How to make line plan for garment production

Line plan:Daily production target plan of multiple styles in order to meet delivery date of each style by keeping in knowledge about line capacity as per construction features and order quantity of each styles.  Line plan is the key aspect in garment planning division. Planning section is making the production out cum plan as per line capacity in order to achieve delivery date. Planner needs to do backward and forward planning based on lead time.Mostly line planning is made after discussion with team of Production and IE.

In order to make target achievable line plan you should have to keep below require data when making a line plan.
1. Order detail sheet
2. No Of Line and there capacity
3. Style SAM as per quality stander
4. Average manpower absenteeism percentage
5. Production lead time of an order
6. Holiday list

See below line plan chart to understand all above requirement sequence wise in order to make a line plan.

1. Order detail sheet:Order Detail sheet is the first requirement for making a line plan in order to take decision about line selection for an order as per there quantity and production lead time considering delivery date.

Order No	Category	Order qty	Delivery date
MARITO	Trouser	6400	31st July
Jet king	Trouser	33000	31st Aug
Merina	Trouser	2336	3rd Aug
Elvis	Trouser	5400	4th Aug
Ertica	Trouser	6000	19th Aug
Stylek	Trouser	3240	28th Aug

2. No Of Line and there capacity: Its very important for a planner to know about No of production line available for total order in hand.Capacity of line is require to set daily production target of an order.Average Line capacity chart can be prepare as below.

Line No.	No. of Operator	Minutes/Day	Line Efficiency	Absenteeism %	Capacity available
		(Daily working Hrs. X 60)
Line 1	30	480	40%	10%	5184
Line 2	28	480	50%	10%	6048
Line 3	32	480	55%	10%	7603.2
Line 4	32	480	45%	10%	6220.8
Line 5	25	480	39%	10%	4212

 

3. Style SAM/SMV : Stander allowed minute or stander minute value of  style helps a planner to fix daily target qty of a line by calculating production rate through it.

4. Average manpower absenteeism percentage: Man power absenteeism is common in garment or any other industries.Line capacity can't complete without knowing absenteeism in order to make actual capacity of production line.

5. Production lead time of an order: Production lead time helps to select no of production lines for  style as per there qty to complete production on time.

Order No.	Loaded to Line No.	Order Quantity	Style SMV	Capacity Required (Minutes)	Capacity available per day	Capacity Required (Days)
MARITO	Line-1	6400	28	179200	5184	35
Jet king	Line-2	33000	25	825000	6048	136
Merina	Line-3	2336	20	46720	7603.2	6
Elvis	Line-4	5400	10	54000	6220.8	9
Ertica	Line-5	6000	18	108000	4212	26
Stylek	Line-1	3240	28	90720	5184	18

 

6. Holiday list: List of holiday need to know while making line plan order to extend the date if there any holiday in between.

Style change production lose need to be consider while making a line plan, for example-  If line-1 per day capacity for style is 400pcc. But production starting days (first,second and third day) the output will be in ascending orders like- First day-50pcs, second day-150 pcs, and third day-300pcs after that out cum will be 400pcs/day.