Capacity planning in garment industry22

1. Capacity Planning In Garment Industry
Factory production capacity is derived from the resources available at the manufacturing plant. It
is calculated simply by the amount of machines available and hours per day determined to work
to be realistic, one has to determine the efficiency level of the operators and incorporate the
percentage to derive actual capacity.
Example: if a factory has 100 machines and working hours are 8 hours per day and 26 days per
month. the efficiency level of operators is observed to be at 80% . The production capacity
available time per month would be calculated as below:
o Available monthly production time capacity :
o 100 machines x 480 Mins x 80 / 100 = 38400 Mins / day.
o 38400 Mins x 26 days = 998400 Mins /month or 16640 hours/month
SPECIAL MACHINE PRODUCTION CAPACITY
Once planning production, it has to be known that if any special operation is required within the
garment which requires special machine or machines. if so , the output capacity for those
garments have to base upon special machine production . The management can then decide if
those machines be worked overtime or if required to meet shipment date, additional machines be
purchased.
To calculate special machine capacity per month , the available machines are 10 , work hours
/day are 8 hours , efficiency level is 80% and working days per month is 26 days.
 Special production capacity in time / month =
 10 machines x 480 Mins x 80 / 100 = 3840 Mins / day
 3840 Mines x 26 days = 99840 Mins / month or 1664 hours /month.

2. PRODUCTION CAPACITY AND TYPES
MAXIMUM CAPACITY:
Total hours available under normal conditions in a given period of time.
POTENTIAL CAPACITY:
Maximum capacity adjusted for efficiency.
COMMITED CAPACITY:
Total hours previously allocated for production during a certain time period.
Total hours available under normal conditions in a given period of time
AVAILABLE CAPACITY:
Difference between potential capacity and committed capacity for a certain time period.
REQUIRED CAPACITY:
Sam or SAH necessary to produce a specified volume in a certain time period.
EXCESS CAPACITY:
Difference between potential capacity and required capacity.
Lets say ABC garments company has 20 operators who work 8 hours a day. The plant has 90% efficiency
level. Working shift is 8 hours a day in which 1 hour is mainly for lunch and tea time break. So their
potential capacity for next 10 days will be, 20 machines x 7 hours /day = 140 hours/day x 90%
efficiency = 126 potential production hours /day.
Potential capacity for 10 days = 10 days x 126 hours = 1260 hours potential capacity.
Lets say ABC garments company has 10 operators who work 8 hours a day. The plant has 90% efficiency
level. A customer brings in order for 6000 units of style “a” that needs to be delivered in 10 days. The
plant already has a committed capacity of 300 hours for the 10 days period.
Working shift is 8 hours a day in which 1 hour is mainly for lunch and tea time break.
It was established that style “ a” has a production time of 5 SAM. The order of 6000 units requires 30,000
SAM (500 hours). What factors should be considered in deciding whether to accept the order or refuse?
Yash (APM-2),Production Planning
Link: slideshare.net/suniltalekar1/capacity-28828885?from_action=save

3. Line Balancing in Garment Production
1. Introduction-
Construction of a quality garment requires a great deal of know-how, a lot of
coordination and schedule management. Clothing manufacturing consists of a variety of
product categories, materials and styling. Dealing with constantly changing styles and
consumer demands is so difficult. Furthermore, to adapt automation for the clothing
system is also so hard because, beside the complex structure also it is labor intensive.
Therefore, garment production needs properly rationalized manufacturing technology,
management and planning.
In garment production, until garment components are gathered into a finished garment,
They are assembled through a sub-assembly process. The production process includes a
set of workstations, at each of which a specific task is carried out in a restricted sequence,
with hundreds of employees and thousands of bundles of sub-assemblies producing
different styles simultaneously (Chan et al, 1998). The joining together of components,
known as the sewing process which is the most labor intensive part of garment
manufacturing, makes the structure complex as the some works has a priority before
being assembled, Furthermore, since sewing process is labor intensive; apart from
material costs, the cost structure of the sewing process is also important. Therefore, this
process is of critical importance and needs to be planned more carefully (Tyler, 1991). As
a consequence, good line balancing with small stocks in the sewing line has to be drawn
up to increase the efficiency and quality of production.
2. Experimental-
In the production of garment, at first garment model is designed. Then, according to
model requirements, a sort of fabrics are cut as well as classified due to their sewing
sequences.
Then, cut fabrics are sewn and assembled in order to form garment. After the sewing and
Pressing process, garment is controlled for eliminating sewing faults, and finally it is sent
to package and expedition.
2.1 Sewing line flow-
The whole trousers manufacturing cycle includes a sequence of different phases of
assembly operations.
In the production of trousers, there are mainly four sequences of phases namely (i) prep
reparation of pockets, fly and labels, (ii) production of back of trousers, (iii) production
of front of trousers, and (iv) Assembling of fabric parts. As seen in Fig.1. At first pockets,
fly and labels are prepared in order to be ready for insertion to fabric parts. Then, both
back. And front pockets are inserted to back and front fabric of the trousers, respectively.
Fly is sewn on the front fabric. Front and back fabrics of trousers are prepared
individually. Then all fabric parts are assembled in order to form trousers sequentially:
Back and front fabrics are assembled. Zipper is attached and, belt and waistband are
attached and sewn as well.
Finally, hems, pockets, belt loop bar tack seams are done and, by this way the sewing
Process of trousers is finished.

