Planning & Order Management

Session 12

Business of Design

Calendar Planning & Order

Management

Process Flow & Plan and Execution of

a particular Order / Style/ Account

Calendar Planning & Order Management

Introduction

Key activities for effective calendar planning and

order management

Coordination of materials with suppliers

Efficient utilization of people and machines

Efficient flow of materials

Good communication with buyers

4

Introduction

Raw Materials

Finished Products

Raw MaterialMachines

People Suppliers Customers

A typical manufacturing system

5

SAMPLES   DATE Style No.:       TRIMS   DATE

Size Set Submit   Date:       Main Lable      

Expected Appvl.   W/Care Lable      

PP Submit   Button        

Expected Appvl.   Zip          

      Lace          

     

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

FABRIC                                                          

CUTTING                                                                    

PRINTING                                                                    

EMBROIDERY                                                                    

SEWING                                                                    

FINISHING                                                                    

Pilot Run                                                                  

Initial Insp                                                                    

Mid Insp                                                                    

Final Insp                                                                    

Time and Action Calendar for 1style

7

SAMPLES  DATE   Style No.:  TRIMS DATESize Set Submit     Date:   Main Lable  

Expected Appvl.    W/Care Lable  

PP Submit       Button  Expected Appvl.     Zip            Lace                    

Fabric Cutting Printing Embroidery Sewing Finishing

ORDER NO.

STYLE NO. EDT Start End Start End Start End Start End Start End Start End Pilot Run Initial Insp Mid Insp Final Insp

                                                                                                                                                    

Time and Action Calendar for many styles

8

BUYER : CLT-182SEASON : S'07STYLE NO. : 150336STYLE DESC : strap to with pleating and embr stitching detail at empire lien QTY : 5,000 Pcs, PARISFABRIC ; 70’s Cotton voile print stripes+Plain 70’s Cotton voile

FABRIC MILL :

Fabric Supplier: Nagpal Textiles

Contact No: 9810035088printing mill SPL, Faridabad

MANPREET 989121102

R.K. GUPTA 981499986Office Responsible SLA

in days POSSIBLE ACTUAL DEVIATION REMARKSParis office 1/10/2007

OC Received from Paris Ishwar India 1/13/2007Teck Pack received from Paris Paris office/ Roopneet 1/16/2007OC issued to Factory India & Roopneet 1/14/2007

Ishwar India 1/22/2007 24/01/06India & Roopneet 1/29/2007India & Roopneet 2/2/2007India & Roopneet 2/9/2007

Technical sample (4 days after the fit is approved India & Roopneet 2/13/2007Technical samples (6 days after the comments received India & Roopneet 2/19/2007

POSSIBLE ACTUAL DEVIATION REMARKS Roopneet 1/11/2007

Labdip/Strikeoff/Deskloom off Submit- (6days after po issued to factory) Roopneet 1/18/2007Approval of Labdip/Strikeoff/Deskloom off Submit- (comments from sent date) India + Paris 1/23/2007First of bulk 10 days after labdip/Strikeoff/Deskloom approval Roopneet 2/2/2007

Roopneet 2/9/2007

Roopneet + Paris 2/14/2007 Roopneet + India 2/11/2007

Roopneet 2/10/2007Shade lots approved Ishwar India 2/11/2007

Roopneet 2/10/2007Embroidery Submit Roopneet 2/9/2007Embroidery Approvals Ishwar India 2/16/2007Garment Print submitsGarment Print ApprovalSpecial Trims Submit Roopneet 1/15/2007

Roopneet 2/7/2007Trim Card Submit Roopneet 2/8/2007

Roopneet+ India 2/18/2007

ACTUAL DEVIATION REMARKS Roopneet 2/14/2007India + Paris 2/15/2007

PP meeting India+ Roopneet 2/16/2007India+ Roopneet 2/19/2007India+ Roopneet 2/16/2007India+ Roopneet 2/17/2007

Bulk wash approval India+ Roopneet 2/19/2007Wash Test Garment India+ Roopneet 2/21/2007

