# How to Make Line Loading Plan for Garment Production?

#### How to Make Line Loading Plan for Garment Production?

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

Image-1: Planning Board