Assignment : 1

Advanced Apparel
Manufacturing Management
AAMM
Submitted By:
Abhinav Anshu
Reeya Chhetri
Subject Faculty: Urvashi Tomar
Prof. Vaseem Chavhan Department of Fashion Technology, SEMESTER - 7
Acknowledgement
In preparation of the assignment, we had to take the help and guidance of a few respected sources,
who deserve our deepest gratitude. As the completion of this assignment gave us much pleasure,
we would like to show our gratitude towards our faculty Prof. Vaseem Chavhan, Advanced Apparel
Manufacturing Management Instructor, National Institute of Fashion Technology, who after
numerous consultations, guided us well on this opportunistic assignment.
In addition, we would also like to thank him for introducing us to the methodology of work, and
whose passion for the "underlying structures" had lasting effect.
We would also like to thank our parents and friends for motivating us while the completion of the
assignment.
Last but not the least we would also like to thank Lord Almighty for keeping us safe while working
hard in by ensuring highest health standards and physical wellbeing for successfull completion of
this assignment
ABSTRACT
This study tries to eavesdrop on the retailer's impression of that
customer segment in order to optimise the product mix. The
emphasis is on small businesses who lack the financial
resources to effectively coordinate choices on the product mix.

For this study, a medium-sized business with no funds for

product mix software was chosen. The information covered a
single season, from April through March. The information was
examined to determine the earnings before and after linear
programming.
Introduction
ABOUT
Every business seeks to turn a profit in order to maintain and expand. For manufacturing
industries at all levels, the goal today is to produce goods of the proper quality, quantity,
and timing at the lowest possible cost to ensure their existence. As technology develops,
new trends, up-to-date information, and unheard-of issues also continually emerge. Over
and above their own personal experience and market trends, marketers must use
operational research approaches to overcome these difficulties. When it comes to client
preference, the apparel business is quite dynamic and trendier, which presents a
comparable difficulty for producers. The indigenous textile and clothing sector in India is
expected to reach US$75 billion by 2020.
STUDY
Market revenue decreased from US$ 106 billion in 2019–20 by 30%. By 2025–2026, the market
is projected to rebound and expand at a 10% CAGR, reaching US$ 190 billion. In India, 73% of
the total T&A market is made up of apparel. Even while SMEs produce a sizable portion of
the world's clothes, the unique problems facing this industry demand special attention. In
India, 93 percent of the working force works for unorganised SMEs, with the garment industry
playing a key role. Each clothing company aggressively reduced expenses and restructured
their supply chains. It guarantees that clothing prices fall in comparison to the costs of other
consumer goods and raises the affordability of clothing.
By purchasing more products, consumers respond to decreased pricing and a better
selection of clothing. As a result, from 2000 to 2014, the average consumer's yearly purchase
of clothing climbed by 60%. Particularly in emerging economies like India, where more
consumers entered the middle class group, massive increases in garment sales were seen.
This pattern is expected to continue given the expanding middle class, growing global
population, and rising living standards. Their demand is primarily for affordable, basic
clothing items, which helps the population in rural Asian countries that doesn't consider
itself a part of the alluring nursing market for branded players.
There isn't much research in this field, where the linear programming (LP) quantitative
decision making tool can be applied for the optimization problem of product mix to draw
and keep customers for tiny or non-branded clothing businesses.
This study tries to eavesdrop on the retailer's impression of that customer segment in
order to optimise the product mix.
The emphasis is on small businesses who lack the financial resources to effectively
coordinate choices on the product mix.
However, while offering clients a great variety helps them make better choices and is
more satisfying, it also places restrictions on the business (in terms of cost and stocking
complexity) and the customer (confusion of intention and obligation to purchase).
The money is put on hold once the inventory is stocked until it is sold, which rarely
happens.
Due to media exposure and reach, these swings are noticeable even in small towns and
rural marketplaces.
 LINEAR PROGRAMMING
By examining the maximum or minimum
objective functions for any given situation,
the linear programming model is typically
used to find the best solutions under a variety
of constraints.
This idea has been around since before World
War II, when Soviet mathematician A. N.
Kolmogorov created it.
The topic of linear programming was expanded
further, and several researchers used it to
determine the best solutions to diverse issues.

The University of Benin Bakery in Benin City, Edo State, Nigeria, did one of the most recent studies on
profit maximisation utilising linear approaches. The corporation utilised a linear programming solver to
determine how much bread should be produced each day in order to maintain high profitability at the
lowest possible cost. Profit maximisation was likewise the main concern here. There is no industry- or
domain-specific restriction on the application. It is also clear that decision-making about the use of
resources like water, fertilisers, labour, feed mix, crop rotation, etc. involves the use of quantitative
methodologies. It provides information about the practical side of linear programming.
 SOME Commercial Solvers
Though some commercial solvers like CPLEX and LINGO, can
address Linear programming, the computation for large-scale
data becomes a challenge. The calculation takes a lot of time if
the product mix exceeds 100 and the solutions are multiples.

