{"id":263,"date":"2019-05-22T04:28:26","date_gmt":"2019-05-22T04:28:26","guid":{"rendered":"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/?post_type=chapter&#038;p=263"},"modified":"2019-05-22T04:52:43","modified_gmt":"2019-05-22T04:52:43","slug":"apparel-industry-organizational-set-up-planning-and-product-selection-production-planning-and-control","status":"publish","type":"chapter","link":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/chapter\/apparel-industry-organizational-set-up-planning-and-product-selection-production-planning-and-control\/","title":{"rendered":"Apparel Industry &#8211; Organizational set up &#8211; Planning and product selection &#8211; production planning and control"},"content":{"raw":"<div><span style=\"float: right\"><a href=\"https:\/\/youtu.be\/kajr39AxJjU\" target=\"_blank\" rel=\"noopener\"><img src=\"http:\/\/epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/2018\/11\/download.png\" alt=\"epgp books\" width=\"75px\" height=\"75px;\" \/><\/a>\r\n<\/span><\/div>\r\n&nbsp;\r\n\r\n&nbsp;\r\n\r\n&nbsp;\r\n\r\n&nbsp;\r\n\r\n&nbsp;\r\n<div>\r\n\r\n<strong>1. INTRODUCTION<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">Over a period of time, Apparel industry experienced strategic growth and competitiveness among the manufacturers. Apparel industry are just as diverse as the design they produce. They can be large or small have one employee or thousands, produce high end high fashion or budget everyday garments. Apparel is an ideal industry and it helps to account for large number of jobs associated with the industry. Furthermore, it has extensive forward and backward linkages with associated industry. Clearly no two industry are exactly alike, but there is a transition from the traditional focus on production efficiency to more focus on consumer's changing needs. Technology has dramatically altered the apparel industry and provided the manufacturers with the ability to respond quickly to change. Moreover it allows global expansion and communicate the apparel specifications instantly through the internet.<\/p>\r\n&nbsp;\r\n\r\n<strong>2. OBJECTIVES<\/strong>\r\n\r\n&nbsp;\r\n\r\n<strong>Upon Completion of the module, students will be able to<\/strong>\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Describe the organizational structure of the Apparel Industry<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Explain the fundamental steps in product planning and selection<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Outline the need and functions of production planning and control<\/p>\r\n&nbsp;\r\n\r\n<strong>3.\u00a0 <\/strong><strong>APPAREL INDUSTRY<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">Any organization need structuring so that, lines of authority along with individual duties and responsibilities can be understood by every company member. Most of the companies prepare graphical representation of organizational structure and the method of presenting in graphical manner is called organizational chart. The Apparel industry is fascinating example of manufacturing and the supply chain. The supply chain of the apparel industry commence from\u00a0<span style=\"text-align: initial;font-size: 1em\">farming of cotton in the cotton fields, manufacturing man made fiber to selling clothes in retail stores to the consumer.<\/span><\/p>\r\n\r\n<\/div>\r\n<div>\r\n\r\n&nbsp;\r\n\r\n<strong>3.1 Structure of the Apparel Industry<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">Broadly the skeleton of the Apparel industry can be divided into four stages. (Figure 1)<\/p>\r\n&nbsp;\r\n<p style=\"text-align: justify\"><strong>Stage 1: Textiles and Findings Manufacturers<\/strong><\/p>\r\n&nbsp;\r\n<p style=\"text-align: justify\">In the mill level, the raw materials for the apparel manufacturing process such as fibres, yarns, fabrics, zippers, threads, trims and buttons are manufactured and apparel manufacturer are vertically integrated or buy from vendor's open stocks.<\/p>\r\n&nbsp;\r\n\r\n<strong>Stage 2: Apparel Manufacturers<\/strong>\r\n\r\n&nbsp;\r\n\r\nApparel Manufacturers are responsible for the marketing, merchandising and production of products. In this stage, there are two types of apparel manufacturers.\r\n\r\n&nbsp;\r\n\r\ni.\u00a0 \u00a0 Perform manufacturing within their own facilities and employees\r\n\r\nii.\u00a0\u00a0 Contract some or all manufacturing functions to other firms. There are 3 types of contractors:\r\n<ul>\r\n \t<li>Cut-make-trim (CMT) Contractors<\/li>\r\n \t<li>Full package program (FPP)<\/li>\r\n \t<li>Specialty contractors<\/li>\r\n<\/ul>\r\n<strong>\u00a0 Stage 3: Retailers<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">The Apparel manufacturers may be vertically integrated into the retail sector through owning their own stores which aid decision making during product development.<\/p>\r\n&nbsp;\r\n<p style=\"text-align: justify\">There are different types of retailers in today's consumer goods markets: catalogue retailers, department store retailers, internet retailers, mass retailers, specialty retailers, warehouse\/wholesale clubs, Retail outlets.<\/p>\r\n&nbsp;\r\n\r\n<strong>Stage 4: Consumers<\/strong>\r\n<ul>\r\n \t<li>The target of the textile and Apparel manufacturers are the ultimate consumers.<\/li>\r\n \t<li>Satisfied consumers make business growth and profitability possible.<\/li>\r\n \t<li>Decisions made at all levels are based on forecast of consumer demand.<\/li>\r\n<\/ul>\r\n<\/div>\r\n<div>\r\n\r\n<img class=\"aligncenter size-full wp-image-266\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-127.png\" alt=\"\" width=\"644\" height=\"270\" \/>\r\n\r\nFigure1 : Structure of the Apparel Industry\r\n\r\n&nbsp;\r\n\r\n<strong>4. ORGANIZATIONAL SETUP OF THE APPAREL INDUSTRY<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">The flow chart shows the organizational Set up of the Indian Apparel Export Industry. The Managing Director is responsible for the performance of the company. The Operation Head Manages the entire factory operations and ensure that factory is running profitability. Design Head Responsible for the design and development of clothing. Marketing Head Focuses on publicizing and increasing awareness of a particular brand, such as designer labels or department stores. Merchandising Manager Creates a good relationship in between exporter &amp; buyer. Production Manager heads the factory and Quality. Logistics Head looks after the Export documentation and arranging vessels for goods. Administrative head directs the activities of subordinate staff in the coordination and management of various administrative activities for an organization.