India+ Roopneet 2/19/2007India+ Roopneet 2/26/2007India+ Roopneet 1/23/2007

Final Inspection Date India+ Roopneet 2/28/2007India+ Roopneet 2/28/2007

Final X China 3/4/2007SEA

REVIEWED & CONFIRMED BY VENDOR (SIGNATURE W/NAME)

REVIEWED & CONFIRMED BY ISHWAR (SIGNATURE W/NAME)

BCD(30 DAYS Sewing Start ( )

Mid Inspection

Pilot Offer ()

Top Sample Exit (E)

GMT LC

At the Forwarder (50 Days from OC to Fty)

PP/Sealer Sample Approval

Thread Panel Submit(days)

Gpt Sample Report

Fabric Inspection Report

Shade lots submit by fty

Trims Inhouse 50 Days

PP/Sealer Sample ( )

Fit sample re submit (4 days from the Ist fir comments received)FA 2 Comnts Fom Buyer (Max 6 days frm revised smpl sent)

Fit sample Exit from India (5 days + teck pack Received)Fit sample comments received (exit + 6 days)

Bulk Fabric Inhouse

Fabric Test Report with Wash care

Fabric Booked

Order confirmation (60 days from goods Ex-China) Olivier

9

From: bhavna.sharma [mailto:bhavna.sharma@impulse.co.in] Sent: Wednesday, February 07, 2007 2:51 PM To: vishal Cc: 'Impulse - Shivani Choudhary (E-mail)'; toni@orchidoverseas.com Subject: Re: 4782-T&A Hi Toni/Vishal, Pls. note that the attached FPO's and POD's have already been sent to you which clearly mention that the dates are x-india not x-factory. Resending the same.Pls make sure that the deliveries are met or factory has to air the goods at it's own cost. Confirm yr understanding. Regards Bhavna Sharma -------------------------------------------------- Debenhams Impulse +91-124-4026-459 ----- Original Message ----- From: bhavna.sharma To: vishal Cc: 'Impulse - Shivani Choudhary (E-mail)' ; toni@orchidoverseas.com Sent: Wednesday, February 07, 2007 11:08 AM Subject: Re: 4782-T&A

Order Management

Orders need to be managed because in real life

there always exist a gap between planned and

actual.

We need to monitor to check if everything is

going as per the plan

When delays start creeping in, managers have to

take actions to ensure timely deliveries.10

Order Management

Orders are managed based on the following

factors:

Delivery dates

Quality

Price

Order quantity

Importance of buyer11

Family sequencing

Product sequencing

Machinery

Labour

Software for Planning

Software for production planning provides

support for decision making

Software does not make decisions or manage

the operations, Managers do

However, today some software support the

decision makers as well as make (at least) some

of the decisions! 12

Planning Activities

Materials PlanningPurchasing

Raw Material Inventory Control

Capacity PlanningScheduling Machine and People

WIP Inventory Control

- Fabric store- Accessory store

Production Department

13

Hierarchical Planning

1. Overall Manufacturing Planning

2. Detailed Materials and Capacity Planning

3. Execution of Plans

14

1.Overall Manufacturing Planning

Demand Management

Forecasting

Order Promising

Order Booking

Order Entry

15

- Monthly Plans for Product Families- Weekly Plans for Individual Products

1.Overall Manufacturing Planning

16

Example

Product Family: T-shirts

Products: Red, Blue, Green

Usually a period is one month and a sub-

period is one week (s=4)

17

Example (Cont’d)

Production Plan Months

1 2 T-shirts 100000 120000

Master Production Schedule Products Weeks

1 2 3 4 1 2 3 4 Red 10 10 10 10 15 15 15 15 Blue 10 10 10 10 10 10 10 10

Green 5 5 5 5 5 5 5 5

18

1.Overall Manufacturing Planning

Resource Planning Long-Range Capacity Requirements

Number of Machines

Number of Employees

Overtime

Shifts

Plants19

20

Materials Planning of raw materials,

components, parts, sub-assemblies, etc.

