the cost sheet is signed, ordering is done. The PCD (Planned Cut Date) is decided and 40% of all the materials should be enclosed by this date. If the order quantity is less than 5000 pcs, the 100% of the materials should be enclosed. 7- 10 days before the planned cut date, 2 samples and 2 files are received sealed from the buyer. Production File (It has details about the marker, tech pack, color of thread, trims, hanger, specification sheets etc.) is given to the OAD (Order analysis department). The OAD checks the patterns and other techniques. If it is approved, the garment is sealed and sent to the I.E.D.

MAIN KRATo ensure proper feeding in the lines To prepare a bills of materials To calculate the average i.e. the consumption of material in a garment Follow up of the processes To ensure regular flow of materials in a line

DOCUMENTS MAINTAINEDDaily production reports Production File Internal Movex reports Conversion costs for units Planned vs. HO reports Production Variance Reports (PVR)