<\/p>\r\n&nbsp;\r\n\r\nThe roles and responsibility of the important personnel in the Apparel Industry.\r\n\r\n&nbsp;\r\n\r\n<strong>4.1 Managing Director<\/strong>\r\n<ol>\r\n \t<li style=\"text-align: justify\">Managing Director reports to the chairman or board of directors.<\/li>\r\n \t<li style=\"text-align: justify\">As the Managing Director, responsibilities will include:<\/li>\r\n<\/ol>\r\n<ul>\r\n \t<li style=\"text-align: justify\">formulating and successfully implementing company policy;<\/li>\r\n \t<li style=\"text-align: justify\">directing strategy towards the profitable growth and operation of the company;<\/li>\r\n \t<li style=\"text-align: justify\">closely monitoring the operating and financial results against plans and budgets;<\/li>\r\n \t<li style=\"text-align: justify\">taking remedial action where necessary and informing the board of significant changes;<\/li>\r\n \t<li style=\"text-align: justify\">maintaining the operational performance of the company;<\/li>\r\n \t<li style=\"text-align: justify\">representing the company to major customers and professional associations;<\/li>\r\n \t<li style=\"text-align: justify\">building and maintaining an effective executive team.<\/li>\r\n<\/ul>\r\n<\/div>\r\n<strong>4.2 Operations Head<\/strong>\r\n<ul>\r\n \t<li style=\"text-align: justify\">Operation Head Coordinates with Design, Marketing and merchandising, Logistics, Production and Administrative team<\/li>\r\n \t<li>Planning of production units<\/li>\r\n \t<li>Style allocation to units<\/li>\r\n \t<li>Technical setting of the garment<\/li>\r\n \t<li>Involvement in pp meetings<\/li>\r\n \t<li>Production monitoring<\/li>\r\n \t<li>Factory work study\/industrial engineering<\/li>\r\n \t<li>Quality of the finished product<\/li>\r\n \t<li>Shipment planning and shipments<\/li>\r\n \t<li>Costing of production floor<\/li>\r\n \t<li>Cost cutting of production processes<\/li>\r\n \t<li>Employee Training<\/li>\r\n \t<li>Buyer Compliance<\/li>\r\n \t<li>Recruitment:<\/li>\r\n \t<li>Workers personal &amp; welfare activities<\/li>\r\n \t<li>Inter departmental issues<\/li>\r\n<\/ul>\r\n<img class=\"aligncenter size-full wp-image-267\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-128.png\" alt=\"\" width=\"945\" height=\"518\" \/>\r\n<div>\r\n\r\n<strong>4.3 Design Head<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 In charge of guiding all steps of the design process, from initial conception to final manufacture and marketing.<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 monitoring current fashion<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Supervising a team of technical designers<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Working with individual clients to design pieces of custom couture<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Collaborating with sales and marketing managers to determine the best way to present new ideas to the public.<\/p>\r\n&nbsp;\r\n\r\n<strong>4.4 Marketing Head<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Assisting their employers with analyzing advertising campaigns and monitoring brand quality.<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Monitoring the reactions of customers and retail outlets to new products and brand initiatives.<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Overseeing a number of subordinate employees.<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 In charge of branding and marketing new products.<\/p>\r\n&nbsp;\r\n\r\n<strong>4.5 Merchandising Manager<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">\u2022\u00a0 \u00a0Looks after every job like buying the raw material, making the garment, finishing the garment, documentation, finally shipping<\/p>\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Internal &amp; external communication\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Sampling\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Lab dips\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Preparing internal order sheet\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Preparing purchase orders\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Advising and assisting production\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Advising quality department about quality level\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Mediating production and quality departments\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Giving shipping instructions and following shipping\r\n\r\n<span style=\"font-size: 1em;text-align: initial\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Helping documentation department<\/span>\r\n\r\n<span style=\"text-align: initial;font-size: 1em\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Taking responsibility for inspections<\/span>\r\n\r\n<span style=\"text-align: initial;font-size: 1em\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Following shipment<\/span>\r\n\r\n<\/div>\r\n<div>\r\n\r\n&nbsp;\r\n\r\n<strong>4.6 Production Head<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">\u2022\u00a0 Production planning for the lines (manpower, machine and styles)<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 Giving instruction to the line supervisors<\/p>\r\n<p style=\"text-align: justify\">\u2022 Line performance analysis (efficiency, man to machine ratio, cost\/pieces) and plan for continuous improvement<\/p>\r\n<p style=\"text-align: justify\">\u2022 Analysis of quality data<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 Discussion with other team members (like merchants, fabric manager, cutting team, planning, IE team)<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 Taking main role in PP meeting<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 Looking after job works (such as printing, embroidery, garment dying etc) and taking decision on selection vendors for job work<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 \u00a0Planning for Overtime work<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 Deciding rate for piece rate employees (sewing, thread cutting, pressing etc.)<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 \u00a0Examining the finished product carefully and look for flaws in them<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 The flaws found in manufacturing have to be rectified immediatel<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 Have to check for the quality of the raw materials and standardize it<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 \u00a0Coordinating with the main office from where the manufacturing orders come from<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 Hiring the workers for the factory and provide training for them<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 Assigning the workers to the different department according to their skills<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 Ensuring all the manufacturing targets are met<\/p>\r\n&nbsp;\r\n\r\n<strong>4.7 Administration Head<\/strong>\r\n\r\n<\/div>\r\n<div>\r\n<p style=\"text-align: justify\">\u2022Managing various operations at a facility (i.e. food service, physical plant, warehouse, accounting and finance, environmental health and fire safety).