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 incenti
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

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
operations.

eration or m/c to work.

here they work on incenti
t operator. Please avoid

to teacher.

e the exercise.

tual property of NIFT,

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
WIP Operator Hrs Prod WIP Operator Hrs Prod WIP Operator Hrs Prod WIP
1 Devi ###
2 95 Devi ###
2 95 Devi 0.5
### 24
Ramar ###
2 117 Ramar ###
2 117 Ramar ###
1 58
100 Gita 1.5
### 72 102 Sunil 0.5
### 19 108 Gita 1
### 48 181
2 Gita 0.5
### 56 Gita ###
2 225 Gita 0.5
### 56
Sangita 1.5
### 225 1.5
### 0 Sangita ###
0 0
100 Floater ### 0 102 ### 0 141 ### 0 104
Ramesh 0.5
### 93 Ramesh ###
1 186 ### 0
3 Floater 1.5
### 186 ### 0 Ramesh 0.5
### 93
100 ### 0 247 ### 0 199 ### 0 98
4 Bhanu ###
1 102 Bhanu ###
2 204 Kalindi 0.5
### 41
Sangita 0.5
### 31 Sangita 0.5
### 31 Floater 1.5
### 153
100 Sangita ### 0 77 ### 0 85 ### 0 16
5 ###
2 0 Sunil ###
1 56 Sunil ###
2 112
Kalindi ###
2 140 Kalindi ###
2 140 Kalindi 1.5
### 105
100 Ramesh 0.5
### 15 15 Ramesh ###
1 31 2 Ramesh 1.5
### 46 25
6 Urvashi ###
2 240 Urvashi ###
2 240 Urvashi ###
2 240
### 0 ###
1 0 ### 0
### 0 ### 0 ### 0
St.dev.(WIP) Total Production
59.99 960

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, Departmen
unauthorized copy is strictly prohibited.

New Delhi Kolkata Hyderabad Chennai Mumbai Gandhinagar Bangalore

Copyright © GMT-NIFT 2000-2008

rocess

14:30 - 16:30
Operator Hrs Prod WIP
Devi 1.5
### 72
Gita 1.5
### 72
Ramar ###
0 0 118
Gita 0.5
### 56
Sangita ###
1 150
### 0 124
Ramesh ###
1 186
### 0
### 0 60
Sangita ###
1 61
Kalindi ###
2 163
### 0 13
Sunil ###
2 112
Ramar ###
2 84
Ramesh ###
1 31 12
Urvashi ###
2 240
### 0
### 0
Line Efficiency Operator Utilisation
92% 88%

property of NIFT, Department of Fashion Technology and any

re
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
WIP Operator Hrs Prod WIP Operator Hrs Prod WIP Operator Hrs Prod WIP
1 Gita 1.5
### 72 Gita ###
1 48 Gita ###
1 48
Ramar ###
2 117 Ramar ###
2 117 Ramar ###
2 117
100 Devi ###
2 95 132 Devi 2
### 95 130 Devi 2
### 95 127
2 Gita 0.5
### 56 Gita ###
1 113 Gita ###
1 113
Sangita ###
1 150 Sangita ###
1 150 Sangita ###
1 150
100 Floater 0.5
### 45 103 ---N/A--- ###
0 0 117 Floater ###
0 0 69
Ramesh ###
1 186 Ramesh ###
1 186 Ramesh ###
1 186
3 Floater 0.5
### 62 Floater 0.5
### 62 Floater 1
### 124
100 ---N/A--- ###
0 0 134 ---N/A--- ###
0 0 117 ---N/A--- ###
0 0 122
4 Sangita 0.5
### 31 Sangita ###
1 61 Sangita ###
1 61
Kalindi ###
1 82 Kalindi ###
0 0 Kalindi 0.5
### 41
100 Bhanu ###
1 102 101 Bhanu ###
2 204 84 Bhanu ###
2 204 142
5 Sunil ###
2 112 Sunil ###
2 112 Sunil ###
2 112
Kalindi ###
1 70 Kalindi ###
2 140 Kalindi 1.5
### 105
100 Ramesh ###
1 31 58 Ramesh ###
1 31 86 Ramesh ###
1 31 86
6 Urvashi ###
1 120 Urvashi ###
1 120 Floater 0.5
### 68
Floater ###
1 135 Floater ###
1 135 Urvashi 1.5
### 180
### 0 ### 0 ### 0
St.dev.(WIP) Total Production
22.90 1013

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
unauthorized copy is strictly prohibited.

New Delhi Kolkata Hyderabad Chennai Mumbai Gandhinagar Bangalore

Copyright © GMT-NIFT 2000-2008

cess

14:30 - 16:30
Operator Hrs Prod WIP
Gita ###
2 95
Ramar ###
2 117
Devi ###
2 95 134
---N/A--- ###
0 0
Sangita ###
2 300
---N/A--- ### 0 121
Ramesh ###
1 186
Floater 0.5
### 62
### 0 126
Kalindi 0.5
### 41
---N/A--- ###
0 0
Bhanu ###
2 204 139
Sunil ###
2 112
Kalindi 1.5
### 105
Ramesh ###
1 31 79
Urvashi ###
1 120
Floater ###
1 135
### 0
Line Efficiency Operator Utilisation
82% 92%

operty of NIFT, Department of Fashion Technology and any

 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 Sco 40
Score Ob 37 Score Obtain 38

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, D
Fashion Technology and any unauthorized copy is strictly prohibited.
New Delhi Kolkata Hyderabad Chennai Mumbai Gandhinagar Bangalore

Copyright © GMT-NIFT 2000-2008

nt Manufacturing Process
ersion: 2008.01
rabir Jana

tudents of NIFT. This remains a intellectual property of NIFT, Department of

py is strictly prohibited.
bai Gandhinagar Bangalore