Planning is the term widely used for its immense importance in day-to-day life. It comes with strategy, mission, scheduling & routing. Though it seems like planning & scheduling are the same stuff, but in real practice, it is not. Planning is a summary view of a set of activities in which proper objective, mission, routing path & scheduling are included. From planning, we can find alternative paths & solutions. Scheduling is a part of planning with proper time & action plan of selective activities.
Garments production planning
Planning is an important factor in the garments industry. Garments manufacturers take orders based on production planning. Proper planning can execute the right time delivery (shipment) of export garments, that’s why planning is a department in the garments manufacturing industry and getting high value to middle and top management. Among cutting, sewing, washing, and finishing departments; sewing capability is the main factor of garments production planning. Getting a job in garments production planning is like a dream come true. A demandable job sitting at a cool desk, very much respected by all departments. A production planner's salary is comparatively more than other departments; not needed to deal with too many people, report, and work with top management what makes a production planner very special in the apparel manufacturing industry.
Planning is an important factor in the garments industry. Garments manufacturers take orders based on production planning. Proper planning can execute the right time delivery (shipment) of export garments, that’s why planning is a department in the garments manufacturing industry and getting high value to middle and top management. Among cutting, sewing, washing, and finishing departments; sewing capability is the main factor of garments production planning. Getting a job in garments production planning is like a dream come true. A demandable job sitting at a cool desk, very much respected by all departments. A production planner's salary is comparatively more than other departments; not needed to deal with too many people, report, and work with top management what makes a production planner very special in the apparel manufacturing industry.
1. Utilize full production capacity
2. Right product input right line
3. Meet customer given delivery date.
4. Execute whole garments manufacturing process
5. Give feedback to top management
Production planning process execution flow chart
Order confirm
↓
Production planning
↓
Sample development and approval from buying house
↓
Order chart and QC file received
↓
Trims, Accessories and Fabric in-house
↓
Pre-production sampling
↓
Pre-production sample approval
↓
Bulk cutting
↓
Sewing
↓
Washing
↓
Finishing
↓
Final Quality inspection
↓
Goods release/ pass in inspection
↓
Shipment
Cutting Plan
Cutting is not all about capacity, efficiency, and working hours. Cutting starts as per the planning sequence if the garments production preparation process has already been completed. Cutting delay for some quality issues of fabrics. Based on shade grading, shrinkage, there has a cutting plan.
Cutting Planning process:
i. Cutting Planning is done based on the following:
iii. The Cutting In-Charge informs Size, Ratio, and fabric width to the CAD department for marker preparation by preparing cutting lay order sheet.
iv. Once the Cutting In Charge has approved the marker after it has been checked for the pattern direction and tightness and consumption, it is further approved by the Production Manager for efficiency.
v. Cutting In-Charge requisition slip based on the consumption approved by Production Manager and give to the store's department for issuing of fabric.
i. Cutting Planning is done based on the following:
- Production Plan
- Order details e.g. Size breakdown, Specifications, etc.
- Approved Shade Band chart, Approved fabric swatches.
- The Production Plan is received from the Production Manager, order details from Merchandiser, and Shade Band Chart from the QC Department.
iii. The Cutting In-Charge informs Size, Ratio, and fabric width to the CAD department for marker preparation by preparing cutting lay order sheet.
iv. Once the Cutting In Charge has approved the marker after it has been checked for the pattern direction and tightness and consumption, it is further approved by the Production Manager for efficiency.
v. Cutting In-Charge requisition slip based on the consumption approved by Production Manager and give to the store's department for issuing of fabric.
Sewing Plan
A Sewing plan depends on per hour production capacity, working hours, efficiency, order quantity, machine types, and product difficulties. The first day is to set the Line layout, 2nd day you will get output but production will be less than average.
Sewing planning for example:
For a lot of 5000 pcs, Your sewing 1st-day production 300, 2nd Day 700, 3rd day 1000, 3rd Day 1150, 4th day 1150, 5th day, 6th day the rest 700 and layout of next lot. So your average production per day is 833.
For a lot of 5000 pcs, Your sewing 1st-day production 300, 2nd Day 700, 3rd day 1000, 3rd Day 1150, 4th day 1150, 5th day, 6th day the rest 700 and layout of next lot. So your average production per day is 833.
Washing process Plan
When it is coming to the wash process, generally a minimum of 3 days keep after the sewing completion date for the washing plant. In the garments industry, everything never going to happen as per planning. Sewing may take two days more than the planned date. So pressure going to hit on Washing and Finishing. A production planner has to follow up washing backlog with Washing factories; what goods are urgent, what washing delay is allowable. If garments manufacturer does not have own washing plant, they have to give subcontract in another factory. In this case communication with a washing plan, washing follows up are very much necessary for a production planner.Finishing Plan
The finishing process is very complex of fancy style. Casual styles are comparatively easier than fancy styles. Based on the buyer's product quality standard and the number of the finishing process, finishing the production plan can be done. If you have many lots in hand in finishing, you have to check which delivery is tight. Finishing is done on a priority base and Shipment date status.
1. Order Sheet
2. QC File (Trim Card)
3. Approved sample
4. Size set cutting and approval status
5. Supplier raw materials quality clearance
6. Bulk cutting start date
7. Daily sewing production
8. Washing status
9. Finishing Backlog
10. Shipment date
Final Audit and shipment
Final quality inspection is done when goods packing is already completed. If a final inspection fails and the buyer asks to recheck the whole quantity of goods, you will fall in trouble if you do not have time in hand to ship the goods. So it's really necessary to keep one week in advance when you do production planning.Garments Production Planning and Execution Factors
These factors are related to start and execute planning.1. Order Sheet
2. QC File (Trim Card)
3. Approved sample
4. Size set cutting and approval status
5. Supplier raw materials quality clearance
6. Bulk cutting start date
7. Daily sewing production
8. Washing status
9. Finishing Backlog
10. Shipment date
Conclusion
You may love to read: Pre-production processes of Garments Industry