<\/p>\r\n<p style=\"text-align: justify\">\u2022 Identifies legal requirements and government reporting regulations affecting human resources functions and ensures policies, procedures, and reporting are in compliance.<\/p>\r\n<p style=\"text-align: justify\">\u2022 Recruits, interviews, tests, and selects employees to fill vacant positions.<\/p>\r\n<p style=\"text-align: justify\">\u2022 Plans and conducts new employee orientation to foster positive attitude toward company goals.<\/p>\r\n<p style=\"text-align: justify\">\u2022Keeps records of benefits plans participation such as insurance and pension plan, personnel transactions such as hires, promotions, transfers, performance reviews, and terminations, and employee statistics for government reporting.<\/p>\r\n<p style=\"text-align: justify\">\u2022 Advises management in appropriate resolution of employee relations issues.<\/p>\r\n<p style=\"text-align: justify\">\u2022 Administers salary administration program to ensure compliance and equity within organization.<\/p>\r\n<p style=\"text-align: justify\">\u2022Conducts wage surveys within labor market to determine competitive wage rate. Prepares budget of human resources operations.<\/p>\r\n<p style=\"text-align: justify\">\u2022 Prepares employee separation notices and related documentation, and conducts exit interviews to determine reasons behind separations.<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 Prepares reports and recommends procedures to reduce absenteeism and turnover.<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 Represents organization at personnel-related hearings and investigations.<\/p>\r\n<p style=\"text-align: justify\">\u2022 Contracts with outside suppliers to provide employee services, such as canteen, transportation, or relocation service.<\/p>\r\n&nbsp;\r\n\r\n<strong>5.\u00a0 <\/strong><strong>PRODUCT PLANNING AND SELECTION<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\"><strong>Product Planning <\/strong>phase begins with stating product objectives which includes assessment of technology development and market objectives. The output of the planning phase specifies the target market for the product, business goals, key assumptions and constraints. Product planning is an activity that considers the apparel <strong>product mix<\/strong> that an organization might pursue and determines what <strong>product assortment<\/strong> will be pursued over a\u00a0<span style=\"font-size: 1em;text-align: initial\">period of time. product mix is the total selection of goods and services that a company makes or sells. product assortment is the range of merchandise within categories that a company sells.<\/span><\/p>\r\n\r\n<\/div>\r\n<div>\r\n\r\n&nbsp;\r\n\r\n<img class=\"aligncenter size-full wp-image-268\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-129.png\" alt=\"\" width=\"633\" height=\"105\" \/>\r\n\r\nFigure 3 : New product development process.\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">The product Planning phase precedes the product development process. It identifies the product assortment to be developed by the organization and the timing of their introduction to the market. It regularly updated on an annual basis \/ season basis and it should be reviewed to reflect changes in the competitive environment, changes in technology, and information on the success of existing products. Several product revisions occur, with continuous interaction among designers, stylists and marketing functions. Product planning are developed with the company\u2019s goals, capabilities, constraints and competitive environment in mind.<\/p>\r\n&nbsp;\r\n\r\n<strong>5.1 Product failure - Why?<\/strong>\r\n\r\n&nbsp;\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Inadequate coverage of target market\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Poor timing of market introduction of products\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Poor capacity planning for product development\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Mismatch between resource requirement and development competency\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Frequent changes in Product line\r\n\r\n&nbsp;\r\n\r\n<strong>5.2 Product Planning Process<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">The Planning Process comprises Determine strategy for products, Market Strategy &amp; Feasibility Study, Identification of specific work activities, Positioning and testing of<\/p>\r\n<img class=\"aligncenter size-full wp-image-269\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-130.png\" alt=\"\" width=\"590\" height=\"438\" \/>\r\n<div>\r\n\r\nFigure 4: Product Planning Process\r\n\r\n&nbsp;\r\n\r\n<strong>5.3 Product Planning and Selection<\/strong>\r\n\r\n<\/div>\r\n<div>\r\n\r\n<strong>Determination of strategy for Products<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">Defines an overall strategy for products to guide in selection, development of products and product to be produced and results to be obtained, time, cost and performance standards, to achieve the objectives<\/p>\r\n\r\n<\/div>\r\n<div>\r\n\r\n<strong>Define market &amp; Feasibility study<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">Market study describes definition of target markets, customer, competitive strengths, and a competition strategy.<\/p>\r\n\r\n<\/div>\r\n<div>\r\n\r\n&nbsp;\r\n\r\nFeasibility study involves assessment of technology, assessment of market and Cost-Benefit analysis. Based on the study, the product to be identified as techno economically feasible or not.\r\n\r\n<\/div>\r\n<div>\r\n\r\n<strong>\u00a0 Identification of specific work activities<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">It refers to breaking the entire product into definable and executable jobs using work breakdown structure. It lists various tasks needed to achieve the product objectives.