How much

When (time phased deliveries)

Dependent/independent materials/activities

2.Materials & Capacity Planning

21

Detailed Capacity Planning

Labor Hours Required

Machine Capacity Required

2.Materials & Capacity Planning

Purchasing Purchasing Plan

Vendor Search/Vendor Capacity

Quotation

Order Release

Order Follow-up

22

3. Execution of Plans

23

Shop Floor ControlAssembly line layout may be usedSimilar machines may be grouped into work

centers OR Similar parts are grouped into familieswork orders with schedules may be released to

work centers / departments / machinesstart and end date of orders are determinedschedules are daily updated

3. Execution of Plans

Case study 2

Resource Planning:

Assume that a dress manufacturing company

decided to open three manufacturing sites

(Mexico, Ireland and Singapore)

Each plant is going to run one shift except

embroidery area which will be run in 2 shifts due

to high investment requirement.24

Mexico plant

(Units/yr) Ireland plant (Units/yr)

Singapore Plant (Units/yr)

Formal dresses

300000 200000 150000

Party dresses

350000 225000 200000

Hi-fashion dresses

150000 100000 75000

25

Example contd.Demand Management:Demand is forecasted for different product families and different plants as follows:

Months 1 2 3 4 5 6 7 8 9 10 11 12 Formal 20K 20K 20K 20K 20K 20K 30K 30K 30K 30K 30K 30K Party 20K 20K 20K 20K 20K 20K 30K 40K 40K 40K 40K 40K Hi-fashion 10K 10K 10K 10K 10K 10K 15K 15K 15K 15K 15K 15K

PRODUCTION PLAN IS PREPARED FOR IRELAND AND SINGAPORE PLANTS AS WELL.

26

Example contd.

Production Plans:Mexico Plant

Mexico plant Ireland plant Singapore

plant Manpower 300 200 150

Machine Type X

50

40

30

Machine Type Y

100

120

50

Machine Type Z

150

40

70

27

Example contd.Demand Management:Following manpower and resources requirements are estimated for each plant:

Weeks 1 2 3 4 Silk satin dresses 1K 1K 1K 2K Silk satin dresses with silk thread emb.

1K 1K 2K 1K

Polyester crepe dresses 1K 2K 1K 1K Polyester crepe dresses with viscose thread emb.

2K 1K 1K 1K

TOTAL 5K 5K 5K 5K

28

Example contd.

Master Production Schedule:Mexico Plant – Party Line – 1ST Month

Master schedule is prepared for each month (possibly for the 1st couple of months, not for the entire year) and product family.

Mexico plant Manpower 340 (300)

Machine Type X 55 (50) Machine Type Y 95 (100) Machine Type Z 190 (150)

29

Example contd.Rough-cut Capacity Planning:Due to shortfall in production rates, the Manpower and Machine requirements is revised.

Weeks 1 2 3 4 5 6 7 8 9 10 11 12 Silk satin (‘000 mts.)

7 7 10 10 …

PES crepe (‘000 mts.)

9 9 6 6 …

Silk thread (‘000 mts.)

500 500 1000 500 …

Viscose thread (‘000 mts.)

2000 1000 1000 1000 …

30

Example contd.Materials Planning:Detailed material plans are prepared for subassemblies and parts to be manufactured; components and raw materials to be purchased.

Weeks 1 2 3 4 5 6 7 8 9 10 11 12 Manpower 320 310 330 322 … Machine X 52 55 60 57 … Machine Y 90 92 98 95 … Machine Z 178 163 172 170 …

31

Example contd.Capacity Requirements Planning:

Cell1 Job1 Job 3 Job 7 Cell2 Job 2 Job 4 Cell3 Job 5 Job 8 Job 6 Time (hrs) 32

Example contd.Purchasing:Contact vendors, evaluate quotes and cut purchase orders.Shop Floor Control:Assign parts to be embroidered to different embroidery machines (computer, machine, hand)Load manufacturing cells with products and determine start and completion times

Process Flow and Plan

34

Process Flow

Execution of a particular Order/Style/Account

Actual samples of garments is to be used to illustrate and discuss the step by step process of executing a simple, intermediate and complex style in the class.

Execution of a particular Order/Style/Account