4. 2.2 Time study-
In order to balance the sewing line as well as to increase the efficiency of the line, at first
a detailed work and time study was carried out to find the task durations However, the
time required to complete a task depends on a lot of factors such as the task, the operator,
the properties of fabric and sub materials, working environment, quality level of the
product, the hour of the day, psychology of the operator etc.
2.3Model building basics-
In the creation of a model, the decision of right atom at a right place is critical issue. An
Atom can be a machine, a counter, a queue or a product etc. To create our sewing line
model, mainly six different types of Atoms that were used in our model are as follows:
 Product: This atom represents the products/customers/raw materials that comes
into An atom through an input channel and leave the atom through an output
channel
 Source: The function of this atom is to produce products into the model
 Queue: This atom represents the waiting area for customers or products.
 Server: This atom corresponds to a machine or a counter. Atoms coming to a
server undergo a process and stay in this atom for a certain time (the process
time).
 Assembler: The atom which is used for assembly operation
 Sink: The products or customers leave the model through this atom and finishes
The schedule.
Simulation model of sewing line-
To analyze the real system and create the model, some conjectures were
Considered:
• The 8 hour working day of the system.
• Only one worker is at each machine.
• Allowances are not taken into consideration.
• Delay times (machine breakdowns, changing apparatus) are not taken into
Consideration.
• There is no energy problem in the system.
• Fabric loss is not taken into consideration.
• Raw material is unlimited.
• The supervisor’s job on the line was ignored.
Summary
In this chapter, the structure of garment balance line was analyzed by simulation. A
Trousers sewing line was considered for simulation model. Firstly, the work flow of the
Line as well as the chronological sequence of assembly operations needed to transform
Raw materials into finished trousers were described in detail. Then, a detailed work and
Time studies were performed along the line. Secondly, real-data gathered from factory

5. Floor was tested for distribution fit, and a Kolmogorov-Smirnov test was carried out for
the goodness of fit. Afterwards, the creation of model was explained. To set-up the
model, all fitted data and allocation of operations to the operators with machines
considering precedence constraints were transferred to simulation model. Model
verification was done by comparing the results of the model with the ones of the actual
system. Then, bottlenecks in the line were determined. In order to eliminate bottlenecks
in the line and to balance line, the model statistics; number of current and average content
in workstations in the system, cycle time, server utilization percentage, average staying
time of jobs in queues, average output, throughput values of workstations.. Etc. was taken
into account. Due to model statistics, possible scenarios were formed by various what-if
analyses in order to balance line as well as increase its efficiency. These scenarios can
provide investment decision alternatives to company administrators. Moreover, in order
to present more comprehensive decision alternatives, study can be enhanced by a cost
analysis of the possible scenarios.
YASH
APPAREL PRODUCTION MANAGEMENT (SEM-2)
PRODUCTION PLANNING

