Production Control

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Report on Production Control
Sewing, Finishing and Packaging


1. Introduction
1.1 Production Control
1.2 Objectives of Production Planning Control
1.3 Production Planning and Control Functions
2. Basic Garment Process
3. Sewing
3.1 Introduction
3.2 Process Flow
3.3 Production Control in Sewing
4. Finishing and Packaging
4.1 Introduction
4.2 Process Flow
4.3 Production Control in Finishing and Packaging
5. Production Control and Technology

1.1 Production control
The production control activity is a chain of interrelated events that functions as a system. The decisions are made for different horizons in time and with different degrees of accuracy. Yet they must all occur if the ultimate objective is to be met: that is, to use limited resources effectively to produce goods that satisfy customer demands and create a profit for investors.

In any manufacturing enterprise production is the driving force to which most other functions react. This is particularly true with inventories; they exist because of the needs of production. So, production planning and control is vital for any manufacturing enterprise.

1.2 Objectives of Production Planning Control
The ultimate objective of production planning and control, like that of all other manufacturing controls, is to contribute to the profits of the enterprise. As with inventory management and control, this is accomplished by keeping the customers satisfied through the meeting of delivery schedules. Specific objectives of production planning and control are to establish routes and schedules for work that will ensure the optimum utilization of materials, workers, and machines and to provide the means for ensuring the operation of the plant in accordance with these plans. The intentions are to:

* Meet- customer order due dates
* Maximize- utilization of labor, materials and machines
* Minimize- idle time, overtime, step delays, lead/queue time, time in the system and WIP (Work in Process) * Control- historical and current operator and machine data and efficiencies. With major reductions in operators’ clerical work, they experience fewer interruptions, allowing increased garment production at the same workload and better quality. 1.3 Production Planning and Control Functions

Forecasting to predict customer demand on various products over a given horizon. * Objective: predict demand for planning purposes.
Aggregate Planning to determine overall resources needed.
* Objective: generate a long-term production plan that establishes a rough product mix, anticipates bottlenecks, and is consistent with capacity and workforce plans. Materials Requirement Planning to determine all required components and timing. * Objective: Determine all purchase and production components needed to satisfy the aggregate/disaggregate plan. Inventory Management to decide production or purchase quantities and timing. * Objective: Establish an interface between the customer and the plant floor, that supports both competitive customer service and workable production schedules. Scheduling to determine shop-floor schedule of various components. * Objective: develop a plan to guide the release of work into the system and coordination with needed resources (e.g., machines, staffing, materials).


Stepwise garments manufacturing sequence on industrial basis is given below:

Design / Sketch
Pattern Design
Sample Making
Production Pattern
Marker Making
Pressing/ Finishing
Final Inspection

Design / Sketch:
In the garment manufacturing the first step is designing the sketch for the dresses that have to be prepared. For this purpose the designer first draw several rough sketches in the sketch book. The...
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