NZ Denim Limited Planning & Production Control.

Innovation makes us different

PLANNING & PRODUCTION CONTROL.

NZ Denim Ltd.
Innovation makes us different

NZ Denim Ltd.
Innovation makes us different

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 NZ Denim Limited Planning & Production Control.

Innovation makes us different

 Introduction:
Planning is an important process that is made before any kind of activities & try to achieve the best shape for the future. That is through planning, easy ways to consciously
accomplish future large tasks are observed to achieve specific goals. In a word, planning is making decisions in advance to target the goal of a big project or work in future &
achieve them in a certain time to completion without damaging any kind of material. Which indicates what types of work to be done? When & where should be done? How will it
be done? How many days are required to finish this work ? An arranges to complete the system process within specified time. Which is observed by planning & production control
department.

NZ Denim Ltd.
 Planning & Production Control: Innovation makes us different
Planning is the process of thinking regarding the activities required to achieve a desired goal. Planning is called before starting any work the activities about the scope, duration
and materials of the work & maintain the accurate distribution. To ensure the right quantity and quality of raw material, equipment, etc. are available during times of production.
NZ Denim Ltd.
Innovation makes us different
Planning Production:- Before starting any work to determine the amount of raw materials & complete the production within a specified time is Called Production Plan .So
production planning is to arrange the raw material for the products & making schedule , collecting & completing the work or production in just time Production.

Planning Control:- Production control refers to the production process by establishing control in every stage and realizing the supply time of the product by collecting the
necessary raw materials of the product within the specified time.
Production control looks to utilize different type of control techniques to achieve optimum performance out of the production system as to achieve overall production planning
targets.

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 NZ Denim Limited Planning & Production Control.

Innovation makes us different

Functions of Planning & Production Control.

Planning & Production Control.

Capacity Calculation Time & Action Plan Pre-Production Meeting Tasks Execution Corrective

 Warping.  Order & LC received date.  Production order.  Order confirmation.  Analysis weaker spots
 Dyeing.  Approval received date.  Approval wash standard.  Consumption & costing.  Correctives
NZ Denim Ltd.
 Weaving.  Customers require delivery dates.  Dyeing lab test report.  Production order (P.O) measurement
Innovation makes us different
 Finishing.  Priority basis production plan.  Customer comments.  Lead time/space  Data keeping all
 Inspection.  Bulk production start/ends date.  Matching wash with buyer availability. production summary
 Delivery.  Raw material & loom allocation plan. approval wash standard.  Inquiry of product.  Analysis & improve.
 Follow-up.  Shrinkage test report.  Guarantee of payment
 Instruction setting productive &  Physical lab test report. (LC).
activities.

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 NZ Denim Limited Planning & Production Control.

Innovation makes us different

 Capacity calculation:
Production capacity estimation for a manufacturing sector is an important issue .
The production capacity of a denim factory is totally related to machine (hours) capacity, machine efficiency of that factory
and standard allowed minute of produced item.

Standard minutes help planners to set a target for denim production. On a daily basis when planners check production status
planners can compare actual production with target production. In case production is getting delayed, planners can push the
production team based on the given target. For achieving accurate production capacity of a denim factory, Planners should
confirm accurate warping, dyeing, sizing, weaving, finishing, inspection & delivery capacity Calculation also.

 Time and action plan: NZ Denim Ltd.

Innovation makes us different
Time and action plan (TNA) is very important and advantageous for the denim industry. In denim manufacturing, the
process starts from receiving orders and ends at delivery of order to customer, so simply TNA plan is creating a time calendar
NZ Denim
to accomplish the whole export order from starting to closing. Time and action calendar Ltd. process scheduling of
or production
each order is done by the planning department. Innovation makes us different

Like for the order received date, approval received date, customers require delivery date, priority basis production plan, bulk
production start/ends date, raw material & loom allocation plan, follow-up, instruction setting productive & activities etc.

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 NZ Denim Limited Planning & Production Control.

Innovation makes us different

 Pre-Production Meeting :
​ pre-production meeting is basically a meeting before starting bulk production, to set every production
A
procedure and core decision of production.
In a pre-production meeting discussion of every important customer comments, procedures to be followed,
shrinkage test report, physical lab test report related to bulk production is done, so that we can ensure
successful delivery of ordered goods.
All the production related people need to be present in the Pre-Production Meeting. Its arrangement by the
planning department.