<\/p>\r\n\r\n<\/div>\r\n<div>\r\n\r\n&nbsp;\r\n\r\n<strong>Positioning and Testing of Products<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">It Involves positioning of planned products relative to competitive products and identify superior quality that differentiate or distinguish these products from the competitive counter parts in the market &amp; modification in design if required. It also requires rationalizing these competitive products developed and establishment of priorities for products to be developed.<\/p>\r\n\r\n<\/div>\r\n<div>\r\n\r\n<strong>\u00a0 \u00a0Preparation of production process, budget and resource plan<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">It establishes preparation of process plan and procure machines, work aids and other resources and also constitutes estimation of development resources and balance product requirements with a budget in the overall business plan<\/p>\r\n\r\n<\/div>\r\n<div>\r\n\r\n<strong>\u00a0 \u00a0 Forecasting of time, cost and performance<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">It determines in advance the time, cost, time and performance projections for the completion of the product.<\/p>\r\n\r\n<\/div>\r\n<div>\r\n\r\n<strong>\u00a0 \u00a0 6. PRODUCTION PLANNING AND CONTROL<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">Production consists of a series of sequential operations, involves transformation of materials into a desirable product. It is a vital tool available to the management for streamlining the production operations and attaining the maximum utilization of firm\u2019s resources to enhance the productivity. It helps to achieve uninterrupted flow of materials through production line by making available these materials at right time and required\u00a0<span style=\"font-size: 1em;text-align: initial\">quantity. Thus production planning and control can be defined as the \u201cdirection and coordination of firms\u2019 resources towards attaining the prefixed goals\u201d.<\/span><\/p>\r\n\r\n<\/div>\r\n<div>\r\n\r\n&nbsp;\r\n\r\n<strong>6.1 Need for Production Planning and Control<\/strong>\r\n\r\n&nbsp;\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Effective utilization of resources\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Steady flow of production\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Estimates the resources\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Ensures optimum inventory\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Co-ordinates activities of departments\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Minimizes wastage of raw materials\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Improves the labour productivity\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Helps to capture the market\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Provides a better work environment\r\n\r\n\u2022\u00a0 \u00a0 \u00a0 Facilitates quality improvement\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Results in consumer satisfaction\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 On time Supply of\u00a0 goods to the customers on time\r\n\r\n\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Reduces the production cost\r\n\r\n&nbsp;\r\n\r\n<strong>6.2 Three levels of Production Planning<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">\u2022 <strong>FACTORY PLANNING<\/strong> - The sequence of work tasks planned in terms of building, machines, equipment's and space availability. This stage deals with plant location and layout<\/p>\r\n<p style=\"text-align: justify\">\u2022<strong>\u00a0 PROCESS PLANNING<\/strong> - This stage deals with location of the operations in the production process and layout of work centres<\/p>\r\n<p style=\"text-align: justify\">\u2022\u00a0 <strong>OPERATION PLANNING<\/strong> - This stage deals with methods required to perform each operation, selection of work centres, designing of tools.<\/p>\r\n&nbsp;\r\n\r\n<strong>6.3 Production Control<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">Even though planning of activities is done, most of the time it is not possible to achieve 100% productivity as per the plan schedule. There are numerous factors which will\u00a0<span style=\"text-align: justify;font-size: 1em\">affect production system &amp; deviate the planned activities. At that time production control comes into action and takes corrective action to match the planned and actual production. Thus the production control directs and regulates all the activities of the production process and verifies whether the activities are going in accordance with production plan or not.<\/span><\/p>\r\n\r\n<\/div>\r\n&nbsp;\r\n\r\n<strong>6.4 Functions of Production Planning and Control<\/strong>\r\n\r\n&nbsp;\r\n<p style=\"text-align: justify\">Preplanning is a macro level planning which deals with analysis of data based upon the forecasted demand, market analysis and product design and development. Preplanning function is concerned with new processes and developments, equipment policy, replacement and work flow. The preplanning function of PPC is concerned with decision making with respect to methods, machines and workflow with respect to available scope and capacity. The planning function deals with analysis of 4M's i.e. Machines, Methods, Materials and Manpower. Control phase is effected by despatching, inspection and expediting material control, analysis of work in process. Finally, evaluation makes the PPC cycle complete and corrective actions are taken through a feedback from analysis. A good communication and feedback system is essential to enhance and ensure effectiveness of PPC.<\/p>\r\n<img class=\"aligncenter size-full wp-image-270\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-131.png\" alt=\"\" width=\"575\" height=\"422\" \/>\r\n\r\n<img class=\"aligncenter size-full wp-image-271\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-132.png\" alt=\"\" width=\"635\" height=\"552\" \/>\r\n<ol start=\"7\">\r\n \t<li><strong> Summary<\/strong><\/li>\r\n<\/ol>\r\n<p style=\"text-align: justify\">In order to maximize the profits and optimize the utilization of resources, each apparel industry must continuously adjust and adapt its products and services to the changing requirements of customers. To be successful and to stay in business each company must be structured in such a way that best serves its needs.<\/p>\r\n\r\n<\/div>\r\n<table>\r\n<tbody>\r\n<tr>\r\n<td><strong>you can view video on Apparel Industry - Organizational set up - Planning and product selection - production planning and control <\/strong><\/td>\r\n<td><a href=\"https:\/\/youtu.be\/kajr39AxJjU\" target=\"_blank\" rel=\"noopener\"><img class=\"alignnone wp-image-120\" src=\"http:\/\/epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/2018\/11\/download.png\" alt=\"\" width=\"36\" height=\"36\" \/><\/a><\/td>\r\n<\/tr>\r\n<\/tbody>\r\n<\/table>\r\n&nbsp;\r\n<div>\r\n\r\n<strong>References<\/strong>\r\n\r\n&nbsp;\r\n<ul>\r\n \t<li style=\"text-align: justify\">Grace I Kunz, Ruth E Glock, \" Apparel Manufacturing - Sewn Product Analysis\", 4th edition, Prentice hall, ISBN-13: 978-0131119826.