Apparel Production

Planning Control

Assignment

Submitted by:

Ankita Kumari (BFT/18/244)

Shagun Sinha (BFT/18/172)

Tanya Choudhary (BFT/18/895)

On the ‘Production Order Control Record’ you will find the entry of five cutting orders,
mentioned as style 1A, 2B….5E, where order quantity and delivery date for each style is
mentioned. For example order quantity and delivery for style 1A is 2600 pieces and 26 th October
respectively. You have to calculate the deliverables based on the following parameters.

 Production Cycle Times

Complete cutting 4 days after cut issue
Complete sewing 9 days after complete cutting
Complete finishing 4 days after complete sewing

 Calendar
October Mon Tues Wed Thurs Fri Sat Sun
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
November Mon Tues Wed Thurs Fri Sat Sun
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

 Garments received into warehouse are considered ready for delivery.

 Working days are from Monday to Friday.

1. Assign the planned completion date for the following steps for each order:

a. Complete cutting
b. Complete sewing
c. Complete finishing - into warehouse

2. Each day the Planning department receives information on the garments completed in three
main departments; cutting sewing & finishing. An extract of ‘actual’ daily
Cutting/Sewing/Finishing reports for 5 styles are enclosed. Based on daily reports:

a. Enter the information on the 'Production Order Control Record'

b. If the daily capacity of cutting/sewing/finishing is 3000 garments per day, then
what is average utilization of cutting, sewing and finishing capacity during above
period?
c. Write down your observations regarding problems in the factory.
Daily Cutting report
Date Style No. No. of Garments cut
3-Oct 1A 400
4-Oct 1A 800
4-Oct 2B 290
5-Oct 1A 1400
5-Oct 2B 600
8-Oct 3C 940
8-Oct 5E 1150
9-Oct 4D 480
10-Oct 3C 1100
10-Oct 4D 2500
10-Oct 5E 1000
11-Oct 3C 700

Daily Sewing report

Date Style No. No. of Garments sewn
17-Oct 2B 790
18-Oct 1A 960
19-Oct 1A 1600
22-Oct 1A 40
22-Oct 4D 1900
22-Oct 5E 1000
23-Oct 5E 500
24-Oct 3C 2000
24-Oct 5E 650
25-Oct 4D 600
26-Oct 3C 720
29-Oct 4D 490

Daily Finishing Report

Date Style No. No. of Garments Finished

23-Oct 2B 160
24-Oct 1A 800
24-Oct 2B 20
25-Oct 2B 600
26-Oct 1A 1760
29-Oct 1A 40
30-Oct 3C 1500
31-Oct 3C 1000
1-Nov 3C 150
1-Nov 4D 2400
2-Nov 4D 480
5-Nov 5E 1900
7-Nov 5E 150
9-Nov 5E 100
 PRODUCTION ORDER CONTROL RECORD
Style Quantity Date Complete Cutting Complete Sewing Complete Finishing - into Ready for
No. Issued Warehouse Customer
Delivery
Issued Cut Plan Actual Plan Actual Plan Actual
Date Date Date
Qty Date Qty Date Qty Date

1A 2600 2600 1. 10 5.10 400 3.10 18.10 960 18.10 24.10 800 24.10 26-Oct

800 4.10 1500 19.10 1750 26.10

1400 5.10 40 22.10 40 29.10

2B 800 790 2. 10 8.10 290 4.10 19.10 790 17.10 25.10 160 28.10 25-Oct

600 5.10 20 24.10

600 25.10

3C 2600 2740 2. 10 8.10 940 8.10 19.10 2000 24.10 25.10 1500 30.10 26-Oct

1100 10.10 720 26.10 1000 31.10

700 11.10 150 1.11

4D 3000 2980 3. 10 9.10 480 9.10 22.10 1900 22.10 26.10 2400 1.11 26-Oct

2500 10.10 600 25.10 480 2.11

490 29.10

5E 2200 2150 4. 10 10.10 1150 8.10 23.10 1000 22.10 29.10 1900 5.11 10-Nov

1000 10.10 500 23.10 150 7.11

650 24.10 100 9.11

Answers:
1. The planned completion date for the following steps of each order are:
a. Complete cutting

b. Style Number Planned Date

1A 5/10
2B 8/10
3C 8/10
4D 9/0
5E 10/10
Complete Sewing

Style number Planned date

1A 18/10
2B 19/10
3C 19/10
4D 22/10
5E 23/10

c. Complete Finishing

Style Number Planned Date

1A 24/10
2B 25/10
3C 25/10
4D 26/10
5E 29/10

2. b. Average utilization
Cutting
3/10 – 400/3000 = 13.33%
4/10 – (800+290)/3000 = 1090/3000 = 36.33%
5/10 – (1400+600)/3000 = 2000/3000 = 66.66%
8/10 – (940+1150)/3000 = 2090/3000 = 69.66%
9/10 – 480/3000 = 16%
10/10 – (1100+2500+1000)/3000 = 4600/3000 = 153.33%
11/10 – 700/3000 = 23.33%

Average utilization of cutting= 54.091%

Sewing
17/10 – 790/3000 = 26.33%
18/10 – 960/3000 = 32%
19/10 – 1600/3000 = 53.33%
22/10 – (40+1900+1000)/3000 = 2940/3000 = 98%
23/10 – 500/3000 = 16.66%
24/10 – (2000+650)/3000 = 2650/3000 = 88.33%
25/10 – 600/3000 = 20%
26/10 – 720/3000 = 24%
29/10 – 490/3000 = 16.33%

Average utilization of Sewing= 41.66%

Finishing
23/10 – 160/3000 = 5.33%
24/10 – (800+20)/3000 =
25/10 – 600/3000 = 20%
26/10 – 1760/3000 = 58.66%
29/10 – 40/3000 = 1.33%
30/10 – 1500/3000 = 50%
31/10 – 1000/3000 = 33.33%
1/11 – (2400+150)/3000 = 2550/3000 = 85%
2/11 – 480/3000 = 16%
5/11 – 1900/3000 = 63.33%
7/11 – 150/3000 = 5%
9/11 – 100/3000 = 3.33%

Average utilization of finishing = 30.72%

Observations

1. The daily cutting report and the Production order control record doesn’t
match for the style no. 2B, with a difference of 100pcs.
2. Quantity Problems
 For style no. 2B and 3C, 90 and 140 pcs are being cut extra than the
issued quantity of 800 and 2600 pcs respectively. Thus, there is
wastage of resources (labor, machine power, fabric, time)
 In case of style no. 4D and 5E, 20 and 50 pcs are being cut less than
the issued quantity of 3000 and 2200 pcs respectively. There is
underutilization of resources.
3. Delivery problems
There is delay in delivery for style no. 1A, 3C and 4D.

Style no. Delivery Final Quantity Days

Date Delivery Delayed Delayed
Date
1A 26/10 29/10 40 3 Days
3C 26/10 1/11 150 4 Days
4D 26/10 2/11 480 5 Days

4. Over utilization of capacity on 10th October by 1600 pcs in the cutting

department. (the total capacity is 3000 garments per day)
5. As we know there is delay for style no. 1A, 3C, 4D and the delivery date of
5E is 10th November so the cutting, sewing and finishing of the delayed
styles should be done prior to 5E.
6. For optimum utilization of resources, effective distribution of load on each
day should be ensured. (i.e. the capacity of 3000 garments/day should be
maintained.)