Tops & Dress Division

“A person who never made a

mistake never tried anything new.”

 CONTENTS

Assumptions for the Project Planning

Proposed Layout

Planning: Machine / Manpower

Parameters for Estimated Production & Revenue/ Year

Estimated Production Projections

Estimated Revenue Projections

Final Slide
 ASSUMPTIONS FOR THE PROJECT PLANNING

Product Development & Lead Production

Time
• Fabric Inventory: 30 days
• Ratio of Product ( Dress/ Blouse): 40/60
• Cutting Capacity: 1.5 times to sewing production
• Sampling/ day : 20 pieces
• Cutting Ready WIP: 1.5 days
• Sample Approval Time : 30 days
• No of Sewing Lines: 10
• Production Lead Time: 30 days
• Per/ line sewing machines:28-32 machines
• No of fit rounds: 2
• No of sewing operators: 30 each line (300)
• Ratio of Product ( Dress/ Blouse): 40/60
• Weighted SAM for Product Mix: 28.4
• Iron capacity: 1.5 times to production value
• Finished Goods WIP: 30 days
PRODUCT MIX:
RECENT
DEVELOPMENTS
 Machine Planning( based on 10 sewing lines):
Machine M/C per line Total M/C Price($) Total Cost($)
SNLS 24 240 700 168,000
SNLS(DLU) 1 10 2500 25,000
SNLS(DLN) 1 10 900 9,000
O/L 5T 2 20 1500 30,000
O/L 4T 1 10 1400 14,000
O/L 3T 4 40 1200 48,000
Button Hole 0.5 5 2000 10,000
Button Stitch 0.5 5 4500 22,500
Bar tack 0.25 3 1500 4,500
Blind Stitch 0.5 5 400 2,000
Smocking 0.25 3 2000 6,000
Zig Zag 0.25 2 5600 11,200
Edge Cutter 0.5 5 400 2,000
Hand Iron 3 30 500 15,000
367,200
Note : Machines price is quoted based on recent machines from websites. It will vary in bulk purchase.
Manpower Planning ( based on 10 sewing lines):

Cutting: Manpower Planning

Cutting I.E
Operators

Technical

Technical
Incharge

Cutting

Head
Q.C

I.E
CAD Room 1 0 0 1 3
Cutting planning 1 0 2 1 0
Pre-Production 0 1 1 0 0
Layer & Cut 24 3 1 1 1
Numbering 6 0 1 1
Bundling 6 0
Panel Inspection 10 0 1 1 1
Fusing 4 1
Repinning/Embroidery Cut 6 1
80 58 6 5 4 5 1 1
Manpower Planning ( based on 10 sewing lines):

Sewing I.E/ Planning & Production

Sam ple

Sewing Technical
Pattern Technical

Senior Technical
Data Recorder
Roaming QC

Quality Head
Room /I.E &

QC Incharge

Maintenance
Supervisor
Operators

Mechanic
Incharge

I.E Head
Planning/

Head
Q.C

I.E
Sew ing
Production/
Maintenance/
Training
Sample Room 15 2 1 1 1 1 0 1 1 6 1
Pre-Production/
0 2 0 1 0 0 0 2 0 1
Planning 1 1 1 1
4 4 5 5 1 1
Production 350 20 10 10 20
Training 15 0 0 1 1 0 0 0 0 0
459 380 24 11 13 22 5 4 8 6 8 2 1 1 1 1
Manpower Planning ( based on 10 sewing lines):

Senior Technical
Finishing Head
Data Recorder
Roaming QC

Quality Head
Maintenance
QC Incharge
Supervisor
Operators

Incharge
Finis hing

Head
Q.C

I.E
&
Ins pe ction

Ironing 25 2 1 1 1 1 0 1
Quality 0 25 0 1 1 0 0 0

Packing 25 4 0 1 1 1 0 0 1 1 1 1

Inspection 0 4 0 1 0 0 0 0

FCQA 0 0 0 1 4 0 0 0
100 50 35 1 5 7 2 0 1 1 1 1 1
 Estimated 3 Years Production Projection
(After 10 sewing lines functional):
Per Days Production is calculated as below-
Total no of Machine Operators: 300
Parameter Dress Tops Weighted Weighted SAM ( Standard allowed minutes)= 28.4
Percentage 40% 60% min
Working hours= 10 hours
SAM (Average) 35 min 24 min 28.4 min Working Minutes = 10x60 min = 600 min
FOB Price ($) 13$ 6$ 8.80$ Total Minutes available per day= 300x600xEfficieny%
Per Day Production = {(300x600xEfficiency%)/28.4}

SAM Available in
Production Lead

Plant Efficiency
Order Quantity

SAM Assumed

in 10 working
Lead Time in
No of Sewing

Product Mix

Production/
Estimated
Operators

Weighted

Garment
based on

FOB($)
hours
/Style
days
Year

Day
First 300 30 >5000 40% 28.4 180,000 8.80 2,535
Second 300 30 >5000 48% 28.4 180,000 9.20 3,042
Third 300 30 < 5000 55% 28.4 180,000 10.00 3,486
Estimated Revenue Projection for 3 years (After
10 sewing lines functional):
Average
Yearly Average FOB($)/
Garment Monthly Yearly
Year Production
Production Production Revenue($)
(no of pieces)
/Day
First 2,500 62,500 750,000 8.80 6,600,000
Second 3,000 75,000 900,000 9.20 8,280,000
Third 3,500 87,500 1,050,000 10.00 10,500,000
Production Value ( No of garments) Estimated Revenue Projection
12,000,000 0.4
37.14%
1,050,000 0.35
10,000,000
900,000 0.3
750,000 8,000,000
0.25
6,000,000 0.2
20.3%
0.15
4,000,000
0.1
2,000,000
0.05
0 0
1st Year 2nd Year 3rd Year
1st Year 2nd Year 3rd Year Revenue($) Percentage Increase in Revenue
PROJECT OUTCOMES:

6,600,000
Revenue from sales in 1st
Year

137%
Project Achievements in 3rd Year
as compared to 1st Year

20%
Mark up per garment
Thanks!