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This document provides calculations for determining the raw material warehouse capacity needed to store a 32-day inventory for a garment factory. It calculates space needed for storing fabric, trims, threads, and finished goods. For fabric, it allocates 324 cells for shell fabric, 23 for pocketing material, and 12 for fusing material. It also allocates cells for storing threads, buttons, labels, velcro, zippers, hangtags, polybags, empty cartons, and hangers. The total cell usage is 568 cells. It also provides suggestions for rack and storage configurations to optimize warehouse space.

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SHASHANK ROHIT
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58 views34 pages

Simple Office Computer View PowerPoint Template

This document provides calculations for determining the raw material warehouse capacity needed to store a 32-day inventory for a garment factory. It calculates space needed for storing fabric, trims, threads, and finished goods. For fabric, it allocates 324 cells for shell fabric, 23 for pocketing material, and 12 for fusing material. It also allocates cells for storing threads, buttons, labels, velcro, zippers, hangtags, polybags, empty cartons, and hangers. The total cell usage is 568 cells. It also provides suggestions for rack and storage configurations to optimize warehouse space.

Uploaded by

SHASHANK ROHIT
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 34

RAW MATERIAL WAREHOUSE

CAPACITY CALCULATION
CONSTRAINTS:
 Total number of cells available = 568 cells

 Average yardage of 1 Shell fabric roll = 110 yds.

 Average capacity of 1 cell = 40 rolls, therefore capacity of 1 cell for


shell fabric = 4400 yards.

 With 70% loading efficiency, capacity of 1 cell = 28 rolls = 3080 yards

 Average number of Pocketing rolls a cell can accommodate = 50, with


average yardage = 200yds.

 Average number of Fusing rolls a cell can accommodate = 200, with


average length = 109 yard.

 Maximum Thread quantity in 1 cone = 5,000 meters


CALCULATION:
Taking the maximum fabric consumption per garment = 1.2
yards.
Consumption of pocketing material per garment = 0.28 yards.
Consumption of fusing material per garment = 0.30 yards.
Consumption of thread per garment = 485 meters.
Total number of cells available = 568

Using the available space, we can hold an inventory for 32 days


(5+ weeks), which is = 997920 yards.

 Breakdown of allocated space is as follows:


PLANNING 32 DAYS INVENTORY
 FOR SHELL FABRIC:

 Consumption/ garment = 1.2 yards


 Total production / day = 26000 pieces
 Inventory period = 32 days.
 Total fabric to be stocked = 1.2 X 26000 X 32 = 997920 yards.

 Now, capacity of 1 cell = 3080 yards. Therefore total number of


cells required for fabric = 997920/3080
324 cells

 Total fabric rejected = 10 % = 99792 yards.


 Total fabric leftover = 5 % = 49896 yards.
 FOR POCKETING MATERIAL:

 Consumption/ garment = 0.28 yards


 Total production / day = 26000 pieces
 Inventory period = 32 days.
 Total fabric to be stocked = 0.28 X 26000 X 32 = 2329600
yards.

 Now, capacity of 1 cell = 10,000 yards. Therefore total


number of cells required for fabric = 2329600/10000

23 cells
 FOR FUSING MATERIAL:

 Consumption/ garment = 0.30yards


 Total production / day = 26000 pieces
 Inventory period = 32 days.
 Total fusing material to be stocked = 0.30 X 26000 X 32 =
2496000 yards.

 Now, capacity of 1 cell = 20,000 yards. Therefore total


number of cells required for fusing = 2496000 /20000
12 cells

Total cells utilized for pocketing, shell fabric, fusing material


= 324 + 23 + 12 = 359 cells.
 FOR THREAD INVENTORY:

 Average Consumption/garment = 300 meters.


 Total production / day = 26000 pieces
 Inventory period = 32 days.
 Total thread requirement = 249600000 meters for 32 days.

 Now, Maximum thread in 1 cone = 5000 meters.


 Capacity of 1 crate = 65 cones.
 Therefore, number of crates required = 403520000/325000
768 crates.

If we put 25 crates in one cell, total cells required =. 31


TRIMS
LABELS:

 Average number of labels required/ garment = 2.


 Inventory period = 32 days.
 Total requirement = 1664000
 Capacity od 1 cell = 3,60,000

5 cells required.
TRIMS
VELCRO:

 Average number of velcro required/ garment = 2.


 Inventory period = 36 days.
 Total requirement = 1664000
 Capacity od 1 cell = 3,60,000

No. of cells required = 1664000 /360000


= 5 cells
TRIMS
ZIPPERS:

 Average number of zippers required/ garment = 1.


 Inventory period = 32 days.
 Total requirement = 832000
 Capacity of 1 drawer = 3000 zippers
 Capacity of 1 cell = 45,000 zippers

No. of cells required = 832000/45000


= 18 cells
TRIMS
HANGTAGS:

 Average number of hangtags required/ garment = 2.


 Inventory period = 32 days.
 Total requirement = 1664000
 Capacity of 1 crate = 12000 tags
 Capacity of 1 cell = 12000X2X9 = 216000 tags

No. of cells required = 1664000 /216000


= 8 cells
TRIMS
BUTTON:

 Average number of hand buttons required/ garment = 3.


 Inventory period = 32 days.
 Total requirement = 2496000
 Capacity of 1 crate = 15X1440 = 21600 buttons
 Capacity of 1 cell = 21600x2x9 = 388800 buttons

No. of cells required = 2496000 /388800


= 6 cells
TRIMS
POLYBAG:

 Average number of polybag required/ garment = 1.


