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Effective Management in
Apparel Industry
Tarun Pandey,
Associate Professor,
Pearl Academy of Fashion,
Delhi, India.
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New Realities-Market
Recessionary market.
Customer wants more range at a cheaper
price.
Seasons becoming more frequent
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Time-Line
PerformanceBenchmark
Concept to availability
Product development
Fabric procurement
Manufacturing
Delivery
1997
167
104
34
39
7
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Time-Line
PerformanceBenchmark
Concept to availability
Product development
Fabric procurement
Manufacturing
Delivery
2007
126
84
34
28
3-4
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Evolution of Supply Chain Management
Consumer
NeedsProduct
DesignProduct
Development
Raw MaterialSourcing
Factory sourcing
Manufacturingcontrol
Shipping
consolidationForwarder consolidation
Customs clearance
Local Forwarderconsolidation
Wholesaler
Consumer
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Order ProcessingRange for buyers
Sample selection by buyers
Fit Sample
Approval
Size set
Approval
Sealer / Pre-Production
sampleReady for
Production
Greige Order Lab dip /
Strike off / Bit Loom
Fabric Processing
yes
yes
no
no
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How can we avoid this situation?
Through proper planning in-
Sampling
Merchandising Production processes
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But it is not planning only..
You have to be
Faster
Better Productivity Reduce Cost
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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
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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
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Follow up
Success can only be through-
Daily monitoring
Weekly M.I.S. Meetings Right-first-time (R.F.T) Approach
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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
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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
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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.
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Production GANTT Chart
Key components
Days in X-Axis
Number of lines/machines in Y-Axis Activity block is made up of-
480 x No. of machines x Efficiency
S.P.T.
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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
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Efficiency
The efficiency will not be same for all the
days. It will be different as per the learning
curve.
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Sewing duration is dependent on
Learning curve
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Fabric Flow
Based on the above data-one can also
make a fabric flow chart.
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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
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Think : The Beginning of
Improvement