Effective Management in Apparel Industry

Tarun Pandey, Associate Professor, Pearl Academy of Fashion, Delhi, India.

New Realities-Market
Recessionary market. Customer wants more range at a cheaper price. Seasons becoming more frequent

Time-Line
Performance Benchmark Concept to availability Product development Fabric procurement Manufacturing Delivery 1997 167

104 34 39
7

Time-Line
Performance Benchmark Concept to availability Product development Fabric procurement Manufacturing Delivery 2007 126

84 34 28
3-4

Evolution of Supply Chain Management

Consumer Needs Consumer Product Design Product Development Raw Material Sourcing Wholesaler Factory sourcing Local Forwarder consolidation Manufacturing control Forwarder consolidation

Customs clearance

Shipping consolidation

Order Processing
Range for buyers

Sample selection by buyers

Fit Sample Greige Order Lab dip / Strike off / Bit Loom

Approval

no

Approval
no

yes

Fabric Processing Sealer / Pre-Production sample Ready for Production

yes

Size set

How can we avoid this situation?

Through proper planning inSampling Merchandising Production processes

But it is not planning only..

You have to be Faster Better Productivity Reduce Cost

Production planning is dependent on:

Planned-cut-date (P.C.D.) P.C.D. is dependent on: -Fabric /Trims In house date -Final Sample Approval date -Capacity Available

T&A
Time and Action calendar can be great tool to follow as it has Fabric and Trims In house (Target/Actual) Dates Sampling Approval In house (Target/Actual) dates Production Processes start and end dates

Follow up
Success can only be throughDaily monitoring Weekly M.I.S. Meetings Right-first-time (R.F.T) Approach

Capacity Calculation
Example on production capacity calculation
A manufacturing facility has
820 sewing worker 22 working day in a month 8 Hours in a day 60 minute in an hour

Capacity Calculation
Capacity input:
820 X 22 X 8 X 60 = 8,659,200 minute Or 144,320 hour

If basic garment with 18.8 SAM is defined, the factory theoretical should be able produced 460,595 garment in a months time 8,659,200 minute / 18.8 SAM = 460,595 piece

GANTT CHART
A Gantt chart is a graphical representation of the duration of tasks against the progression of time. A Gantt chart is a useful tool for planning and scheduling projects.

Production GANTT Chart

Key components Days in X-Axis Number of lines/machines in Y-Axis Activity block is made up of480 x No. of machines x Efficiency S.P.T.

Example
Style #378407(Spght strap tank) Delivery-7200pcs-5/03+4800pcs-25/3 SPT-11.58 No . of pcs. In a day = 480 x30 m/cs x50 11.58 x100 =621 pieces

Efficiency
The efficiency will not be same for all the days. It will be different as per the learning curve.

Sewing duration is dependent on Learning curve

Fabric Flow
Based on the above data-one can also make a fabric flow chart.

Costing
Costing now days is approached in a different way: Cut Make = C.P.M. x S.P.T C.P.M.->Cost per Minute S.M.V.->Standard Processing time

Think : The Beginning of Improvement