 Inventory period = 32 days.
 Total requirement = 832000
 Capacity of 1 carton = 2500 polybag
 With 70% loading efficiency number of carton= 28
 Capacity of 1 cell= 2800*2500= 70000

No. of cells required = 832000 /70000


= 12 cells
TRIMS
EMPTY CARTONS:

 Average number of garments/carton = 10


 Inventory period = 32 days.
 Total requirement = 2600
 With 70% loading efficiency number of carton in 1 cell= 300

No. of cells required = 2600*7 /300


=
60 cells
TRIMS
HANGERS:

 Number of hangers in 1 carton = 200


 Inventory period = 32 days.
 Total requirement = 10000
 With 70% loading efficiency number of carton in 1 cell= 30

No. of cells required = 320000/200*30


=
cells 53
23
POCKETING
POCKETING CELLS

FABRIC INTERLINING 12
FABRIC INTERLINING CELLS

SHELL 324
SHELL CELLS

31
THREAD
THREAD CELLS

76
BUTTONS
BUTTONS CELLS

5
LABELS
LABELS CELLS

VELCRO
VELCRO 5
CELLS

TRIMS
TRIMS ZIPPER
ZIPPER 18
CELLS

TAGS
TAGS 8
CELLS

12
POLYBAG
POLYBAG CELLS

EMPTY
EMPTY 60
CARTONS
CARTONS CELLS

53
HANGERS
HANGERS CELLS
TOTAL CELL BREAKDOWN

HANGERS
10%
EMPTY CARTON
11%

POLYBAG
2%
BUTTON
1%
HANG TAG
1%
ZIPPER SHELL FABRIC
3% 58%
VELCRO
1%
THREAD
LABEL 6%
1%

FUSING
2%
POCKETING
4%
SUGGESTED RACKS FOR
INVENTORY STORAGE
Storage Racks for Shell Fabric

Traditional racks for fabric roll storage with cells of dimension


= 79’’ X 49’’
For Storing Thread Cones:

• Crates shall be used for storing


thread cones.

• Different colors can be allotted


to different styles, Tex, color etc.

• One crate capable of holding 65


cones ( of 5000 meters).

• If needed, these crates can be


divided into smaller
compartments , as shown in the
figure.
For Pocketing & Fusing Material

• Storage of pocketing in roll form.


• Each rolls will be stored in a cylindrical frame.
• Segregation according to color, style, length and width will help in
easy and fast tracking.
For Small Trims:

• Specially designed drawers/sections for small trims like labels, tags


and buttons with proper allocation according to the style no., buyer, file
no.
For Velcro:

• Velcro being very light, can be stored in big drawers.


• Each cell will have 3 drawers.
• Dimensions of each drawer 79’’ X 15” X 38”
For Tags and Price Tickets:

• Each cell can be divided into


5 drawers width wise and 4
drawers length wise.

• Size of each drawer = 15” X


11” X 38”.

• Utilization : For small trims


like tags, labels, price tags
etc.
For Carton Storage

• For the storage of packing like


hangers, polybag, which has to be
stored in carton form, existing cell
can be used to its full capacity.

• Fork lift shall be used for loading


and unloading of the cartons.

• Cells may be further divided into 2


depending upon the carton size of
the trim.
38”

15”

25”

Similar divisions can be made to the drawers which would facilitate easy
segregation of trims, thus using the cell capacity to the fullest.
Utilization – For storing zippers
Finished good warehouse
Stacking with palettes on the floor
JCP Boys Chinos Wal-Mart 10’’ shorts
Pcs packing/day 10,000 6,000 8,000
Carton size(LWH) 22.5"x15.5"x5" 22"x12"x4" 26"x22.5"x4"
Pcs in 1 carton 10 10 12
Stack height 72” 72” 72”
Carton height 5” 4” 4”
Cartons/ pallets/ layer 5 6 3
Total cartons on 1 pallets 72 108 54
Total number of pallets 394
Pallets distribution% 42% 25% 33%
Pallets distribution quantity 164 99 131
Carton capacity 11,820 10,638 7,092

Total cartons 29550


Pcs by product 118,200 106,380 85,104
Total Pcs 309,684
Stacking with pallets on the floor

 So inventory days= 13 days

 Total space used pallets = 10,500 Sq. ft.

 Average area required per pallets = 27 Sq. ft.


Capacity required for 30 days
inventory
JCP Boys Chinos Wal-Mart 10” shorts
Pcs packing /day 10,000 6,000 8,000

Pcs for 30days storage 300,000 180,000 240,000

Number of cartons 30,000 18,000 24,000

Number of pallets 417 167 370

Total pallets required 953.70

Total area required 25,416


Option -1
Racking: Single racking
mezzanine
JCP Boys Chinos Wal-Mart 10” shorts
Total nos. of pallets 394
on ground floor
Total pallets on 348
mezzanine floor
Total pallets 742
By product 309 186 247
Cartons required 22,260 20,034 13,356
By pieces 222,600 200,340 160,272
Total garments 583212

Total inventory days 24.3


Option -1
Racking - Single racking mezzanine

 Area used = 10,500 Sq. Ft.

 Estimated cost per Sq. Ft. = $10

 Estimated total cost = $105,000


Option -2
Racking: mezzanine & middle layer
JCP Boys Chinos Wal-Mart 10” shorts
Total nos. of pallets 394
on ground floor
Middle selves 328
Total pallets on 328
mezzanine floor
Total pallets 1,050
By product 437.50 262.50 350
Cartons on 1 pallet 60 90 45
Cartons required 26,250 23,625 15,750
By pieces 262,500 236,250 157,500
Total garments 687750
Total inventory days 29
Option -2
Racking: mezzanine & middle layer

 Area used = 10,000 Sq. Ft.

 Estimated cost per Sq. Ft. = $8

 Estimated total cost = $80,000

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