Garment Manufacturing Process / Apparel Production Planning and Control

Apparel Production Planning & Control / Garment Manufacturing Process

Computer Aided WIP Management Version: 2008.01
Developed by: Sunil Motwani & Prabir Jana

Guidelines for Faculty Monitored Exercise

General Rules:
1 Operation flow is as per serial no. of operations. That is operation 1 feeds Operation 2, operation 2 feeds operation 3 and so on.
2 Enough hours must be worked on each operation to give the target output in this case 1000pcs/Day.
3 Any operator should work for minimum ½ hour at any allocated operation, i.e. in a two-hour slot any operator can work for maximum 4 different operations.
4 You may allocate floaters to cover for absenteeism and/or WIP/production balancing. (i.e. allocate floater as and when required)
5 Machine/attachment used in different operations is different.
6 All production and WIP should be written in round figure (no decimal)
7 Maximum three machines are available for each operation
8 Opening WIP between operations are 100. Negative WIP figure to be avoided, any negative WIP figure will disqualify the team
9 Try to maintain maximum WIP of total 400-600 pieces in line.
10 When any operator is unavailable, his/her machine can be utilised by other operator. During any m/c breakdown operator can move to other operation or m/c to work.
11 Use operators or floaters on operations they can do best, i.e. try to get maximise time on standard (by using operators/floaters on operations where they work on incentive).
12 Any operator can work for maximum 2 hours in any two hours slot. If your allocation exceeds 2 hours, red colour alert will be shown against that operator. Please avoid same.

Instructions to fill up ‘production balance’ worksheet

1 You are supposed to fill only columns titled ‘Operator’s Name’ and ‘Hrs’ for every two hour slot. Rest is calculated automatically.
2 Use separate ‘production balance’ sheet for solving different days problem. Save each production balance sheet in different names and submit to teacher.

Rules for Evaluation

1 Students will be marked based on the following parameters:
2 Total production, maintaining consistent WIP from starting amount, operator utilization%, balance efficiency%, and time required by you to solve the exercise.

This module was developed as a part of APPC subject for B.F.Tech and GMP subject for M.F.Tech students of NIFT. This remains a intellectual property of NIFT, Department of
Fashion Technology and any unauthorized copy is strictly prohibited.

New Delhi Kolkata Hyderabad Chennai Mumbai Gandhinagar Bangalore

Copyright © GMT-NIFT 2000-2008

Garment Manufacturing Process / Apparel Production Planning and Control

Apparel Production Planning & Control /Garment Manufacturing Process

Computer Aided WIP Management Version: 2008.01
Developed by: Sunil Motwani & Prabir Jana
Output Operators Performance (%)
@ 100%
Perf. (Per
SM Per Hour) Bhanu Devi Floater Gita Kalindi Ramar Ramesh Sangita Sunil Urvashi
Operation Unit 1 2 3 4 5 6 7 8 9 10
1 1.13 53 90 40 90 110 70
2 0.4 150 60 75 100
3 0.29 207 60 90
4 0.59 102 100 100 80 60
5 1.08 56 85 125 75 55 100
6 0.4 150 90 80
SAM 3.89

This module was developed as a part of APPC subject for B.F.Tech and GMP subject for M.F.Tech students of NIFT. This remains a intellectual property of NIFT,
Department of Fashion Technology and any unauthorized copy is strictly prohibited.

New Delhi Kolkata Hyderabad Chennai Mumbai Gandhinagar Bangalore

Copyright © GMT-NIFT 2000-2008

Garment Manufacturing Process / Apparel Production Planning and Control

Apparel Production Planning & Control / Garment Manufacturing Process

Computer Aided WIP Management Version: 2008.01
Developed by: Sunil Motwani & Prabir Jana
Operation Open 8:00 -10:00 10:00 -12:00 12:30 - 14:30 14:30 - 16:30
WIP Operator Hrs Prod WIP Operator Hrs Prod WIP Operator Hrs Prod WIP Operator Hrs Prod WIP
1 Devi ###
2 95 Devi ###
2 95 Devi ###
2 95 Devi 1.5
### 72
Ramar ###
2 117 Ramar ###
2 117 Ramar ###
2 117 Gita ###
1 48
100 Sunil ###
2 74 11 Sunil 0.5
### 19 17 ### 0 4 Ramar ###
1 58 69
2 Gita ###
2 225 Gita ###
2 225 Gita ###
2 225 Gita ###
1 113
Sangita ###
1 150 1.5
### 0 ### 0 ### 0
100 ### 0 41 ### 0 80 ### 0 26 ### 0 46
Ramesh ###
1 186 Ramesh ###
1 186 ### 0 Ramesh 0.5
### 93
3 Floater 2
### 248 ### 0 Ramesh 1.5
### 279 ### 0
100 ### 0 330 ### 0 312 ### 0 #N/A ### 0 #N/A
4 Bhanu ###
2 204 Bhanu ###
2 204 Bhanu ###
2 204 Bhanu ###
2 204
###
0 0 0.5
### 0 ---N/A--- 0.5
### #N/A Kalindi ###
2 163
100 ### 0 149 ### 0 126 ### 0 #N/A ### 0 #N/A
5 ###
2 0 Sunil ###
1 56 Sunil ###
2 112 Sunil ###
2 112
Kalindi ###
2 140 Kalindi ###
2 140 Kalindi ###
1 70 Ramar ###
1 42
100 Ramesh 0.5
### 15 135 Ramesh ###
1 31 92 Ramesh 0.5
### 15 86 Ramesh 1.5
### 46 16
6 Urvashi ###
1 120 Floater ###
2 270 Floater 1.5
### 203 Floater ###
2 270
### 0 ###
1 0 ### 0 ### 0
### 0 ### 0 ### 0 ### 0
St.dev.(WIP) Total Production Line Efficiency Operator Utilisation
#N/A 863 82% 93%