NZ Denim Ltd.
 Tasks Execution: Innovation makes us different
Task execution is a consistent process of doing planned tasks and producing expected results by one individual
or a group of individuals joined into a team, in compliance with preset requirements and expectations.
NZ Denim Ltd.
It determines a sequence of tasks assigned to the update including datamakes
Innovation is order confirmation, consumption &
us different
costing, production order (P.O), lead time/space availability, inquiry of a product, guarantee of payment (LC)
etc.

 Corrective
At the evaluation process, a thorough analysis is done and corrective measures are taken in the weaker spots.
Like analysis of weaker spots, correctives measurement, data keeping all production summary, analysis &
improvement etc.

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 NZ Denim Limited  Flowchart of Planning Working Process:
Planning & Production Control.

Innovation makes us different

Delivery f o rm a )
Pe r I
 All orders received from marketing & scheduling delivery circulate the planning to all Plan i c e (P
o
production related persons & meetings to implement planning. I nv
n
M on
i to d u ct i o
)
activ r Daily Pr o r ( PO
it i es e
 Making warp/weft yarn & chemical consumption requisition as per order quantity. Ord

 Making priority basis warping, dyeing, and loom plan, finish plan, Inspection Plan & also Inspe r i al
ct i at e n
delivery plan accordingly committed delivery schedule. P l a n on M
Raw quisit
io
R e

 Follow-up bulk production trial, pre-production activities according to plan & chase with
inspection team for in time fabric delivery. Finishing Planning r Wa
sh
Buye ndard
Plan WIP St a
 Monitor daily production, making daily production reports & sharing with higher
management, history tracking for section wise production & documentation.
y
i ve r
Loom Del edule
 Yarn requirement submitted to procurement department. All time communication with Plan S ch
procurement concerns the person about its matter.

&
r p l an ct i on
 Expert in operation and WIP analysis. Able to handle the task on ERP Software. Wa ng P Produ dule
ei Sc he
Dy
e - on
P r uc t i g

Sh g r a m
 Overall we maintain Production Planning, Team management, Production management, n
od eet i

t
r

ee
Quality management, Delivery commitment, Production follow-up, Outside sourcing, Buyer

o
P M

Pr
satisfaction.

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 NZ Denim Limited Planning & Production Control.

Innovation makes us different

 Stages Steps in Planning & Production Control:

 Routing: Routing can be defined as the process of deciding the path (route) of work and the sequence of operations.
This depends upon the nature of production.
Routing
 Scheduling: Scheduling is also done for Production to till fabrics delivery. There are many types of schedules like
Yarn, Dyes & Chemical schedule. It helps to complete the job systematically and in time.
Delivery Scheduling
 Loading: Loading is the third step is the execution of the schedule plan as per the route chalked out it includes the
production. So loading determines what will do the work as routing determines where and scheduling determines
when it shall be done.

 Dispatching: It is the action, doing or implementation stage. It comes after routing and scheduling. Dispatching
NZwork.
means starting the process of production. It provides the necessary permit to start the
Innovation
DenimItLtd.
makes
is based on route-
us different
Planning
sheets and schedule sheets.
Inspection Loading
 Follow-up: Ensuring that the productive operations are taking place in accordance with the plans. All problems or
NZ Denim
deviations are investigated and remedial measures are undertaken to ensure the completion of Ltd.
work by the planned
date. Innovation makes us different

 Inspection: This is mainly to ensure the quality of goods. It can be required as an effective agency of production
control. Follow up Dispatching

 Delivery: It's the next step of inspection. After the inspection of the cloth is done, arrangements are made to send
the cloth to the fabrics store & fabrics are delivered to garments according to delivery orders clearance

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 NZ Denim Limited Planning & Production Control.