<\/li>\r\n \t<li style=\"text-align: justify\">Karl T. Ulrich, Steven D. Eppinger, \" Product design and development\", 5th edition, McGraw-Hill, 2012 ISBN 978-0-07-340477-6.<\/li>\r\n \t<li style=\"text-align: justify\">Jay Diamond, Ellen Diamond, Sherri Litt, \" Fashion Retailing - A Multi channel Approach\", 3rd edition, Fair child books, 2015 ISBN 9781609019051.<\/li>\r\n \t<li style=\"text-align: justify\">Martand Telesang, \" Industrial Engineering and Production Management\", 2nd edition, S.Chand Publisher, 2006 ISBN -13 9788121917735.<\/li>\r\n \t<li style=\"text-align: justify\">B.S.Goel, \" Production Operation Management\", K.K.Mittal for Pragati Prakashan, Meerut.<\/li>\r\n<\/ul>\r\n<\/div>\r\n&nbsp;","rendered":"<div><span style=\"float: right\"><a href=\"https:\/\/youtu.be\/kajr39AxJjU\" target=\"_blank\" rel=\"noopener\"><img decoding=\"async\" src=\"http:\/\/epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/2018\/11\/download.png\" alt=\"epgp books\" width=\"75px\" height=\"75px;\" \/><\/a><br \/>\n<\/span><\/div>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<p>&nbsp;<\/p>\n<div>\n<p><strong>1. INTRODUCTION<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">Over a period of time, Apparel industry experienced strategic growth and competitiveness among the manufacturers. Apparel industry are just as diverse as the design they produce. They can be large or small have one employee or thousands, produce high end high fashion or budget everyday garments. Apparel is an ideal industry and it helps to account for large number of jobs associated with the industry. Furthermore, it has extensive forward and backward linkages with associated industry. Clearly no two industry are exactly alike, but there is a transition from the traditional focus on production efficiency to more focus on consumer&#8217;s changing needs. Technology has dramatically altered the apparel industry and provided the manufacturers with the ability to respond quickly to change. Moreover it allows global expansion and communicate the apparel specifications instantly through the internet.<\/p>\n<p>&nbsp;<\/p>\n<p><strong>2. OBJECTIVES<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p><strong>Upon Completion of the module, students will be able to<\/strong><\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Describe the organizational structure of the Apparel Industry<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Explain the fundamental steps in product planning and selection<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Outline the need and functions of production planning and control<\/p>\n<p>&nbsp;<\/p>\n<p><strong>3.\u00a0 <\/strong><strong>APPAREL INDUSTRY<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">Any organization need structuring so that, lines of authority along with individual duties and responsibilities can be understood by every company member. Most of the companies prepare graphical representation of organizational structure and the method of presenting in graphical manner is called organizational chart. The Apparel industry is fascinating example of manufacturing and the supply chain. The supply chain of the apparel industry commence from\u00a0<span style=\"text-align: initial;font-size: 1em\">farming of cotton in the cotton fields, manufacturing man made fiber to selling clothes in retail stores to the consumer.<\/span><\/p>\n<\/div>\n<div>\n<p>&nbsp;<\/p>\n<p><strong>3.1 Structure of the Apparel Industry<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">Broadly the skeleton of the Apparel industry can be divided into four stages. (Figure 1)<\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\"><strong>Stage 1: Textiles and Findings Manufacturers<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">In the mill level, the raw materials for the apparel manufacturing process such as fibres, yarns, fabrics, zippers, threads, trims and buttons are manufactured and apparel manufacturer are vertically integrated or buy from vendor&#8217;s open stocks.<\/p>\n<p>&nbsp;<\/p>\n<p><strong>Stage 2: Apparel Manufacturers<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p>Apparel Manufacturers are responsible for the marketing, merchandising and production of products. In this stage, there are two types of apparel manufacturers.<\/p>\n<p>&nbsp;<\/p>\n<p>i.\u00a0 \u00a0 Perform manufacturing within their own facilities and employees<\/p>\n<p>ii.\u00a0\u00a0 Contract some or all manufacturing functions to other firms. There are 3 types of contractors:<\/p>\n<ul>\n<li>Cut-make-trim (CMT) Contractors<\/li>\n<li>Full package program (FPP)<\/li>\n<li>Specialty contractors<\/li>\n<\/ul>\n<p><strong>\u00a0 Stage 3: Retailers<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">The Apparel manufacturers may be vertically integrated into the retail sector through owning their own stores which aid decision making during product development.<\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">There are different types of retailers in today&#8217;s consumer goods markets: catalogue retailers, department store retailers, internet retailers, mass retailers, specialty retailers, warehouse\/wholesale clubs, Retail outlets.<\/p>\n<p>&nbsp;<\/p>\n<p><strong>Stage 4: Consumers<\/strong><\/p>\n<ul>\n<li>The target of the textile and Apparel manufacturers are the ultimate consumers.<\/li>\n<li>Satisfied consumers make business growth and profitability possible.<\/li>\n<li>Decisions made at all levels are based on forecast of consumer demand.<\/li>\n<\/ul>\n<\/div>\n<div>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-266\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-127.png\" alt=\"\" width=\"644\" height=\"270\" srcset=\"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-127.png 644w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-127-300x126.png 300w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-127-65x27.png 65w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-127-225x94.png 225w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-127-350x147.png 350w\" sizes=\"auto, (max-width: 644px) 100vw, 644px\" \/><\/p>\n<p>Figure1 : Structure of the Apparel Industry<\/p>\n<p>&nbsp;<\/p>\n<p><strong>4. ORGANIZATIONAL SETUP OF THE APPAREL INDUSTRY<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">The flow chart shows the organizational Set up of the Indian Apparel Export Industry. The Managing Director is responsible for the performance of the company. The Operation Head Manages the entire factory operations and ensure that factory is running profitability. Design Head Responsible for the design and development of clothing. Marketing Head Focuses on publicizing and increasing awareness of a particular brand, such as designer labels or department stores. Merchandising Manager Creates a good relationship in between exporter &amp; buyer. Production Manager heads the factory and Quality. Logistics Head looks after the Export documentation and arranging vessels for goods. Administrative head directs the activities of subordinate staff in the coordination and management of various administrative activities for an organization.