Garment Assortment Pack-Ratio Generator

The formula

This is the expression the tool evaluates. Every term is named underneath, with the unit it must be supplied in.

How the result is derived

Step by step, from the values you type to the figure on screen.

1. The 6 inputs are read from the form on every keystroke: Small Share, Medium Share, Large Share, Extra Large Share, Garments per Carton and Order Quantity.
2. Each value is checked against the accepted range in the input table below. A value outside its range stops the calculation rather than producing a misleading figure — the results blank out and a message appears.
3. The validated values are substituted into the expression above, which resolves Largest Size Deviation together with every supporting figure in one pass — no value is carried over from a previous entry.
4. The supporting outputs — Small per Carton, Medium per Carton, Large per Carton, Extra Large per Carton, Cartons Required and Largest Size Overage — come from the same pass, so they always describe the same case as the headline figure.
5. Results are rounded for display only. The full-precision value is used throughout the chain, so reading a rounded intermediate figure back into the tool by hand can shift the last digit.

What each input means

Where to read each value on the floor, the unit it must be in, and the range the tool accepts.

What the tool returns

The headline figure and every supporting value it is built from.

Worked example

The tool loads with this case already solved — the Largest Size Deviation shown above is its answer. Change one value and the difference from this baseline is the sensitivity of the result to that variable.

How to use it

1. Work through the input groups in order — Size Demand and Packing. The defaults are a realistic case, so you can change one value at a time and watch what moves.
2. There is no calculate button. Every figure recalculates as you type or drag, which is what makes this usable for a what-if sweep rather than a single answer.
3. Read Largest Size Deviation in the dark results panel — that is the headline figure, expressed in points.
4. Check the supporting rows underneath (Small per Carton, Medium per Carton, Large per Carton, Extra Large per Carton, Cartons Required and Largest Size Overage) before acting on the headline — they are where an implausible input usually shows itself first.
5. Reset to defaults returns every field to the reference case, which is the quickest way to check whether a surprising result came from the tool or from an input you had changed earlier.

Where this is used

• Process planning — establishing Largest Size Deviation before a trial is booked, so machine time and material in Supply Chain, Inventory & Logistics are committed against a calculated figure rather than an estimate.
• Costing and quotation — Largest Size Deviation is an input to the cost sheet, and quoting from a worked number rather than a remembered one is what keeps a margin intact.
• Troubleshooting — when the floor result drifts from plan, entering the measured values (starting with Small Share) shows how much of the gap in Largest Size Deviation each variable explains.
• Teaching and study — the accepted ranges bracket normal Supply Chain, Inventory & Logistics practice, so moving one variable at a time shows the shape of the relationship rather than a single answer.

Assumptions and limits

• The four shares should sum to 100; if they do not, the allocation still fills the carton but the deviations are measured against a curve that does not exist and mean nothing. A larger carton always tracks the demand curve more closely — the deviation falls roughly as one over carton size — so where handling permits it, a bigger ratio pack is the cheapest fix for assortment error. Ratio packs also assume every store wants the same curve, which is the real limitation: stores differ by demographic and climate, and a single national ratio guarantees markdown at both tails somewhere.
• Every input is bounded to the range normal practice occupies (Small Share 0 to 100 %, Medium Share 0 to 100 % and Large Share 0 to 100 %, and so on for the rest). Those bounds are guard rails against typing errors, not a claim that the formula fails one unit outside them.
• The calculation is deterministic: the same inputs always give the same result. It carries no allowance for machine condition, operator skill, ambient conditions or lot-to-lot material variation unless an input above explicitly represents one.
• Nothing is sent anywhere. The maths runs in your browser, so the numbers you type never leave the page.

Questions people ask