Production Planning & Merchandising

Southeast UniversityDepartment of Textile Engineering Production Planning & Merchandising... Southeast UniversityDepartment of Textile Engineering Study On Production Planning & Merchand

Southeast University

Department of Textile Engineering

Production Planning & Merchandising

Southeast University

Department of Textile Engineering

Study On Production Planning & Merchandising

We are pleased to get a fabulous opportunity to carry on our internship program with one of the finest garment manufacturer of the country namely FCI situated in Old DEPZ.We are very much grateful to Prof Sayed Fakhrul Hassan, Chairman of Textile dept of Southeast University for making this arrangement in such a garment of the country We herewith thankfully remember the name

Md Moniruzzaman (Deputy Manager) and Md Habibur Rahman (Personnel), Azharul Islam, General Manager (Marketing & Merchandising) Padma Polycotton who has helped us attaining our internship in Garments sector and guided me by providing necessary information and advices throughout this program

Southeast University

Department of Textile Engineering

Introduction

Company profile

Padma poly cotton knit fabrics ltd.

• Situated at Tejgaon industrial area

• Year of established in 1995

• Main section

1 Knitting section

2 Dyeing & finishing section

3 Garments section( includes sewing, cutting, finishing unit)

• Major buyer: Europe & USA (S.oliver, Defacto etc.)

There are three types of planning:

1.Production planning relating the qualities of sale

2.Production planning relating to the method

3.Production planning relating to time

Southeast University

Department of Textile EngineeringProduction

Production is the process by which goods and services are created Production systems combine materials, labors, and capital resources in an organized way with the objective of producing some goods or service Production system may occur in factories, banks, stores, hospitals etc In all instances, some input to the system is being processed within the system

to produce a goods or services as an output; we are in fact dealing with the operations phases

of any enterprise

Objectives of Production Planning

• To determine capacity of all manufacturing departments and to plan systematically coordinated

• To translate orders received from sales department into orders on the works department and to ensure steady plans of production activities.

• To promote fuller utilization of plants.

• To assist labor towards right and greater earnings.

according to the buyers being handled.

Type of merchandising done in garment exports

• Marketing merchandising

• Product merchandising

Southeast University

Department of Textile Engineering

Merchandisers responsibility

• Product Development

• Market and product Analysis

• Selling the concept

• Booking orders

• Confirming Deliveries

• Designing and Sampling

• Costing

• Mediating production and quality departments

• Giving shipping instructions and following shipping,

• Helping documentation department

• Taking responsibility for inspections and

• Following up the shipment

Southeast University

Department of Textile Engineering

Background

Mainly we found this reports on production planning &

merchandising-• 01 A study book about production planning -Mintu Sarker & Taslima Akter (3rd batch,SEU)

• 02 A study book about production planning and merchandising-pritam das & Kamrul, 4thbatch, SEU

• 03 A Study on production planning and merchandizing in a garments industry- Md Mahfuzur Rahman

Khan & Md Kamrul Hasan Joarder, 5th Batch.SEU.

• 04 A Study on Production planning and Merchandising of Garments industry-6th Batch.SEU

All the report is written by them following our topic on production planning & merchandising

Southeast University

Department of Textile Engineering

Theirs Findings

• Flow chart of production planning

• Description of production planning

• Procedure of production planning

• Garments export procedure

• Process of line balancing

• SMV calculation & analysis

• Sequence of product development

• Company profile

• Planning & Production Planning

• Types of production planning

• Object & procedure of production planning

• Qualification & responsibilities of a merchandiser

• Work study & method study

• Objects of their work

Southeast University

Department of Textile Engineering

Description of Export procedure:

P.O sent by buyer

Full meaning of P.O is purchase order It is sent by buyer when order is confirmed P.O contains order no, date, supplier description, buyer name & address, factory name & address, product description, packing description, terms & conditions & various instructions.

