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Practical Garment Production Process – A Case Study

End-to-End detailed garment production process

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This project work deals with the productivity and quality enhancement in a garment manufacturing unit through a practical study conducted in the stitching department.

Banswara Garments

Banswara Garments is located in Daman and Surat. The garment units are specialized in Trousers, Jackets and Waistcoat production. It makes the offering of Banswara complete textile vertical. Their team will take you right from conceiving an idea for the fabric to the final product ready to wear in the least possible lead-time.

Capacities

Industry Process Flow

The installed capacity is for about 3, 45,000 pairs of trousers and 37,500 jackets per month. The entire focus of the factory is on producing Trousers and Jackets that are able to match the highest standards of workmanship, quality, and appearance.

Facilities

These factories are equipped with a full complement of machines to be able to manufacture trousers and Jackets of the finest quality. They are doing all their order and material-related work on ERP software VISUAL GEMS. They do all their marking and grading on a CAD system from Rich Peace. The sewing line primarily consists of Juki machines. There are automatic Welting Machines from Durkopp Adler. Curtain Felling Machines from Union Special, Eyelet Buttonhole Machines from Reece and Blind Loop Machines from Maier. The pressing is entirely from Roton D, including leggers, toppers and side seam presses

Product Range

Banswara Garments is specialized in the production of jackets. They are making high-class jackets with all the Fusible that are required in making jackets. Most attractive prices, latest signs and the finest quality are their forte. The products are a class of their own. When it comes to quality and comfort, they can be compared with the best in the world. With innovative styles, they occupy a prominent position in the domestic as well as an international market:

  • Men’s trousers(Formal, Casual)
  • Women’s trousers(Formal, Casual)
  • Children’s casual wear
  • Jackets

Planning Department

The planning department plans every style to execution the order within the time limit. Without a time frame garments cannot sustain so the industry follows every task by scheduling. Each order has a delivery date & the production plan department follows the production plan on the basis of the delivery date. They know when fabric & trims in-house in the factory will. Basically, some of the fabric & trims come from Local vendors. So, they plan both options on the basis of the delivery date. So the production planning department follows some of the important tasks in the following.

Standard Operating Process
  1. Capacity planning.
  2. Time & Action (TNA)
  3. PP meeting.
  4. Order Allocation.
  5. Manpower & M/C allocation.
  6. Execution of every task.
  7. Materials planning & In-house follow-up.
  8. Delivery Meet.

Capacity planning

The production planning department makes the production capacity of a factory because capacity determined need to order or not. If order capacity is full whole the year then does not take over capacity order because it is needed over cost to make extra capacity order. On the other hand, if the capacity order is not full then take more orders to fill the capacity otherwise factory will be a loser by financing. Production planning department informs forecast capacity order to merchandisers & management so they can inform to the buyer for order.

Time & Action

The planning department follows every style as per schedule. Every order has its own time frame & meet delivery time. Every style follows product development to shipment. It is a job task for the planning department otherwise they cannot meet delivery as per the planned schedule. The planning department takes action very styles to follow up within the time & Action calendar.

 

Date June 10 July 15 July 20 Aug 1-4 Aug 5-7 Aug 8-21 Aug 22-24 Aug 25-29 Aug 30
Operation Order received, Trims ordered, Fabric ordered Fabric and Trims in-house PP Fabric Inspection Cutting Stitching Press and Packing Final Inspection Delivery

Table 2.2- Time & Action

Scheduling

The production planning department takes decisions when a style is input into line. On the schedule, they cheek fabric & trims with the store department & Merchandising department. If get on-time in-house every item they can input into line. On the other hand if not get fabric & trims on time they can change the line plan to reduce the cost.

PP Meeting

Production planning department cheek particular style fabric & trims status with store & merchandising department. If every item & approval is done then they co-operation with all related departments like as Merchandising, Production, store, cutting, Finishing, quality & buyer representative to make clear understanding for a particular style for production. Before the PP meeting, they cheek all approval, production file, trim card & ready size set.

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Order allocation

The planning department does line allocation for every style. When got any order from the buyer they allocation line plan. Without a line plan, an order cannot smoothly run for production. So order allocation is very important for the planning department.

Manpower &machine allocation

The production planning department takes decisions about how many operators need for a particular style to output. They take a decision line layout for a particular style. And also take decision how many machines need to operate the line. Then they take effective decisions for productivity for a particular style.

Materials planning & In-house

The planning department follows up the fabric & trims follow up with the store & merchandising department so they can pre-plan to effective line planning date.

Delivery Date

The production planning department follows the delivery date of garments. If not maintain the delivery of the garments on time it will be loser planning & fall down of the company. So, every style maintains to meet the delivery of the garments. So, they can make effective decisions for garments delivery.

  • Planning is done 6 months in advance.
  • The merchandiser either goes to fieldwork to collect orders or the order is automatically given by the buyer.
  • Planning is done in the reverse process.
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