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How to Make Line Loading Plan for Garment Production?

How to Make Line Loading Plan for Garment Production?


In “Line loading plan” planner decides on which date a style to be loaded and how many lines to be considered for the style to meet the production completion date. Line loading plan is an important task for a production planner. Planner needs to do backward and forward planning based on lead time. In this article I will explain how to make line loading plan and what things are important during making a loading plan. Explanation is given step by step in the following with examples. There is lot of mathematical calculation. So, I will suggest you to use spreed sheet for the making the plan.

Step 1: Make a list of current orders with details such as order no., order quantity, style description, and production completion date. Refer to the Table-1. Suppose order has been received on the month March and production completion date on May from 4th to 21st.

Table- 1: Order list

Order No. Garment Description Order Quantity
(pieces)
Production completion date
OCS101 Dress 2000 10th May
OCS102 Blouse 3000 12th May
OCS103 Trouser 5000 15th May
OCS104 Long sleeve Tee 3000 17th May
OCS105 Skirt 3000 21st May
OCS106 Dress 1500 21st May
OCS107 Long sleeve Tee 10000 10th May
OCS108 Skirt 1200 04th May
Total 28,000

Step 2: Suppose a factory has 5 production lines. Calculate available capacity of the line using capacity calculation formula considering absenteeism (10%) and line efficiency %. You should have knowledge about line wise production efficiency to calculate actual capacity of a line. Or calculate it prior to line loading plan.

Available capacity in hours = {(No. of operators/machines x working days in a month x daily work hours x 60) – absenteeism %} x Efficiency %

Line wise available capacity has been shown in the Table-2. It is considered that each line is equipped with 25-32 machines (operators), factory’s normal shift time is 8 hours (480 minutes) and line efficiency is in the range of 39% to 55%.

Table- 2: Available capacity calculation

Line No. No. of Operator Minutes/Day (Daily working Hrs. X 60) Line Efficiency Absenteeism % Capacity available
Line 1 30 480 40% 10% 5184.0
Line 2 28 480 50% 10% 6048.0
Line 3 32 480 55% 10% 7603.2
Line 4 32 480 45% 10% 6220.8
Line 5 25 480 39% 10% 4212.0

Step 3: Next, calculate required capacity for each order (style) in minutes and in days. Assume that above 8 styles to be run in 5 lines and styles will be loaded only in single line. Consider that all lines blank and you have no issue with starting date. In this stage you have to also decide which line to be chosen for the styles. Allocate order to the line according to product category and line set up (machines laid). In Table-3 line number has been mentioned against the order number. Use the following formula for the calculation.

Capacity required in minutes = Order Quantity X Style SMV

Capacity required in days = Capacity required in minutes / Capacity available per day.

Refer to the table-3 for calculated minutes and days required for each style.

Table-3: Required capacity calculation

Order No. Loaded to Line No. Order Quantity Style SMV Capacity Required (Minutes) Capacity available per day Capacity Required (Days)
OCS101 Line-1 2000 28 56000 5184 11
OCS102 Line-2 3000 25 75000 6048 12
OCS103 Line-3 5000 20 100000 7603.2 13
OCS104 Line-4 3000 10 30000 6220.8 5
OCS105 Line-5 3000 18 54000 4212 13
OCS106 Line-6 1500 28 42000 5184 8
OCS107 Line-7 10000 10 100000 6220.8 16
OCS108 Line-8 1200 18 21600 4212 5

Step 4: Now do backward calculation to find the date for style loading. Days needed to complete production on due date, Sundays and holidays must be excluded in day count. And add one to two days initially for line setting according to style requirement. If required, you can add buffer for one to two days. To make it easy in calculating the loading dates considering above points use spreadsheet based planning board. For example refer to the following image-1. I have made loading plan on the planning board for theses styles. Light blue colored columns represent Sunday (weekly off days). Finally make another table (Table-4) representing loading date against orders.

Image-1: Planning Board

Table-4: Order loading date

Order No. Garment Description Loaded to Line No. Production completion date Capacity Required (Days) Loading date Comments
OCS101 Dress Line-1 10th May 11 26th April
OCS102 Blouse Line-2 12th May 12 27th April
OCS103 Trouser Line-3 15th May 13 28th April
OCS104 Long sleeve Tee Line-4 17th May 5 11th May
OCS105 Skirt Line-5 21st May 13 5th May
OCS106 Dress Line-6 21st May 8 11th May
OCS107 Long sleeve Tee Line-7 10th May 16 21st April
OCS108 Skirt Line-8 04th May 5 28th April