Apparel Production Planning and Control

Introduction
Industry: Celebrity Fashions, MEPS, Chennai

Date: 23/09/19
Collected information:
 Sewing line: LL Bean Men’s Trouser (Faded Pink)
 Line: B
 Style being processed: Men’s Trouser
 No. of machines: 65
 Types of Machines:
1. Single Needle Lockstitch machine
2. Double Needle Lockstitch machine
3. Bar tack machine
4. Overlock Machine ( single thread and 3 thread )
5. Pocket welting machine
6. Flatlock machine
7. Button hole machine
8. Button sew machine
 No. of operators (including floaters): 76
 No. of helpers: 10
 No. of checkers: 5
 Supervisor(s): 1 - Anusiya & 2 Asst. Supervisors
 No. of QC: 1 – Saraswati
 Mechanic for the line: Dinesh Kumar (Factory Staff)
 Production System: Progressive Bundle Unit System
 No. of Operations: 64 Operations

 SAM: 25.1mins
 Target Fixed: 864
 Target Achieved: 654
 Hourly Target: 120
 Line Efficiency(Avg.): 50%
 Absenteeism: 6%
 Operation wise no. of machines allocated:
 Bundle size:
 Average WIP between operators: 5
 Defective Production: 7%
Calculations
1. Ideal Target based on SAM(on 100% efficiency):

= (Total working minutes in a day* No. of operators* Line efficiency) / SAM
 Total working minutes in a day = 8 hours * 60 = 480

 No. of operators= 76
 Line efficiency= 100 percent
 SAM = 25.1
= (480 * 76 * 100) / 25.1*100
=1,650.67
Comparing ideal target with company’s original target
Company’s target to be achieved was 864 but only 654 was achieved with a line efficiency of
50 percentage. So, the difference between ideal target (with 100% efficiency) and the target
achieved is nearly 1000.
2. Capacity in hours:
= Workers present * Line efficiency * Total working hours per day
 Workers present = Total number of workers - (Absenteeism percentage * Total

number of operators )
= 76 - ((5/100) * 76)
= 76 – 3.8
= 72.2
 Line efficiency = 50 percent
 Total working hours per day = 8 hours
= (72.2 * (50/100) * 8)
= 288.8 SAH
3. Capacity in pcs:
= (Capacity in hours * 60)/SAM) * Line efficiency
 Capacity in hours= 288.8
 SAM of the garment = 25.1
 Line efficiency= 50 percent
= ((288.8 * 60) /25.1)* (50/100)
= 345.17
Operation breakdown
Operation description Machine type

Loops
1.Make loops Flatlock Machine
Waistband
1.Attach interlining to top waistband SNLS
2.Press under waistband at fusing Fusing m/c
machine
3. Attach tape at under waistband SNLS
4.Close tape at under waistband SNLS
5.Attach top and under waistband SNLS
6.Close waistband ends or invert SNLS
7.Press waistband Iron Table
Back
1.Mark for dart or pocket lock Table
2.Sew dart SNLS
3.Press dart and fuse interlining or press Iron Table
facing
4.Make welt pocket APW
5.Press welt open Iron Table
6.E S lower welt SNLS
7.Attach facing to pocket SNLS
8.Sew back pocket SNLS
9. Close pocket bag SNLS
10. ES upper welt SNLS
11. ES upper pocket SNLS
12. Close back rise FOA
Front
1.Coin pocket mouth hem SNLS
2. Press coin pocket Iron Table
3. Coin pocket attach to facing SNLS
4.Prepare and attach main/size/care label SNLS
5.Attach facing to pocket SNLS
6.Attach facing to front SNLS
7.Press pocket open Iron Table
8.ES pocket open SNLS
9.TS pocket open SNLS
10. Close pocket bag SNLS
11.Invert pocket bag SNLS
12.Stay stitch-sides/waist SNLS
Down Fly
1.Make down fly invert SNLS
2.Overlock down fly SNLS
3.Binding attach at top fly SNLS
Assembly
1.Overlock front rise 3T Overlock
2.Attach top fly SNLS
3.Attach zipper SNLS
4.Sew J stitch SNLS
5.Attach down fly to zip front SNLS
6.Close front rise SNLS
7.ES front rise DNLS
8.Setting Table
9.Close sides Single thread Overlock
10.Fold and press bottom Iron table
11.Close inseam Single thread Overlock
12.Mark for loops lock/measure and cut Table
loops
13.Attach loops SNLS
14.Attach waistband SNLS
15.ES upper waistband SNLS
16.Sew dummy stitch SNLS
17.Close waist band SNLS
18.Tack lower loops SNLS
19.Fold and tack upper loops SNLS
20.Fold and TS bottom hem SNLS
21.Bar tack loops Bar tack m/c
22. Bar tack back pocket/fly/front Bar tack m/c
pocket/crotch
23.Mark for button lock Table
24.Attach button Button Sew m/c
Layout
Make loops Prepare and Attach facing to Attach loops Attach waistband
attach pocket
main/size/care
label
Attach Coin pocket Attach facing to Mark for loops ES upper
interlining to attach to facing front lock/measure waistband
top and cut loops
waistband
Press under Press coin Press pocket Close inseam Sew dummy stitch
waistband at pocket open
fusing
machine
Attach tape Coin pocket ES pocket open Fold and press Close waist band
at under mouth hem bottom
waistband
Close tape at Close back rise TS pocket open Close sides Tack lower loops
under
waistband
Attach top ES upper pocket Close pocket bag Setting Fold and tack
and under upper loops
waistband
Close ES upper welt Invert pocket ES front rise Fold and TS
waistband bag bottom hem
ends or invert
Press Close pocket bag Stay stitch- Close front rise Bar tack loops
waistband sides/waist
Mark for dart Sew back pocket Make down fly Attach down fly Bar tack back
or pocket lock invert to zip front pocket/fly/front
pocket/crotch
Sew dart Attach facing to Overlock down Sew J stitch Making button
pocket fly hole
Press dart E S lower welt Binding attach at Attach zipper Attach button
and fuse top fly
interlining or
press facing
Make welt Press welt Overlock front Attach top fly
pocket pocket rise
APPAREL PRODUCTION AND PLANNING CONTROL
ASSIGNMENT 1
By:
Asan Marfaq
Aswathy Sudhakaran
Nirmal K Manoj
Priyanka R

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Introduction

Industry: Celebrity Fashions, MEPS, Chennai

 No. of Operations: 64 Operations

1. Ideal Target based on SAM(on 100% efficiency):

 Total working minutes in a day = 8 hours * 60 = 480

 Workers present = Total number of workers - (Absenteeism percentage * Total

Operation description Machine type

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