Ravi Kishore Fashion is Highly Perishable Seminar
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Transcript of Ravi Kishore Fashion is Highly Perishable Seminar
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8/9/2019 Ravi Kishore Fashion is Highly Perishable Seminar
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Inside the Garment Industry
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Fashion is highly Perishable
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Clothes are a highly perishable commodity
like bread. Every consignment is like
freshly baked clothes- Amancio Ortega Gaona
(founder of Inditex S.A) Zara
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hort Lead Times
As short as 30 days
Fashion vs Staple
Is it CMT or OEM business?
Plan capacity & build flexibility
IT & Planning are only Tools Manpower training & orientation
critical
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Manufacturers Role
Visualize the Macro picture
One of the players
Understand the play
Know the role
Play by rules
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Retail to Production
The Supply Chain
Value Addition
I want it NOW!
Is it my size?
Show me other colors
How?
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Retail to Production
Buyer has calendar
Manufacturer adopts Buyers
Make one for Vendor
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Know Your Calendar
Focus on Functions
Time to think ahead
Establish Process Flow
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The Process Flow
Consider garmenting as a
process
Every process has a flow
Identify the processes
Prepare the process flow Define functions by
Process
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Calendar for Function
List functions
Calendar is events in a
function
Highlight Major Events
Prepare Plan of Action Make the Calendar of Critical
Activities
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The Flow Chart
Production - Finishing
Production - Packing
Merchandising
Finance
Sourcing
Sample RoomI.E
Material Inspection
Production Planning
Production- Cutting & Sewing
Production - Washing
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Critical Path
Develop Standard Operating
Procedures
Example Merchandisers jobs - order
processing, make Bill of Materials, rise
indents for sample & bulk fabrics andaccessories, get approvals
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DEPARTMENT ACTIVITY PLAN ACTUAL
Merchandising Receive PO 0 0
Sampleapprovals 28 20
Fabric approval 22 22
Accessory
approval 22 23
Sourcing Fabric sourcing 11 15
Accessory
sourcing 6 12
Fabric order to
in-house 50 52Accessory order
to in-house 50 52
Sampling Fit samples ready 20 21
Production Cut to finish 49 47
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Days Taken for Activities
4%7%
6%
39%
2%
4%
3%
21%
6%
8%
APPROVALS - BUYER
MERCHANDISING
SAMPLING
SOURCING
FINANCE
EXPORT - IMPORT
MATERIAL INSPECTION
PRODUCTION
COURIER -
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Establish Standard Operating
Procedures List Critical jobs
Make SOP bulletin
Highlights delays
Analysis & course correction
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TnA (Time and Action)
Each Buyer is unique
Identify Critical Requirements
List Critical Actions
Set Time and Action plan
Set-up online alerts
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Do It Now
Time saved is profit gained
Develop TEAM spirit
Online appraisal can do a lot
Avoid building BUFFERS in the TnA
Plan
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Do Not Ask for Extensions Remember you are a service industry
Your buyer is a RETAILER with one or many
stores in one country or many countries
The buyers constraint is season and climate You will not buy woollens in summer or cottons
in winter
A 2 day delay by you will result in a total delay of
nearly 60 days or 2 months. A season may end.
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Right R M on Time
Develop pro-active plan for Raw
Material (RM) procurement
Each RM is different
Establish time lines
Evaluate procurement concerns Domestic vs Imported
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Right RM on Time
Evaluate concerns- price, time &
transport
Set formulae to help in decisionmaking
Import - documentation is critical Customs formalities time consuming
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Other Critical Items
Develop list of critical items by
PROCESS, TIME and QUALITY
Example zipper, interlining, specialthreads and buttons, embroidery,
wash, packing
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Process Planning
Plan Processes in Sequence
Sourcing
Sample making & approvals
R M inspection & testing
Pattern grading & marker planning
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Time Lines
R M domestic 60 days
& imported 25 days
Transport 15 -28 days
Customs 7 days
Inspection & testing 7-15 days Pre-production 4 days
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PPP
THE PRODUCTION PLANNING PROCESS
WHERE IT STARTS
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PPP-THE BUSINESS PLAN
PRODUCTION PLANNING PENULTIMATE RUNNER
BOOK CAPACITY RECEIVE ENQUIRY
IN-HOUSE RAW MATERIALS, INSPECT & CHECK QUALITY /
QUANTITY
ESTIMATE / ANALYSE TIME, DIFFICULTY, R M & COST
CONFIRM PRICE & ACCEPT ORDER
MAKE SAMPLE (S) RECEIVE APPROVAL
SOURCE R M, GET APPROVALS, PLACE ORDERS WITH
VENDORS
CONINUED .
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THE PLAN - 2
PPP
PLAN MACHINE LAYOUT / CUTTING
START PRODUCTION
CHECK QUALITY
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THE PLAN - 3
PPP
FINISH / WASH / PACK
FINAL INSPECTION
DOCUMENTATION &
DELIVERY
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Production Planning & TnA
Buyers time from order placement to
garment delivery
Normal time line 90 to 120 days for
staple
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Sample Making Activity
1) Receive Purchase Order
2) Make sample & courier3) Comments for correction4) Remake & courier
5) Receive approval
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Raw material Sourcing Activity6) Source fabric receive sample
7) Courier swatch for approval
8) Receive approval from customer9) Source accessories receive samples
10) Courier trims/accessory samples
11) Place order with suppliers arrange for pilot yardage/sample qty
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Raw material dispatch Activity12) Fabric production imported
13) Transit - warehouse to warehouse-bysea 14)
Trims/accessory production by suppliers
domestic / imported
15) Transit -warehouse to -warehouse
from overseas by sea
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Production unit Sample making
16) Identify production unit,
sample analysis and making
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Pilot yardage & Trims inspection
17) Pilot R M in-house
18) Check fabric shrinkage, width,
color fastness, defects, shade
variation, bowing & skewing,and wash standard
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Sample garment for Wash care19) Sample for garment test & wash care
instruction
20) Test report & wash care label
Size set samples21) Size set in bulk RM
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Bulk RM Inspection Stores
22) Bulk R M check quantity & quality
23) Issue R M to production unit
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Production
24) Cutting Section Activities25) Set the production line
26) Check quality, machine layout
27) Check product quality28) Pilot production inspection
30) Mid-inspection by customer
31) Pack finished garments
32) Arrange final inspection
33) Arrange to truck-out to
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Total Production Cycle
Time to establish bank limits & LC
Time for sourcing & production
Time for payment realization
Total cycle not to exceed 120 days for
staple items
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The Key
Flexible work culture Team work
Commitment
Strong sourcing
Definite Job description &
responsibility
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Thank You