Chp-2:

Apparel Production Planning & Control

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 Production planning
Meaning:-
Production planning involves management decisions on the
resources that the firm will require for its manufacturing
operations and the selection of these resources to produce the
desired goods at the appropriate time and at the least possible
cost.

So Production Planning is:

"The planning of industrial operations that involves the
considerations, namely, what work shall be done, how the work
shall be done and lastly, when the work shall be done .

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 Production control
Meaning:-
Production control guides and directs flow of production so
that products are manufactured in a best way and conform to
a planned schedule and are of the right quality. Control
facilitates the task of manufacturing and see that every theme
goes as per the plan.

So Production control is:

"Production control refers to ensuring that all which occurs is
in accordance with the rules/standards established and
instructions issued.“ 33
 Production Planning And Control

Meaning:-
Production Planning and Control is concerned with
directing production along the lines set by the planning
department.

Definition:-
"Production Planning and Control is the co-ordination of series
of functions according to a plan which will economically
utilize the plant facilities and regulate the orderly movement
of goods through the entire manufacturing cycle from the
procurement of all materials to the shipping of finished
goods at a predetermined rate."
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 The PPC Cycle

• The PPC Cycle refers to Production Planning

Control cycle. It has 3 Phases—Preplanning,
Planning, Controlling.

• The Pre-Planning Phase consists of-

– product development,
– sales forecasting,
– factory or plant layout,
– equipment selection policy, and
– preplanning of production just prior to large
scale production.
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• The Planning Phase consists of-
– planning of the 4 M's (methods, materials, men
and machines),
– routing,
– estimating,
– scheduling, and
– disspatching.

• The Controlling Phase consists of-

– follow up,
– inspecting, and
– evaluating.
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 Functions of production planning &
control
Productionplanning andControl department is oneof
theimportant department for the manufacturing
apparel company. In the contextof the
primaryapparel
functions of the Production Planning
manufacturing
and
Control (PPC) department has been listed below.
,

1.Job or Task Scheduling

2. Material Resource Planning

(Inventory)
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3. Loading production
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Functions of production planning &
control

4. Process selection & planning

5. Facility location

6.Estimating quantity and

costs of production

7. Capacity planning

8. Line planning

9. Follow up and execution

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• Job or Scheduling: Preparation of time and action
calendar
Taskfor each order from order receiving to shipment
(T&A). The job schedule contains list of tasks to be processed
for the styles. Against each tasks planner mentions when to start
a task and what is dead line for that task. Name of responsible
person (department) for the job is being listed. For example,
scheduling planned cut date (PCD), line loading date etc.

• Material Planning (Inventory): Preparation

Resourcerequirement sheet
Material of according to sample product and
buyer specification sheet. Consumption of material (fabric,
thread, button, and twill tape) is calculated and estimated cost of
each material.

• Loading production: Planner defines which style to be loaded

to the production line and how much quantity to be loaded. 9

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• Process Selection & Planning: Processes needed to complete an
order, vary style to style. According to the order (customer)
requirement PPC department select processes for the orders.
Sometime extra processes are eliminated to reduce cost of
production.

• Facility Location: Where a company has multiple factories

(facilities) for production and factories are set for specific
product, planner need to identify which facility will be most
suitable for new orders. Sometimes there may be a capacity
shortage in a factory, in that case planner need to decide which
facility will selected for that orders.
• Estimating Quantity andCosts of Production: Planner
estimate daily production (units) according to the styles work
content. With the estimated production figure, production runs
and manpower involvement planner also estimate production
cost per pieces.

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• Capacity Planning: PPC department plays a major role during
order booking. They decide (suggest) how much order they should
accept according to their production capacity. Allocating of total
capacity or deciding how much capacity to be used for an order
out of total factory capacity. Regularly updating factories current
capacity (production capacity).

• Line Preparing detailed line planning with

production
Planning: target for the production line. Most cases line planning
daily
is made after discussing with production team and Industrial
engineers.

• Follow up and execution: Whatever plan is made is executed by

PPC department. PPC department keeps close look whether
everything is progressing according the plan. Chasing other
department heads on daily basis to keep plan on track. They
update order wise completed tasks on the Time & action
Calendar. When they found something is going to be late they
expedite and create an alarm about the delay.
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Garments Analysis for Production Planning

• Garments analysis is very important to make a production

schedule or plan.
• At the same time we should have the idea about the
operator’s capacity for particular operation so that the
specific job will be completed smoothly.

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 Garments Analysis for Production
Planning
During garments analysis we should check the following points
very carefully:

❑Garments observations,
❑Key seam quality areas by operation, stitch & seam construction and
SPI,
❑Point out how many operations are involved in the particular item,
❑ Accordingly make a diagram of machine lay out,
❑Point out the critical operation where we can expect the “bottle neck”
during production,
❑Considering bottle neck allow extra machines for that operation to
keep production flow as you expect (Line Balancing),
❑ Find out the input operation and out put operation 1
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also. 3
 Production Planning:

• A successful production planning requires knowledge of two

variables to determine the time required for manufacturing a
contract/ an order.

1. Load – How much work we are putting on a section.

2. Capacity – How much work a section is capable
of completing.

• In an ideal situation, Load = Capacity

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Load = Order or Contract Size x Work Content

• Contract size = Order Qty

• Work Content = Total SMV of a
garment
Capacity = Actual Minutes
= no. of m/c operators x working minutes x efficiency x presents %

For Example:
• Operators = 24
• Working minutes = 8 hrs
• Efficiency = 69.78%
• Absenteeism = 5%
• SMV = 20.1
• Contract Size = 5000 pcs
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 Q. Calculate load and capacity of that order.

