Production Planning and Controlling in Garments industry
Production Planning and Controlling
in Garments industry
Production planning and controlling department is the heart of modern clothing industry.
Shortly abbreviate as PPC. PPC plays roles from order taking from buyer to ex-factory
the goods according to the commitment. Capacity planning, forecasting, delivery
confirmation to buyer, making details plan of each order’s, pre-production
planning, critical path management, pro-active follow up in bulk, supply chain
synchronization, adjustment based on progress, set target in each section. In
this article you will study job area and responsibility of Production Planning and controlling department in clothing
industry.
Before you start, let study the term below,
PRODUCTION: In a simplified way to describe that, production is a
process of conversion of raw materials to finished goods. In clothing industry;
Fabric (S/J, Rib, Terry, and Fleece etc.), Accessory (Sewing thread, button,
zipper etc.) is the raw material and Pants, Jacket, Leggings is the finished
product.
PLANNING: This is the technique which will let to forecast in process, calculate potential
complications and adopts solution in advance to ensure the execution of production
progress is smooth, within timeline and in best direction.
CONTROL: This is the most important phase of planning, from pre-production to bulk
each process need to perform as per schedule. There is timeline to perform each
process which combined execution on time ensure the plan is feasible. If any
process is failed to perform as per calendar it impacts next processes and
ultimate failure for end result.
Production Planning and Controlling schematic arrangement
Job area of
Production Planning and Controlling Department:
PPC department is treated as smartest and unique Gate Keeper of
others department. PPC department actively need to work with another department
directly, as a PPC you need to work with other department directly to make that
ensure below key tasks.
You can represent PPC job area in below diagram
and it is easy appreciative that you need to work with all the constituent part
of the factory and connect each of the department to achieve factory ultimate goal.
Roles of Production planning and controlling department:
➤PPC department ensure smooth supply chain practice of an industry.
➤Calculate factory capacity, follow up accordingly with Sales MER to
ensure order loading
➤Allocate order to the subsidiary factory, monitor and control shipment
deadline
➤Calculate factory capacity; daily, weekly, monthly & yearly.
➤Work directly with merchandising & production dept. and make bridge.
➤Follow up production plan and ensure each event execution as per plan
schedule.
➤Make Plan for Confirm, Projection & Forecast order.
➤Synchronize the Supply Chain in respect of Production Planning to ensure
the full quantity & on time shipment.
➤Maintain the interpersonal relationship to build up a strong bridge of
communication between each department
➤Daily basis tracking production progress, adjust in Fast react
accordingly. Any delay or advance of sewing lines make adjustment in other
processes.
➤Closely work with Compliance & Safety related issues and consider in
planning. Ex: Working hour adjusted as per policy.
➤Material issue in the production as per consumption and make sure no
excess wastage.
➤MPP- monitoring the process of production.
➤INV-Inventory control
➤Provide the sewing target (Daily/Weekly basis) & plan sheet to
production floor.
➤Daily basis input monitoring and discussion in daily production meeting
with team against plan and actual deviation
➤Accurate &timely planning & reporting; stand up in case of any
idle and shipment issue arise
➤T&A calendar preparation, critical path management.
➤Coordinate with other department relating with production to achieve
regular balanced & uninterrupted production flow.
➤Collect SMV from IE department in order to set up line in curve
(Progression) & sewing target.
➤Daily basis hit rate sharing for cutting, sewing, and packing and
evaluate performance.
➤Arrange weekly capacity meeting, review new style for the coming 3 months
and loading situation
➤Coordinate weekly meeting with MER for accessories in-house status to
avoid any crisis execute as per line plan
➤Prepare Print out
print in Plan and daily basis monitoring with supplier
Production Planning and Controlling Work process
➤Loading plan preparation based on
weekly capacity analysis and order information
➤Create strip for newly added order
in FR load list.
➤Prepare fabric and accessories
in-house details to make in order details file
➤Plan new order in FR/Excel both
projection and Confirm order
➤Aligned with IE set Eff, learning
curve and make plan. Generate the plan and send concern department
➤Make Size set and Initial Plan
before Bulk and Follow up Accordingly
➤Making of PO wise follow up plan
base on production plan
➤Follow up Fabric & Accessories
In-house on time
➤Weekly Update the Production Plan
and Loading Plan. Share with management for Overall Capacity and line Gap issue.
➤Ensure input without any gap into
production line
➤Control input and ensure proper
utilization of fabric and material
➤PO closing on Weekly basis to
Ensure on Time Shipment without any Hassle
➤After Shipment GR in SAP
➤Weekly Capacity review with
management and review upcoming new style
➤Prepare next three months factory
and financial Capacity projection
➤Set target on ETS base on capacity
projection for production. Daily SAH and Eff target to achieve production
➤TECO in SAP. After shipment need
to close and calculate material utilization ensure maximum utilization of
resources
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