Master L/C sent by buyer

L/C means letter of credit It is a very important document Master L/C is sent by buyer and it is made by bank L/C contains all the payment & other terms

Making of T & A calendar

It means time & action calendar In this calendar all the planning actions are done by which works run to meet the delivery date.

Fabric & trims in house:

Fabric & trims are come to the store, store in charge check them if there is any damage of box & then in house them

Checking inventory & making inventory report:

Then inventory is checked again and make a report This report goes to the commercial department & merchandiser.

Production planning officer.

Production planning manager

Pattern checking & trial cutting:

After PP meeting pattern is checked again and trial cutting is done to check, the cutting is correct or wrong.

Southeast University

Department of Textile Engineering

Numbering, sorting & bundling:

Cutting pieces are numbered, sorted & then bundled for easy production.

Production line set up:

It is also called line balancing It is very important for bulk production The objectives of line balancing are given below:

In-time delivery to buyer

Increase efficiency etc.

Bulk Production:

It includes:

Sewing

Southeast University

Department of Textile Engineering

Finishing:

After bulk production finishing is done.

Final inspection booking:

Booking is required for final inspection In a inspection industry, time is very sensitive matter So before finale inspection one needs to book the inspection table for a particular order.

The international inspection group gives a certificate of their inspection.

Truck loading & transport to the port:

Cargo Company takes the vessel to the port by truck or other.

Hand over the goods to the logistic firms:

Southeast University

Department of Textile Engineering

Southeast University

Department of Textile Engineering

• Merchandisers work in design section:

Results & discussion:

• We have found that Bangladesh is lacking of quality fashion designers Economy of Bangladesh mostly depends on RMG sector but there is not sufficient opportunity for good fashion designers So there is good possibility of improving our industry if we can improve our fashion as well as design sector.

Southeast University

Department of Textile Engineering

Production planning in pattern section:

Southeast University

Department of Textile Engineering

Merchandiser work in pattern section:

• Pattern master makes the garments pattern Merchandiser only checks that the pattern is according to buyer’s recommendation or not He/she send buyer information if any modification of pattern is possible.

Result & discussion:

• Theoretical and practical section has a huge difference in pattern section Those we have learned in theoretically are not implemented in this section directly; they use their own easy method to make a pattern.

be done such as normal, one way, slitting, zigzag etc

• A sample of Spreading machine inspection of Padma poly cotton is given below

Result & discussion: Spreading quantity depends on buyer requirements In the above table we have seen that the variation of spreading is different because there are different kinds of buyer Another reason is manual spreading is used in

Southeast University

Department of Textile Engineering

Southeast University

Department of Textile Engineering

Merchandiser work in cutting section:

• Merchandiser does the ratio breakdown for marker for marker planning and then he sends it to CAD section for producing an efficient marker He helps to make decision of fabric spreading In cutting his main job is to help in making the flow process of cutting Sometimes when cutting supervisor cannot solve any problem then a merchandiser try to solve it.

Result & discussion:

• Though it is the duty of merchandiser to make ratio breakdown sheet, we have seen it is done

by line in charge practically In case of spreading manual & normal spreading is done Manual spreading is done because spreading machine is very costly & manual spreading method is appropriate for Bangladesh Every marker is checked before starting a cutting in this factory and sometimes it is found that there is measurement mistake in marker, and then is fixed manually It is the fault of CAD operator They should be well trained.

Southeast University

Department of Textile Engineering

Production planning in sewing section:

• In sewing section before starting production some planning is done This planning includes line balancing,

No of machine required for each part, No of operator, planning of inspection When to start, production per day, and fabric & accessories arrival from store etc is discussed here.

