Production Planning Management

ADM 4307 Apparel Manufacturing

Dr. Su-Jeong Hwang Shin, Ph.D. Associate Professor

Productivity

• Productivity concept: • Productivity is measured by achievement toward established goals based on

relationship between inputs and outputs. The productivity and capability are measured with three things:

(1) Throughput Volume (The amount of work completed in a specific time),(2) Throughput Time (The amount of time it takes for a single unit of style to go

through the production process, cutting to shipping)(3) Work in process (The number of garments that are under production at any

given time).

(Input) Materials

(Output) Salable Garments

•High efficiency•Low-cost work•Maximize productivity

Production Strategies

• Production Strategies:• FPP or CMT

• Production is market-driven (=Consumer demand)

• Flexibility and Fast throughput (Quick Response) Strategies.

• Mass Customization

Production Workflow

• Workflow: • Workflow is the movement of materials/garment parts through the processes.

• An inventory buffer to guarantee a smooth and consistent workflow to avoid Bottleneck in process.

• Plant layout: Arrangement of departments, workstations, and equipment's.• Two types of plant layout:

• Line layout (product oriented layout)• Operations are performed in a specified sequence.

• Less work in process, faster throughput time.

• Skill center layout (process oriented layout)• Buildup of work in process, and need more floor space.

Material handling

• Material handling: refers to the efficient movement of goods through the conversion process.

• Just-In-Time (JIT) delivery is an operational strategy that coordinates arrival of goods with immediate use and minimal handing.

Apparel Production Systems

• Progressive Bundle System (PBS):

Gets its name from the bundles of garment parts that are moved sequentially from operation to operation.• 80% of apparel

manufacturers used the bundle system.

• Bundles• Bundle tickets

Apparel production systems

• Unit Production System (UPS):

A type of line layout that uses an overhead transporter system to move garment components from workstation to workstation for assembly.• Advantage: Reducing labor

costs• UPS costs of buying and

installation, training for system, and prevention of down time.

Apparel production systems

• Modular Production System: Modular production system is a contained, manageable work unit that includes an empowered work team, equipment, and work to be executed.

• Management and team training for empowerment (Team-based production system).

• Workflow in modular production

• Work zone consists of a group of sequential operations.

Production Process Work study

• Production process:An operation breakdown is a sequential list of all the operations involved in cutting, sewing, and finishing a garment, component, or style.

Production Process Work study

• Work study- Time study. Work measurement to determine the time required to complete one element or one operation• Average observe time• Standard Allowed Minutes

(SAM)• Allowance factor: a

percentage of time added to the normal time to cover the short delays and interruptions in work.

Production Planning Management

• Production strategies: Mass customization• Mass customization requires processing single orders with

immediate turnaround.

• The goal of mass customization is to be agile enough so products can be made-to-order. (fully customized style, fit, fabric, and trim with delivery direct to home).

• Example: Body scanning technology for custom fit.

Production Planning

Production Planning• Long term production

planning:• Based on forecasts

merchandise plans, and budgets

• Short term production planning:

• Based on customer orders

Production Capacity• Factors affect Output capacity • Product variation.• Equipment type• Capacity Plant capacity. The size, skill,

and productivity of the labor, Space limitation

• Individual operation capacity: Relationship of production standards to capacity (SAMs or SAHs)

• Managing plant capacity

Example of relationships among capacity dimensionsExam