effective management in apparel industry

7/31/2019 Effective Management in Apparel Industry

1/22

Effective Management in

Apparel Industry

Tarun Pandey,

Associate Professor,

Pearl Academy of Fashion,

Delhi, India.


2/22

New Realities-Market

Recessionary market.

Customer wants more range at a cheaper

price.

Seasons becoming more frequent


3/22

Time-Line

PerformanceBenchmark

Concept to availability

Product development

Fabric procurement

Manufacturing

Delivery

1997

167

104

34

39

7


4/22

Time-Line

PerformanceBenchmark

Concept to availability

Product development

Fabric procurement

Manufacturing

Delivery

2007

126

84

34

28

3-4


5/22

Evolution of Supply Chain Management

Consumer

NeedsProduct

DesignProduct

Development

Raw MaterialSourcing

Factory sourcing

Manufacturingcontrol

Shipping

consolidationForwarder consolidation

Customs clearance

Local Forwarderconsolidation

Wholesaler

Consumer


6/22

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


7/22


8/22

How can we avoid this situation?

Through proper planning in-

Sampling

Merchandising Production processes


9/22

But it is not planning only..

You have to be

Faster

Better Productivity Reduce Cost


10/22

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


11/22

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


12/22

Follow up

Success can only be through-

Daily monitoring

Weekly M.I.S. Meetings Right-first-time (R.F.T) Approach


13/22

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


15/22

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.


16/22

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


18/22

Efficiency

The efficiency will not be same for all the

days. It will be different as per the learning

curve.


19/22

Sewing duration is dependent on

Learning curve


20/22

Fabric Flow

Based on the above data-one can also

make a fabric flow chart.


21/22

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


22/22

Think : The Beginning of

Improvement

effective management in apparel industry

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