Apparel Manufacturing Industry Garments | Apparel | Leather Manufacturing

Vital steps involved in Production Planning are as follows:-

Job | Task Scheduling: Preparation of time and action sheet for each order from order receiving to shipment. The task 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 listed. For example, scheduling planned cut date (PCD), production line loading date etc.

Material Resource Planning (Inventory): Preparation of Material requirement sheet according to sample product and buyer specification sheet. This is usually calculated as per Bill of material for the Item being produced. Consumption of material (fabric, thread, button, and twill tape) is calculated and estimated as per cost of each material.

Loading production: Planner defines (as per Orders) which style to be loaded to the production line and how much quantity to be loaded.

Process selection & planning: Processes needed to complete an order vary from style to style. According to the order (customer) requirement PPC department selects processes for the orders. Sometimes extra processes are eliminated to reduce the cost of production.

Facility location: Where a company has multiple factories (facilities) for production, factories are set for a specific product, planner needs to identify which facility will be most suitable for specific orders. Sometimes there may be a capacity shortage in a factory, in that case, planner need to decide which facility will be suitable for new orders.

Estimating quantity and costs of production: Planner estimate daily production (units) according to the style's work content. With estimated production figure, production runs and manpower involvement, planner also estimate production cost per pieces.

Capacity planning: PPC department plays a major role during order booking. It decides (suggests) how much order should accepted according to available production capacity. It allocates total capacity or decide how much capacity to be used for an order out of total factory capacity. It regularly updates factory's current capacity (production capacity).

Line planning: Preparing detailed line planning with daily production target for the production line. Most cases line planning is made after discussion with the 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. It chases other department heads on a daily basis to keep the plan execution on track. It updates order wise completed tasks on the Time & action sheet. When it finds something is going to be late they expedite and create an alarm about the delay.

Production

Maker Making

The maker making is one of the most important tasks in the garment manufacturing industry. Accurate maker making helps to reduce fabric, material wastage which ultimately reduces the cost of making finished garments.

Fabric Spreading

To cut the fabric properly, fabric is spread in the play form. Fabric spreading is done manually or by using the computerized method.

Cutting

In this stage, the fabric is layered on a table, layer by layer up to a certain level. Then by means of cutting machine, fabric are cut into garment shapes or pattern and separated from the layer. This cutting can be done by manually operated blade cutting machines or by computerized laser beam cutting.

Sewing /Stitching

Garments are sewn in an assembly line with the garment becoming complete as it progresses down the sewing line. Sewing machines operators receive a bundle of cut fabric and repeatedly sew the same portion of the garment, and passing that completed portion to the next operator in line.

For example, the first operator may sew the collar to the body of the garment and the next operator may sew a sleeve to the body. Quality assurance is performed at the end of the stitching line to ensure that the garment has been properly assembled.

Thread Trimming

After stitching, all hanging threads are cut by means of hand trimmer. Auto thread trimming machines are also available to perform this task. All loose threads inside the garment are removed as well. Garments without any loose thread and long tail is the very basic requirement.

Washing

This process is performed when the buyer wants washing or special finishes to the garments. generally, for light colour, garment washing is carried out to remove dirt and stains.

Finishing & Ironing

After sewing, we get a complete garment which is treated with steam ironing and several finishing processes are done including extra loose thread cutting.

Additional Processes

To make the garment more attractive / or as per requirement few additional processes are done like dyeing, printing, embroidery for the value addition.

Packing & Folding

Each pressed garment is then folded with tissue or cardboard. Folding varies from product to product and also from buyer to buyer.

Hang tags, special tag and price tag are attached with plastic Kindle or thread. Folded and tagged garments are then packed into the poly bags / desired packing.

Final Inspection

Generally, this process includes checking of the garment, measurements checking. After completion of all process, all pieces are checked by quality check team to ensure that garments are being made as per buyer's quality standards. Checking is normally done for visual appearance and measurement.

Dispatch

After completing all the process, the garment is now ready for dispatch.

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SERVUNTO™ - ERP On Device assists manufacturing houses to carry out multiple processes with ease, particularly when number of simultaneous Buyer Orders increase and when it becomes increasingly difficult in managing the complexity. Few of the functions available in SERVUNTO™ are as follows: -

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