Textile Engineering
Production Planning & Sequencing
14 interactive Production Planning & Sequencing tools. Every one shows its formula, a worked example and the standards it follows.
Professional tools
Full costing sheets, booking schedules and project appraisals. Enter your own figures and see the headline result before you buy.
- Air, Sea or Split: Late Shipment Expedite Sheet Worth of Choosing Style by Style
- Brownfield Expansion: What the Next Increment Costs Shared Plant the Proposal Forces
- Built Into the Fibre or Applied to the Cloth: What Protection Costs Over a Life What Moving to the Cheapest Protection Saves
- Buyer Chargeback: Contest, Fix or Accept Recoverable a Year
- Buyer Cost to Serve & Development Recovery Net Margin After Serving the Book
- Buyer Quotation Generator Order Value
- Buyer Terms & Effective Price Comparison Best Offer, Once Its Terms Are Paid For
- Buyer Test Plan & Laboratory Budget Laboratory Cost for the Range
14
tools
Mill Operations & Industrial Engineering
Production Planning & Sequencing
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Production Planning & Sequencing 14
- Lead Time Under Load: What the Next Order Costs Every Other Order Premium Estimates the lead time a factory actually delivers, including the waiting that deterministic capacity loading cannot see, using Kingman's approximation at each work centre. Reports how much of the lead time is queue rather than work, how many more orders a week can be taken before a centre saturates, and what the next orders add to the lead time of every order already accepted. Lead Time Actually Delivered days
- Machine Loading Plan Premium Loads an order book onto the lines that must make it, in minutes rather than pieces, and sequences it earliest-due-date first so the answer is a date and not a volume. Reports utilisation against real capacity beside nominal, names the orders that will miss and by how many days, and prices the shortfall as overtime or the surplus as idle capacity. Utilisation of Real Capacity %
- Order Acceptance Under a Binding Constraint Premium Chooses which orders to accept when the book is bigger than the capacity, by ranking them on contribution per hour of the resource that binds rather than on margin. Runs both rules over the same book and prices the difference, names which orders change place between them, and reports for every refused order whether it failed on rate or merely on fit. Cost of Ranking by Margin cost
- Sets, Not Pieces: What a Kit Ships and What Is Stranded Premium Counts a made-up programme in sets rather than in pieces, so the yield on one component is charged against every other. Reports what can ship, what is stranded and what it is worth, which component binds and which binds after it, and whether one more of the constraining piece is worth making. What Closing to the Next Constraint Is Worth cost
- Time & Action Calendar Premium Schedules an order backward from its ship date through a chain of milestones, giving every activity a latest start and latest finish in working days before shipment, loading the booked durations with the overrun they historically carry, and naming the milestones that are already behind on the day the order is confirmed. Slack Against the Ship Date days
- Blowroom Blend Changeover Transition Waste Modeler Predicts transition waste when a blowroom line changes blend: hold-up turnovers needed to reach blend tolerance, transition time, off-specification mass produced, the share reclaimable into lower grades and the net cost of the changeover. Off-Specification Mass kg
- Daily Takt Time & Factory Shift Output Modeler Matches a delivery deadline to factory capability: required daily output and takt time from the order and calendar, operators the SMV demands, daily capacity from the operators assigned, the resulting surplus or shortfall and days to complete. Takt Time min
- Dyehouse Light-to-Dark Sequencing & Wash-down Saving Quantifies the gain from ordering dye batches light to dark: total wash-down time sequenced against unsequenced, machine time saved per cycle, water and chemical avoided and the weekly hours recovered. Machine Time Saved per Cycle min
- Garment Cut-Plan Size & Colour Grouping Optimizer Plans multi-size, multi-colour cutting: distinct markers required across the colour and size matrix, garments obtained per lay, total lays for the order, fabric consumed with grouped markers, and the fabric and value saved against cutting each size alone. Lays Required no.
- JIT Yarn Feed Rate vs Loom Weft Depletion Calculator Synchronises spinning output to weaving consumption: weft demand per loom and across the shed, packages consumed per day, the balance against mill output, buffer stock for a chosen cover and how often each loom needs a fresh package. Shed Weft Demand kg/day
- Loom Allocation Matrix & Contribution per Machine Hour Compares fabric order allocation across loom types: metres per hour on air-jet and rapier from insertion rate and pick density, contribution per machine hour on each, the margin advantage of the better choice, width utilisation and machine hours to complete the order. Best Contribution per Hour /h
- Multi-Style Line Changeover Penalty & Recovery Curve Models the efficiency loss when a sewing line switches style: current efficiency at a point on the recovery curve, units needed to reach a target efficiency, production lost to the ramp, changeover downtime cost and the full cost of the change. Efficiency Now %
- Rotary Printing Screen Setup & Washdown Time Predictor Exposes hidden downtime in rotary printing: screen setup and washdown time driven by colour count, actual printing time, total job time, the productive share of it, effective speed across the whole job and the run length at which printing finally outweighs setup. Total Job Time min
- Sizing Batch Washout & Size Box Changeover Optimizer Decides between displacement and draining at a size box changeover: box turnovers and volume needed to bring the recipe inside tolerance, washout time, the drain-and-reheat alternative, time saved and the size liquor a drain would have discarded. Displacement Time h
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