This module was developed as a part of APPC subject for B.F.Tech and GMP subject for M.F.Tech students of NIFT. This remains a intellectual property of NIFT, Department of Fashion Technology and any
unauthorized copy is strictly prohibited.

New Delhi Kolkata Hyderabad Chennai Mumbai Gandhinagar Bangalore

Copyright © GMT-NIFT 2000-2008

Garment Manufacturing Process / Apparel Production Planning and Control

Apparel Production Planning & Control / Garment Manufacturing Process

Computer Aided WIP Management Version: 2008.01
Developed by: Sunil Motwani & Prabir Jana
Operation Open 8:00 -10:00 10:00 -12:00 12:30 - 14:30 14:30 - 16:30
WIP Operator Hrs Prod WIP Operator Hrs Prod WIP Operator Hrs Prod WIP Operator Hrs Prod WIP
1 Devi ###
2 95 Devi ###
2 95 Devi ###
1 48 Devi ###
2 95
Ramar ###
2 117 Ramar ###
2 117 Ramar ###
2 117 ---N/A--- ###
2 #N/A
100 ---N/A--- ###
1 #N/A #N/A Gita 2
### 95 #N/A Gita 2
### 95 #N/A Ramar ###
2 117 #N/A
2 Sangita ###
2 300 Sangita 1.5
### 225 Sangita 1.5
### 225 Sangita 1.5
### 225
---N/A--- ###
0 #N/A ###
0 0 ### 0 ### 0
100 ### 0 #N/A ### 0 #N/A ### 0 #N/A ### 0 #N/A
Ramesh ###
1 186 Ramesh ###
2 373 Ramesh ###
1 186 Ramesh ###
1 186
3 ---N/A--- 1.5
### #N/A 2
### 0 ---N/A--- 2
### #N/A ---N/A--- 2
### #N/A
100 ### 0 #N/A ###
0 0 #N/A ### 0 #N/A ### 0 #N/A
4 Floater 0.5
### 51 Floater 1.5
### 153 Floater ###
1 102 Floater ###
2 204
Bhanu ###
2 204 Bhanu ###
2 204 Kalindi 0.5
### 41 ---N/A--- ###
0 #N/A
100 ### 0 55 ### 0 #N/A 0.5
### 0 #N/A ### 0 #N/A
5 Floater ###
1 48 Kalindi ###
2 140 Kalindi 1.5
### 105 Sunil ###
2 112
Kalindi ###
2 140 ---N/A--- ###
0 #N/A Floater 0.5
### 24 Kalindi ###
2 140
100 Sunil ###
2 112 92 Sunil 1.5
### 84 #N/A Sunil ###
2 112 #N/A Ramesh ###
1 31 #N/A
6 Urvashi ###
2 240 Urvashi 1.5
### 180 ---N/A--- 0.5
### #N/A Urvashi ###
2 240
Floater 0.5
### 68 Floater 0.5
### 68 Urvashi ###
2 240 ### 0
### 0 ### 0 ### 0 ### 0
St.dev.(WIP) Total Production Line Efficiency Operator Utilisation
#N/A #N/A #N/A 104%

This module was developed as a part of APPC subject for B.F.Tech and GMP subject for M.F.Tech students of NIFT. This remains a intellectual property of NIFT, Department of Fashion Technology and any
unauthorized copy is strictly prohibited.

New Delhi Kolkata Hyderabad Chennai Mumbai Gandhinagar Bangalore

Copyright © GMT-NIFT 2000-2008

 Garment Manufacturing Process / Apparel Production Planning and Control

Apparel Production Planning & Control / Garment Manufacturing Process

Computer Aided WIP Management Version: 2008.01
Developed by: Sunil Motwani & Prabir Jana

Student's Name:
_________________________________

Production Balance (1) Production Balance (2)

Total Score (1) Total Score (2)
Maximum 40 Maximum Sc 40
Score Ob #N/A Score Obtai #N/A

This module was developed as a part of APPC subject for B.F.Tech and GMP subject for M.F.Tech students of NIFT. This remains
Fashion Technology and any unauthorized copy is strictly prohibited.
New Delhi Kolkata Hyderabad Chennai Mumbai Gandhinagar Ban

Copyright © GMT-NIFT 2000-2008

Planning & Control / Garment Manufacturing Process
Aided WIP Management Version: 2008.01
loped by: Sunil Motwani & Prabir Jana

nd GMP subject for M.F.Tech students of NIFT. This remains a intellectual property of NIFT, Department of
logy and any unauthorized copy is strictly prohibited.
erabad Chennai Mumbai Gandhinagar Bangalore