<\/p>\n<p>&nbsp;<\/p>\n<p>The roles and responsibility of the important personnel in the Apparel Industry.<\/p>\n<p>&nbsp;<\/p>\n<p><strong>4.1 Managing Director<\/strong><\/p>\n<ol>\n<li style=\"text-align: justify\">Managing Director reports to the chairman or board of directors.<\/li>\n<li style=\"text-align: justify\">As the Managing Director, responsibilities will include:<\/li>\n<\/ol>\n<ul>\n<li style=\"text-align: justify\">formulating and successfully implementing company policy;<\/li>\n<li style=\"text-align: justify\">directing strategy towards the profitable growth and operation of the company;<\/li>\n<li style=\"text-align: justify\">closely monitoring the operating and financial results against plans and budgets;<\/li>\n<li style=\"text-align: justify\">taking remedial action where necessary and informing the board of significant changes;<\/li>\n<li style=\"text-align: justify\">maintaining the operational performance of the company;<\/li>\n<li style=\"text-align: justify\">representing the company to major customers and professional associations;<\/li>\n<li style=\"text-align: justify\">building and maintaining an effective executive team.<\/li>\n<\/ul>\n<\/div>\n<p><strong>4.2 Operations Head<\/strong><\/p>\n<ul>\n<li style=\"text-align: justify\">Operation Head Coordinates with Design, Marketing and merchandising, Logistics, Production and Administrative team<\/li>\n<li>Planning of production units<\/li>\n<li>Style allocation to units<\/li>\n<li>Technical setting of the garment<\/li>\n<li>Involvement in pp meetings<\/li>\n<li>Production monitoring<\/li>\n<li>Factory work study\/industrial engineering<\/li>\n<li>Quality of the finished product<\/li>\n<li>Shipment planning and shipments<\/li>\n<li>Costing of production floor<\/li>\n<li>Cost cutting of production processes<\/li>\n<li>Employee Training<\/li>\n<li>Buyer Compliance<\/li>\n<li>Recruitment:<\/li>\n<li>Workers personal &amp; welfare activities<\/li>\n<li>Inter departmental issues<\/li>\n<\/ul>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-267\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-128.png\" alt=\"\" width=\"945\" height=\"518\" srcset=\"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-128.png 945w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-128-300x164.png 300w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-128-768x421.png 768w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-128-65x36.png 65w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-128-225x123.png 225w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-128-350x192.png 350w\" sizes=\"auto, (max-width: 945px) 100vw, 945px\" \/><\/p>\n<div>\n<p><strong>4.3 Design Head<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 In charge of guiding all steps of the design process, from initial conception to final manufacture and marketing.<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 monitoring current fashion<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Supervising a team of technical designers<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Working with individual clients to design pieces of custom couture<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Collaborating with sales and marketing managers to determine the best way to present new ideas to the public.<\/p>\n<p>&nbsp;<\/p>\n<p><strong>4.4 Marketing Head<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Assisting their employers with analyzing advertising campaigns and monitoring brand quality.<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Monitoring the reactions of customers and retail outlets to new products and brand initiatives.<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Overseeing a number of subordinate employees.<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 In charge of branding and marketing new products.<\/p>\n<p>&nbsp;<\/p>\n<p><strong>4.5 Merchandising Manager<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 \u00a0Looks after every job like buying the raw material, making the garment, finishing the garment, documentation, finally shipping<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Internal &amp; external communication<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Sampling<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Lab dips<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Preparing internal order sheet<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Preparing purchase orders<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Advising and assisting production<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Advising quality department about quality level<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Mediating production and quality departments<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Giving shipping instructions and following shipping<\/p>\n<p><span style=\"font-size: 1em;text-align: initial\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Helping documentation department<\/span><\/p>\n<p><span style=\"text-align: initial;font-size: 1em\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Taking responsibility for inspections<\/span><\/p>\n<p><span style=\"text-align: initial;font-size: 1em\">\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Following shipment<\/span><\/p>\n<\/div>\n<div>\n<p>&nbsp;<\/p>\n<p><strong>4.6 Production Head<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Production planning for the lines (manpower, machine and styles)<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Giving instruction to the line supervisors<\/p>\n<p style=\"text-align: justify\">\u2022 Line performance analysis (efficiency, man to machine ratio, cost\/pieces) and plan for continuous improvement<\/p>\n<p style=\"text-align: justify\">\u2022 Analysis of quality data<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Discussion with other team members (like merchants, fabric manager, cutting team, planning, IE team)<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Taking main role in PP meeting<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Looking after job works (such as printing, embroidery, garment dying etc) and taking decision on selection vendors for job work<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 \u00a0Planning for Overtime work<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Deciding rate for piece rate employees (sewing, thread cutting, pressing etc.)