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TOPIC:
SAMPLE SIZE- 60
WORK PLAN TIMELINE
Phase
Phase Phase
Phase Phase
Phase Phase
Phase
1
1 2
2 3
3 4
4
Activities
Once the order is confirmed, the Grey booking of fabric and trims order are
done on the basis of Wing sheet received from buyer. The total lead time of
Meenu for fabric procurement is 50 - 60 days.
Total Lead Time For Pre Production Activities is
approx 61 days.
APPROVALS OF FABRIC & TRIMS
Fit TD PP/
Fit DC PP
Sample
Sample Sample
Lab dip
Approval
First Of Bulk
Lots Approval
Trims Approval
All PP samples are made in actual bulk only after the approvals of
trims and fabrics. So, the delay in procurement of fabric will lead to
the delay in PP sample approvals which will directly increase the lead
time process.
PRODUCTION ACTIVITIES
PP
PP Bulk Bundlin Sewin Finishin
Meetin Bulk Bundlin Sewin Finishin Packaging
Meetin Cutting g g g Packaging
g Cutting g g g
g
Final Audit
Pilot In line Audit
Audit
2:Merchandiser at sears
2:Meenu creation has certain technological gaps that
reflects while the product is moved through out the
3:Factory manager at workstations.(Absence of ERP). Also less experience in
Meenu creation fitting US size as major business is done for European
market.
In Post production the delays are due to various short comings in the
process. They are listed as follows:
4. Cut order plan is not maintained in cutting room and processes are not
standardised.
5. Bundling is not done in cutting section and is done in sewing floor to
balance out as the cut plan is not made and bundling sheet is not
maintained
6. SAM calculation is done only for costing purpose and not for real time
production and thus is done by assumption and experience basis.
CATEGORISA
TION OF PHASE 2
DATA
Fabric- Polyester
KIDS WEAR V/S PHASE
WOMENS WEAR
2
In case of kids wear the approvals
are quicker technical design team
at Indian business office of sears
does give local approvals for fit
samples.
Kids wear styles were
recently started at In case of womens wear, the
Meenu creations. approval of fit is received from San
Francisco office of sears through a
A total of 4 kids wear waiver that leads to the delay as
styles orders was a the approval takes around 15 days
part of Meenu creations
pre spring season as the sessions are fixed for fitting
consignment. Tuesday and Thursday, and in case
of 1st fit rejection another approval
takes around same time. Hence,
the pre-production is delayed and
production does not get
appropriate time to execute and
MAJOR LEAD TIME
PHASE
CONSUMING PROCESS
2
The most time taking process is the
fabric procurement. Fabric grey is
booked as soon as wings are received.
Also, the fabric is procured from
unorganised sector i.e. Surat
Ahmadabad belt .
FABRIC LEAD TIME-
Fabric received are in form of thans
which are checked for 10% by 4 point
50-60 days.
system.
Fabric checking is very superficial and
4 point system is not properly followed.
Also, end cutter is missing that leads to
4-5 operator at one cutting table to cut
one lay.
REVIEW OF PHASE 2
LITERATURE
In the apparel export business, garment exporters get lead time from
buyers end for shipping finished garment. Sometimes buyer gives fixed lead
time for their orders or buyer asks suppliers to decide best possible lead time
and they mutually agree a date for shipment. Shipment lead time may vary
depending on order volume and product line. This post covers what does lead
time means to a supplier and how to calculate lead time for an order.
Count days required to reach from one event to next event and mark dates for each event.
Write start date and completion date of all processes following critical path.
To get total duration in between order receiving and shipment date count total days from
order receiving date to shipment date. You got lead time for the given order.
REVIEW OF PHASE 2
LITERATURE
According to Indian Labour organisations paper on wages
in apparel industry, China overtook the European Union
(EU) as the biggest textiles and clothing exporter in the
world, and became the number one in the four industries
literally the worlds TCLF factory. In 2012, China exported
33 per cent of world textiles, 38 per cent of clothing, and 60
per cent of leather and footwear, and despite signs that
production is moving to lower cost countries, it remains the
most important TCLF producer and exporter globally.
REVIEW OF PHASE 2
LITERATURE
According to European scientific journal (Nov, 2014)Lead Time in
Production Planning In production planning, lead time is very
important. Suppose, a product is made from material B and
material C. Material B is made from material C. It means, if there is
delay in producing or sourcing material C, there will be delay in
getting material B. So, there will be delay in the production of
product A. Customer will not get delivery in time. So, deadline is
fixed for getting supply and production simultaneously. Suppose, 30
days is the lead time for delivery after customer places the order. It
means, lead time for buying and production of material B and C
should be fixed accordingly. Lead Time in Apparel Industry To lower
the risk of a fashion miss, now days most of the retailers and
apparel companies are pressing their suppliers to crank out a small
order quicklyallowing them to test styles in storesand then fill
re-order requests even faster, a tactic known as chasing.
REVIEW OF PHASE 2
LITERATURE
This chase leads to a stressed out lead time for the
apparel manufacturers. In apparel industry, lead time is the
total amount of time required for completing a product
beginning from the date of receiving raw materials to the
stage shippable to the customer. Total lead-time is made up
of time devoted to processing orders, procuring and
manufacturing items, and transporting items between the
various stages of the supply chain. Lead-time typically
includes two components: Information lead times (the time
it takes to process an order) and Order lead times (the time
it takes to produce and ship the item). An equation may be
able to help us to assimilate the conception. Total Lead
Time = Information Lead Time + Order Lead Time =
Information Lead Time + Manufacturing Lead Time +
Shipping Time for importing fabrics & accessories +
Shipping Time for exporting final product
REVIEW OF PHASE 2
LITERATURE
According to paper in apparel resources ( Aug 2016) Garment exporters catering to
high fashion markets demand a responsive supply chain with a very short lead-time.
CMT exporters in India typically work with a lead-time of 75-90 days, vertically
integrated plants are known to work with even longer lead-time. With turnaround
time becoming a prime factor in attracting business, manufacturers are increasingly
exploring options to reduce the cycle times. (Zaras phenomenon success in high
fashion garments is largely attributed to its agility in responding to customers
requirement). However in the absence of information regarding specific causes of
delays, it becomes practically impossible to tackle the issue of longer lead-time.
Garment pre production activity, time loss in getting approvals and logistics related
issues contribute to more than 80% of delays.
Since the delivery schedules are fixed, the time lines for production activities are
squeezed on an average by 30 %
DATA
ANALYSIS
AND PHASE 3
FINDINGS
CASE STUDY PHASE 3