• Solution:
Load = Contract Size X Work Content (Total SMV of the Garment)

= 5000x20.1
= 100500.00 (ans.)
Capacity = Actual Minutes
= no. of m/c operators X working minutes x efficiency x presents %

= 24 x (8x60)x0.6978 x .95
= 7636.7232 (ans.)

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Q. Kmart placed an order of 40000pcs polo shirts to Viyellatex
ltd. Calculate the load and capacity assuming following data.

✔Operators = 52
✔Working = 8 hrs
minutes = 71%
✔Efficiency = 4%
✔Absenteeism = 26.2
✔SMV

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 Production planning – Scheduling:

Style Order Qty SMV/gmt

A 10,000 42
B 8,000 30
C 24,000 20
D 12,000 65
• A) Calculate the average weekly load of total 13 weeks lead time.
• B) If the factory’s operators 80, has 4% absent, work a 40hrs/week,
has efficiency of 85% what is the weekly capacity?
• C) Has the factory sufficient capacity to meet the plan?
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• Solution:

Style Order Qty SMV/gmt Total SMV

A 10,000 42 4,20,000
B 8,000 30 2,40,000
C 24,000 20 4,80,000
D 12,000 65 7,80,000
--------- ------------
54,000 19, 20,000

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• A) Average weekly load
= 19,20,000 SMV/13
= 147692 SMV

• B) weekly capacity
= 80 x (40X60) X .85
x .96
= 156672 smv

⮚ C) yes .
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 The Line Scheduling
Rule:
During making the schedule for line following
points are considered:

• Load & Capacity Balance

• Arrange the program of works so that the load
can be achieved.
• Use common units – SMV

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There are two types of scheduling :

1. Reverse Scheduling
Schedule starts from the “Due Date (del. Date) & schedule back
ward. External due date considerations will directly influence
activity scheduling in certain structures. Schedule of this type
are usually depicted on the Gantt Charts.

2. Forward Scheduling
Same as earlier but schedule forward from a given start time.

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 Some important formula

• 1) Target (Individual ) =60/ individual SMV

= pcs/hr

• 2) Line target = Actual Min or capacity

Total m/c SMV
• 3) Efficiency = Earned min x 100%
Available Min
= pcs x smv/pc x 100%
working time

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 Some important formula

• 4) Line Efficiency = no. of produced gmt x smv/gmt

no. of operators x working min

• 5) Performance = Earned min x 100

Available min –off std. mins

• 6) Line Labor Productivity=(total no. of output per line per day)/

no of worker worked.

• 7) Line m/c productivity= (total no of output per line per day)/ no

of machine used.
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 CM calculation???

• Total Direct & indirect cost per =A

month =B
• Total no of Machines installed = 26
• No of working days per month =A/(Bx26)
• Average cost per machine per day =C
• No of Machines per Band/Line =N
• Cost per Band or Line = NxC
• Actual output per Band =T
• Cut & Make Value per dozen = (NxC/T)x12

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 CM calculation???

• Calculation of CM (Cost of Making) of a garments can be

calculated in various ways. One of the most simplest formula
of CM calculation
= SMV X CPM,
Here, SMV = Standard Minute Value to complete of a specific
style that is calculated by machine layout & CPM ( Cost Per
Minute)

• CM per pcs= (Factory total expense per month x no of m/c required for making the garment)
(total m/c x total working hrs per month x target production)

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 CM calculation

• i. Monthly total expenditure of your factory with factory rent,

commercial cost, electricity bill, water bill, transportation,
repairing, worker & stuff wages etc. (8hrs/day) is Suppose -
50,00,000/- tk.
• ii. Qty of running Machine of your factory of the following
month (which total expenditure we have consider here),
Suppose - 100 machines.
• iii. Number of machine to complete the layout for the
following Items (which CM we are calculating), Suppose - 25
machines.

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 CM calculation

• iv. Production target/capacity of the following items, per hour

from the existing layout, excluding alter & reject, Suppose -
200 pcs per hour .
• v) Total working day of the followings month,(though the
house rent, commercial expenses, machine overhauling &
some other cost remain same), Suppose- 26 days.
• v. If you want to calculate the CM in US$ (dollar) then pls
input present dollar conversation rate BDT, Suppose $1 =
81BDT.

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 CM calculation (solution)

Garment CM Calculation:

(𝐹𝑎𝑐𝑡𝑜𝑟𝑦 𝑡𝑜𝑡𝑎𝑙 𝑒𝑥𝑝𝑒𝑛𝑠𝑒 𝑝𝑒𝑟 𝑚𝑜𝑛𝑡ℎ 𝑥 𝑛𝑜 𝑜𝑓 𝑚/𝑐 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑓𝑜𝑟 𝑚𝑎𝑘𝑖𝑛𝑔 𝑡ℎ𝑒 𝑔𝑎𝑟𝑚𝑒𝑛𝑡 )
=
(𝑡𝑜𝑡𝑎𝑙 𝑚/𝑐 𝑥 𝑡𝑜𝑡𝑎𝑙 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 ℎ𝑟𝑠 𝑝𝑒𝑟 𝑚𝑜𝑛𝑡ℎ 𝑥 𝑡𝑎𝑟𝑔𝑒𝑡 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 )
(50,00,000 𝑥 25)
= BD
(100 𝑥 26 x 8 𝑥 200)
T
= 30.048 X 12 [per
BDT dozen]
= 360.58 / [1$= 81
81 $ BDT]
= $4.45 /
dozen Ans: CM of this garment is $4.45 2
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per dozen. 9