<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 \u00a0Examining the finished product carefully and look for flaws in them<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 The flaws found in manufacturing have to be rectified immediatel<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Have to check for the quality of the raw materials and standardize it<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 \u00a0Coordinating with the main office from where the manufacturing orders come from<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Hiring the workers for the factory and provide training for them<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Assigning the workers to the different department according to their skills<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Ensuring all the manufacturing targets are met<\/p>\n<p>&nbsp;<\/p>\n<p><strong>4.7 Administration Head<\/strong><\/p>\n<\/div>\n<div>\n<p style=\"text-align: justify\">\u2022Managing various operations at a facility (i.e. food service, physical plant, warehouse, accounting and finance, environmental health and fire safety).<\/p>\n<p style=\"text-align: justify\">\u2022 Identifies legal requirements and government reporting regulations affecting human resources functions and ensures policies, procedures, and reporting are in compliance.<\/p>\n<p style=\"text-align: justify\">\u2022 Recruits, interviews, tests, and selects employees to fill vacant positions.<\/p>\n<p style=\"text-align: justify\">\u2022 Plans and conducts new employee orientation to foster positive attitude toward company goals.<\/p>\n<p style=\"text-align: justify\">\u2022Keeps records of benefits plans participation such as insurance and pension plan, personnel transactions such as hires, promotions, transfers, performance reviews, and terminations, and employee statistics for government reporting.<\/p>\n<p style=\"text-align: justify\">\u2022 Advises management in appropriate resolution of employee relations issues.<\/p>\n<p style=\"text-align: justify\">\u2022 Administers salary administration program to ensure compliance and equity within organization.<\/p>\n<p style=\"text-align: justify\">\u2022Conducts wage surveys within labor market to determine competitive wage rate. Prepares budget of human resources operations.<\/p>\n<p style=\"text-align: justify\">\u2022 Prepares employee separation notices and related documentation, and conducts exit interviews to determine reasons behind separations.<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Prepares reports and recommends procedures to reduce absenteeism and turnover.<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 Represents organization at personnel-related hearings and investigations.<\/p>\n<p style=\"text-align: justify\">\u2022 Contracts with outside suppliers to provide employee services, such as canteen, transportation, or relocation service.<\/p>\n<p>&nbsp;<\/p>\n<p><strong>5.\u00a0 <\/strong><strong>PRODUCT PLANNING AND SELECTION<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\"><strong>Product Planning <\/strong>phase begins with stating product objectives which includes assessment of technology development and market objectives. The output of the planning phase specifies the target market for the product, business goals, key assumptions and constraints. Product planning is an activity that considers the apparel <strong>product mix<\/strong> that an organization might pursue and determines what <strong>product assortment<\/strong> will be pursued over a\u00a0<span style=\"font-size: 1em;text-align: initial\">period of time. product mix is the total selection of goods and services that a company makes or sells. product assortment is the range of merchandise within categories that a company sells.<\/span><\/p>\n<\/div>\n<div>\n<p>&nbsp;<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-268\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-129.png\" alt=\"\" width=\"633\" height=\"105\" srcset=\"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-129.png 633w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-129-300x50.png 300w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-129-65x11.png 65w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-129-225x37.png 225w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-129-350x58.png 350w\" sizes=\"auto, (max-width: 633px) 100vw, 633px\" \/><\/p>\n<p>Figure 3 : New product development process.<\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">The product Planning phase precedes the product development process. It identifies the product assortment to be developed by the organization and the timing of their introduction to the market. It regularly updated on an annual basis \/ season basis and it should be reviewed to reflect changes in the competitive environment, changes in technology, and information on the success of existing products. Several product revisions occur, with continuous interaction among designers, stylists and marketing functions. Product planning are developed with the company\u2019s goals, capabilities, constraints and competitive environment in mind.<\/p>\n<p>&nbsp;<\/p>\n<p><strong>5.1 Product failure &#8211; Why?