Innovation makes us different

Major Duties & Responsibilities of Planning & Production Control:

 Manages activities for continuous improvement while maintaining high quality, on-time fabric delivery and cost-effectiveness.
 Evaluates activities to ensure final product meets customers require & achieve customer’s satisfaction.
 Helps marketing teams in coordinating customer orders and fabrics deliveries.
 Always contacted with marketing person regarding production update, orders, LC status, delivery schedule etc.
 Production is updated from time to time as per current situation and submitted to higher authorities.
 Produces according to capacity and helps to utilize 100% capacity at minimum cost.
 Settings the production targets and archives on time.
 Executes the plan and works to reduce the gap between plan vs. actual.
NZ Denim Ltd.
 Assists in achieving timely delivery and maintaining production work order.
Innovation makes us different
 Creates production plans based on priorities ensuring maximum performance and minimum delays.
 Monitors all manufacturing operations through physical or at ERP (warping, dyeing, sizing, finishing, inspection and delivery) and
priority-based works processing. NZ Denim Ltd.
Innovation makes us different
 Monitoring daily production activities through physical or ERP systems and generating daily production reports and identifying and
resolving department wise production problem reports promptly.
 Pre-production meetings are arranged to decide on each production method and production route plan.
 Identifies raw material shortages and arranges immediate solutions.
 At last analysis of delay points, analysis & improvement, correctives measurement, data keeping all production summary.

…………………………………………….This is how pass our Planning & Production Control Activities………………………………….

………. Thanks………
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 NZ Denim Limited Planning & Production Control.

Innovation makes us different

 Organogram of Planning & Production Control Department:

Planning & Production Control

Manager Senior Officer Officer Junior Officer

NZ Denim Ltd.
 To make the production plan and to cooperate with Innovation makes us different  Created program in ERP.
 Update order statements.
the management and give necessary directives to  Finalize capacity charts, create the loading,  Program sent to QA dep. For checking.
 Dept. Wise production update summary.
the production peoples regarding the production receiving, production plans & to manage  Chemical stock summary (daily)  Update approval swatch in register.
plan. deviations within the planning process. NZDenim
DenimLtd.
Ltd.
NZ Sub contract lot create in ERP.  Contract with marketing about approval &
 Analyze, control and reduce cost in an effective  Plan work flow and schedules for production production related update.
and efficient manner.
Innovation makesus different
Outsource
Innovation makes us different work order create in ERP.
departments.  Outsource lot create in ERP.  Always communicating to R&D & QA dep.
 Monitor operational performance to improve the  Monitor production status and ensure timely  Program sheet mail to every dep.
 Update production & chemical report to PD Sir ,
existing performance and efficiency of the delivery.  Warp length check & update in ERP.
GM Sir & Manager Sir’s board.
production operatives and processes.  Identify delays and accordingly adjust schedules to  Check dyeing program (dyeing reference).
 Communication with marketing person as per
 Overall act as a catalyst for change and meet deadlines.  Collect lab management from R&D dept.
production status.
improvement in better planning for optimum  Finishing Production monitoring according to the  Update subcontract production report.
 Floor production inventory as per plan basis.
production. plan sheet.  Flow-up daily production activities through physical  Calculate & update using sustainable yarn.
 Follow up pre-production activities planning  Plan sheet making as per delivery schedule &  Check dyeing program schedule & arrange for
or ERP systems.
 By time study determining capacity of operation Coordination of fabric delivery. ready program sheet.
 RFD & Ecru order special follow-up.
and planning improvement.  Delivery schedule making as per buyer/Marketing  Summarized count wise daily yarn stock
 Making delivery completed PO wise final summary
 Preparing operation breakdown/layout & calculate required accordingly. report.
statement.
manpower, machinery & martials.  Priority basis yarn requirement making &  Monitoring & signature warping length.
 Daily LC check from ERP & update to order
 Conducting time study and motion study and idle submitted to Procurement Dep. approval copy then mail to audit dept.
statement .
man machine hours on a daily basis.  Always communicate with marketing Persons &  Daily revise pi qty. Monitoring & correction
 Collect code wise dyeing recipe from dyeing
 Keeping updated with all the information of the ensure fabric delivery. program length from ERP.
department.
area assigned & maintain daily production  Making Monthly meeting & Presentation reports.  Record keeping , filing program sheet and also
 Weaving balance updating order statements.
planning related reports.  Subcontract & Outsource works follow up record production documents.
 Mailing to audit for preparation of SO & PO for sub-
 Ensure an incredibly significant role to increase keeping.  Always cooperation to production teams every
contract work both sample / bulk.
productivity with standard.  Supervising and managing the work of junior staff. documents issue.
 Ensure 100% on time shipment as buyer demand.
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