Standard form of LP model:

MAXIMIZE / MINIMIZE
Z = C1 X1 + C2 X2 + …….. Cn Xn →objective function
Subject to
→
a11 x1 + a12 x2 + …... a1n xn <= b1 functional constraint
a21 x1 + a22 x2 + …… a2n xn <= b2→functional constraint
am1 x1 + am2 x2 + ……. amn xn <= bm→functional constraint
x1, x2, ……xn →non negativity constraint
MATERIALS & METHODS
There was a secondary database already in place, and the data collection procedure was objective.
The supplementary information was obtained through in-person performance interviews
conducted by representatives (10) with the owner's approval along with information supplied by
supervisors in accordance with the precedent-setting documents, and significantly altered to
produce the outcome.
The principles are applied to the resources that have been retained while taking into account their
consumption and the output quantity of each good that is used in the business.
The ability to employ resources (use of resources) was identified as the main constraint in the
garment production unit.
It specified the limitations (threads, fabrics, labour, overhead, time for finishing, cutting, and
stitching) and five customer consignments for uppers (Polo T-shirts, round neck T-shirts, basic T-
shirts, singlets, and v neck t-shirts).
Case
STUDY

TABLE 01
TABLE 02

TABLE 03
RESULTS & DISCUSSION
Technically, an LPP must meet five further conditions:
1. The numbers in the target and restrictions are known with certainty and do not violate any
conditions of uncertainty not change throughout the research period.
2. It is thought that proportionality exists between the restrictions and the aim. If a product
requires four units of a particular rare resource to produce one unit, then ten units of that
product require 40 units of the resource.
3. The third theoretical premise is additivity, which states that every activity's average (sum) is
the result of adding all of its fragmented parts.
4. The idea behind divisibility is that the solutions don't have to take the shape of a whole number
(integers). Rather, they are divisible, and a fractional value may be taken.
5. All outcomes or contributing variables are deemed favourable in the end. Physical quantities
that are negative cannot exist; for example, one cannot simply make a negative number of
textile things.
 pre
LP CONSUMPTION

pre
LP PROFIT
Analysis STEPS TO FORMULATE THE
MODEL AND RESULTS
In addition to other operating data and sales, the data collected from the case firm, Hatchers
were analyzed to provide estimates for LPP model parameters.

x1 = number of Polo T-shirts x2 = number of Basic T-shirts x3 = number of Round Neck T-shirts x4
= number of Singlets x5 = number of V neck t-shirts Z = total profit during the month
Now, the linear programming model, maximizing the total
profit is: Maximize Z (INR Profit) = 4.5 x1 + 3.8x2 + 3.5 x3+ 3x4 + 6.5x5
Subject to constraints;
1. 315x1 + 65x2 + 195x3 + 180x4 + 50x5 ≤ 3,71,25,000 (Fabric)
2. 215x1 + 105x2 + 142x3 + 105x4 + 190x5 ≤ 2,56,21,830 (Thread)
3. 11x1, +5x2 + 6x3 + 4 5x4 + 7x5 ≤ 10,01,000 (Labor
4. 31x1 + 19x2 + 20x3 + 15 5x4 + 37x5 ≤ 50,00,000 (Over heads)
5. 03x1 + 0 02x2 + 0 03x3 + 0 02x4 + 0 04x5 ≤ 5,775 (Cutting time- hours)
6. 35x1 + 0 15x2 + 0 16x3 + 0 09x4 + 0 31x5 ≤ 44,500 (Sewing time-hours)
7. 03x1 + 0 02x2 + 0 03x3 + 0 02x4 + 0 04x5 ≤ 6200 (Finishing time-hours)
8. x1≥ 15000; (Customer orders)
9. x2 ≥ 24000; (Customer orders)
10. x3 ≥ 12000; (Customer orders)
11. x4 ≥ 26000; (Customer orders)
12. x5 ≥ 11000 (Customer orders)
DISCUSSION
Since the focus of this research is on maximising resource usage, it is
assumed that all units of the product mix created would be sold in order to
generate profits. A retailer is the best person to provide insight on this
subject since they have a thorough understanding of market patterns and
continuing changes in the retail clothes industry. This analysis separates
the advantage of one of the apparel-producing companies using a linear
programming approach from the existing asset utilisation level. The
organization's full potential was put to use as a goal work. Effective use of
materials, such as textures and sewing threads, and preparation time at
different stages of production, together with the elimination of labour and
material costs, are crucial for improving productivity in clothing
manufacturing companies. A recent study that was done to determine the
best product mix using the theory of limitations lends evidence to this.
Here, two linear programming models used the best resources and
produced the most output to solve the dilemma of choosing the most
effective bird feed.
This analysis shows that every single authoritative resource is being used inefficiently. With the
present structure:
It is often assumed that the company wastes its resources. It was proposed to use data
visualisation to make decision-making easier by using the dashboard to experience
various business situations.
As was already noted, creating organisations' methods for maximising resource usage
and minimising waste pave the way for the organization's sustainability.
According to the research done for Amo Byng Nigeria Limited, the optimal product mix was
maintained while using the Reverse Simplex approach to increase profit by about 9.1%.

Therefore, it is reasonable to assert that revisiting the present agreement might raise the
organization's worldwide effect to a crucial level. In the instance of the Hatchers, the mix of
items consisted of singlets, basic t-shirts, polo shirts, round-neck t-shirts, v-neck t-shirts, and
shirts with different quantities (15,000.00, 24000.00, 12000.00, 26000.00 and 11,000.00
respectively), with an absolute profit of INR 3,50,200.00 every month after selling.
CONCLUSION
The focus of this case study is the medium-sized company Hatchers.

Currently (post-LP), the firm creates five different product categories each month, each with a
corresponding creation volume (pieces):
Men's Polo shirt (15000),
Men's Basic T-shirt (24000),
Round neck T-shirts (12000),
Singlet (26000),
V-neck T-shirt (75285).

Regardless, the company will receive a monthly profit of INR 7,68,056.00 from these generating
volumes.
The production is fairly high and sustainable because it may be utilised every quarter or every
year, especially when taking into account the time and money involved in the application.
Other than this, using Solver, a Microsoft Excel programme, is practical and application-
focused. A lot of market data is updated and worked on constantly regarding the apparel
industry, particularly non-branded garment companies in tier 1 and tier 2 cities.
Gaining a perspective on end-user sales and visualising how expectations for sales and
profitability differ from actual data may both be done.
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Thank you