6. MAN POWER ALLOCATION AND PRODUCTION PLANNING
Needless to mention that you can't ignore making a project plan before you jump into the
business set-up. Every day I get mails asking 'how to start garment business in small scale' and
many other questions related to business start-up in garment industry. Most of the email senders
seem completely new to garment manufacturing.
If you are looking for ideas for starting small business in the garment industry, read 10 Small
Business Ideas in Garment Industry before you start reading following business plan.
This article is written to give you an idea how to make a business plan for garment
manufacturing start-up. What all things you can start working before the approach for an expert's
help. Instead of telling you how to start garment business, I will share what are primary things
you need to know, when you are ready to start your business. There are two ways to a start
business. One, first get customers (buyers) and make products according to them and sell.
Second, make your product first and then get customers to sell your product. Whatever way you
choose to do business, you need to work on the following things to make your project successful.
Read the step-by-step guide for making your business plan. In some steps you might need
expert's advice. In the article, I have included links for your further reading to understand the
business better.
Select Product Category
What type of garments you are going to make? If you plan to make knits garment (T-Shirts,
Polo), you would not try to make woven products (Shirts, Trousers) at the same time. Again in
woven and knits there is wide range of product categories. Narrow you product profile as much
as possible. Let’s say, you are going to make woven shirts - Formals and Casuals. Write name of
the product in your note book and move to the second point.
Estimate Production Requirement
How many pieces are you planning to make daily? 50 shirts or 500 shirts per day? It would be
difficult to decide the figure at this stage but you have to estimate a rough number. Later you can
modify this figure depending on the budget and customer demand. Otherwise you can't move
forward making your business plan. When my clients ask me question how many machines and
what all machines they need to buy for their garment manufacturing set up, I ask them what

7. (product name or type) do they want to make and how many pieces of garments they are
planning to make per day. Read 'How to Calculate Production Capacity of a Factory'.
Number of Machines
On the above I have said to you to estimate production requirement. If you have decided the
production figure, and product type, number of sewing machines and other equipment
requirement can be calculated. Calculation can be also done in reverse way. In case you have a
plan of setting specific number of machines, and product type, estimated production per day can
be calculated. Here is the resource “How to Determine Machine Requirement for a New Factory"
for your further reading.
Type of Machines
Next step is to find what types of machines are required to make garments that you have selected
from the wide range of product categories. For example, read Types of Machines used by Shirt
Making Factory. It is also important to find number of machines to be purchased in each
machine type. This step would help you to calculate capital investment in machines.
With sewing machines, make a list of other essential machines, equipment and set up
requirements. For example, pressing tables, cutting room machines, Boiler (steam generator) for
pressing table, diesel generator for power back-up, finishing room equipment, furnishings etc.
Raw Materials Requirement
You have already selected the product that you are going to make. Now make a list of raw
materials required to make the garment with average consumption. This would help you to
prepare your budget on material sourcing. A sample material list for knitted garment with
projected cost has been published here.
Factory Space Requirement
Now move one step ahead. How much space is required for installing machines and office for
staff? To set up factory you need space for installing machines, office space and setting up
departments for production and associated processes. Calculate space requirement. According to

8. that you have can plan for a factory building or rent a space. Estimate rent amount for the project
budget.
Manpower Requirement
You have already planned for machines and materials. Now plan for the requirement of man
power for the business. Manpower is one of the primary resources for a business. In manpower
planning, include number of staffs, supervisors and workers (operators and helpers) you need to
hire to make projected garments and to run business smoothly. Also estimate salaries for each
employee and add to your budget to running cost. Get an idea from the market how much salary
you need to pay to managers and workers.
Project Cost
I frequently get asked by people, how much money one needs to invest for the small size
garment business? Here it is. To know the estimated budget you have to prepare cost of the
project. You need to calculate total capital investment, Rent, EMI amount (if you are taking
loan), salary for staff, workers’ wages and running costs. Also include finance required for
sourcing raw materials for initial months and other expense etc. To run your business without
financial problem, prepare monthly cash flow requirement for at least one year.
Internal Process Flow
Make detailed process flow of an order. This will help you to decide what all departments you
need to set up and you can plan hiring people accordingly. You can cross check about your
equipment requirement process by process. Read the Garment Manufacturing Process Flow
Chart for the export orders. If you are new to garment manufacturing, read Apparel
Manufacturing -An Overview'
Supplier Listing
This process is not essential at first place. But you can start working on finding good and reliable
suppliers for fabrics, trims and other necessary items required to manufacture your garments.
Start establishing suppliers with your region, then go to other state and even you can source from
international market for the quality and cost effective materials.

9. Reach to Your Customers
You have finished the major part of making the garment manufacturing project. Now make a list
of potential customers and start contacting them for business leads.
If you are new to garment manufacturing and want to enter into garment business seek help from
an expert. An expert's guidance will help you to save your time, money, and efforts. You can
also learn many things about the business insights from an expert. Wish you all the best for your
upcoming garment business project.
YASH
APPAREL PRODUCTION MANAGEMENT (SEM-2)
PRODUCTION PLANNING