Southeast University

Department of Textile Engineering

Merchandiser work in sewing section:

 First of all in sewing section merchandiser do the line balancing to assure maximum production in short time He/she selects the machines & number of machines required for on order If buyer gives the S.M.V sheet, then merchandiser checks if it is appropriate for the factory If it is not appropriate, then merchandiser bargains with buyer to modify S.M.V It’s his duty to reduce S.M.V for factory production, because more the S.M.V lowers, higher the production

• SMV Calculation:

Normal Time: Average observed time × performance rating.

SMV = Basic time + (Allowances × Basic time)

= Basic time (1 +Allowances Time)

∴ Target = × Efficiency

Southeast University

Department of Textile Engineering

Planning in store section:

• Store section is also very important for factory as cutting, sewing and like other section

If improper planning is done for Store section then followings can be occurred:

• Less material (Accessories/Trims/Fabric) can be stored (If not counted properly).

• Quality of stored materials may not be correct (If inspection is done incorrectly).

• Stored materials can be damaged due to improper maintenance (Improper Temperature/Dust/faulty materials control).

• Materials can be stoles if security is not maintained correctly.

Merchandiser work in Store section:

• Merchandiser is responsible to book fabric and accessories from other supplier and he checks the arrival of fabric and accessories in due time He will be responsible it goods are not come in correct time.

Result & discussion:

• In store section we have seen how accessories come, inspected and in house them Unfortunately there was no supply of fabric while we were in fabric sector In fabric sector we have seen the quality inspection process of fabric in 4 point system.

Southeast University

Department of Textile Engineering

• Production planning in finishing section:

• Merchandiser work in finishing section:

In finishing section merchandiser helps to do the planning of a particular order and sometimes his duty is to come in finishing section to check that finishing is running in correct or faulty method.

Result & discussion:

This is the finale section before dispatching goods to ship Outlook is a great factor in RMG sector If all the quality is good but finishing is faulty then customer will not pay attention to it, so buyer will reject the goods before shipment So it is wise to do as buyer requirement & it is better if it is possible to modify the requirement to increase outlook quality, but for this one must take

Southeast University

Department of Textile Engineering

• Merchandising section:

Southeast University

Department of Textile Engineering

• Confirmation & T & AC Make

• Fit sample confirmation & T & AC Make

• Fit sample Approval

• Inventory of received Yarn/Fabric/Tri

• Bulk Fabric/Test reports submission

• Bulk Fabric/Test reports approval

• Bulk production

• Test of production sample

• Test sample approval

• Final Inspection

• Ex-Factory date

• Cut-off d

Southeast University

Department of Textile Engineering

Objective of the study

Broad objective:

• The broad objective of this report is to analyze the entire departmental work process of Garments

(woven/knit) industry and addressing related departmental shortcomings in light of marketing.

Specific objectives:

• To address the broad objectives, there should have some specific objectives These are:

• To find out how all departments of Garments factory operates.

• To analyze critically all aspects of the departmental work procedures.

• To analyze how all departments coordinate among themselves.

• To find out major existing and potential controllable and uncontrollable shortcomings of all departments and their effects on overall marketing of the organization.

• To find ways to overcome the shortcomings in light of marketing tools and concepts.

Southeast University

Department of Textile Engineering

Limitations of the study

• Major limitations of this study are outlined below:

• All personnel are always very much busy and work under extreme pressure for their nature of job and huge volume of the business Thus they couldn’t give me sufficient time

• Since all their buyers are located outside of the country therefore it was not possible

to measure their image from customers’ point of view

• Due to time and cost restriction, the study is concentrated in selected major

departments

• The study has been conducted based on observing and interview of the employees

• Limited sample size for interview

Is further work is necessary:

Production planning & merchandising is a lot of work, we cannot touch the all of thing because of short time There are lots of things which are studying more on production planning & merchandising.

• [4] -Production planning & control (pdf)

• [5] -Practice of garments Merchandising & Management by Engr

Md Faruk Hosen

• [6] -From class sheet

• [7] - Practice of garments Merchandising & Management by Engr

Md Faruk Hosen

• [8] - http://www.textileschools.com