<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Inadequate coverage of target market<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Poor timing of market introduction of products<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Poor capacity planning for product development<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Mismatch between resource requirement and development competency<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Frequent changes in Product line<\/p>\n<p>&nbsp;<\/p>\n<p><strong>5.2 Product Planning Process<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">The Planning Process comprises Determine strategy for products, Market Strategy &amp; Feasibility Study, Identification of specific work activities, Positioning and testing of<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-269\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-130.png\" alt=\"\" width=\"590\" height=\"438\" srcset=\"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-130.png 590w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-130-300x223.png 300w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-130-65x48.png 65w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-130-225x167.png 225w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-130-350x260.png 350w\" sizes=\"auto, (max-width: 590px) 100vw, 590px\" \/><\/p>\n<div>\n<p>Figure 4: Product Planning Process<\/p>\n<p>&nbsp;<\/p>\n<p><strong>5.3 Product Planning and Selection<\/strong><\/p>\n<\/div>\n<div>\n<p><strong>Determination of strategy for Products<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">Defines an overall strategy for products to guide in selection, development of products and product to be produced and results to be obtained, time, cost and performance standards, to achieve the objectives<\/p>\n<\/div>\n<div>\n<p><strong>Define market &amp; Feasibility study<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">Market study describes definition of target markets, customer, competitive strengths, and a competition strategy.<\/p>\n<\/div>\n<div>\n<p>&nbsp;<\/p>\n<p>Feasibility study involves assessment of technology, assessment of market and Cost-Benefit analysis. Based on the study, the product to be identified as techno economically feasible or not.<\/p>\n<\/div>\n<div>\n<p><strong>\u00a0 Identification of specific work activities<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">It refers to breaking the entire product into definable and executable jobs using work breakdown structure. It lists various tasks needed to achieve the product objectives.<\/p>\n<\/div>\n<div>\n<p>&nbsp;<\/p>\n<p><strong>Positioning and Testing of Products<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">It Involves positioning of planned products relative to competitive products and identify superior quality that differentiate or distinguish these products from the competitive counter parts in the market &amp; modification in design if required. It also requires rationalizing these competitive products developed and establishment of priorities for products to be developed.<\/p>\n<\/div>\n<div>\n<p><strong>\u00a0 \u00a0Preparation of production process, budget and resource plan<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">It establishes preparation of process plan and procure machines, work aids and other resources and also constitutes estimation of development resources and balance product requirements with a budget in the overall business plan<\/p>\n<\/div>\n<div>\n<p><strong>\u00a0 \u00a0 Forecasting of time, cost and performance<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">It determines in advance the time, cost, time and performance projections for the completion of the product.<\/p>\n<\/div>\n<div>\n<p><strong>\u00a0 \u00a0 6. PRODUCTION PLANNING AND CONTROL<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">Production consists of a series of sequential operations, involves transformation of materials into a desirable product. It is a vital tool available to the management for streamlining the production operations and attaining the maximum utilization of firm\u2019s resources to enhance the productivity. It helps to achieve uninterrupted flow of materials through production line by making available these materials at right time and required\u00a0<span style=\"font-size: 1em;text-align: initial\">quantity. Thus production planning and control can be defined as the \u201cdirection and coordination of firms\u2019 resources towards attaining the prefixed goals\u201d.<\/span><\/p>\n<\/div>\n<div>\n<p>&nbsp;<\/p>\n<p><strong>6.1 Need for Production Planning and Control<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Effective utilization of resources<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Steady flow of production<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Estimates the resources<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Ensures optimum inventory<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Co-ordinates activities of departments<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Minimizes wastage of raw materials<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Improves the labour productivity<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Helps to capture the market<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Provides a better work environment<\/p>\n<p>\u2022\u00a0 \u00a0 \u00a0 Facilitates quality improvement<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Results in consumer satisfaction<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 On time Supply of\u00a0 goods to the customers on time<\/p>\n<p>\u2022\u00a0\u00a0\u00a0\u00a0\u00a0 Reduces the production cost<\/p>\n<p>&nbsp;<\/p>\n<p><strong>6.2 Three levels of Production Planning<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">\u2022 <strong>FACTORY PLANNING<\/strong> &#8211; The sequence of work tasks planned in terms of building, machines, equipment&#8217;s and space availability. This stage deals with plant location and layout<\/p>\n<p style=\"text-align: justify\">\u2022<strong>\u00a0 PROCESS PLANNING<\/strong> &#8211; This stage deals with location of the operations in the production process and layout of work centres<\/p>\n<p style=\"text-align: justify\">\u2022\u00a0 <strong>OPERATION PLANNING<\/strong> &#8211; This stage deals with methods required to perform each operation, selection of work centres, designing of tools.<\/p>\n<p>&nbsp;<\/p>\n<p><strong>6.3 Production Control<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">Even though planning of activities is done, most of the time it is not possible to achieve 100% productivity as per the plan schedule. There are numerous factors which will\u00a0<span style=\"text-align: justify;font-size: 1em\">affect production system &amp; deviate the planned activities. At that time production control comes into action and takes corrective action to match the planned and actual production. Thus the production control directs and regulates all the activities of the production process and verifies whether the activities are going in accordance with production plan or not.<\/span><\/p>\n<\/div>\n<p>&nbsp;<\/p>\n<p><strong>6.4 Functions of Production Planning and Control<\/strong><\/p>\n<p>&nbsp;<\/p>\n<p style=\"text-align: justify\">Preplanning is a macro level planning which deals with analysis of data based upon the forecasted demand, market analysis and product design and development. Preplanning function is concerned with new processes and developments, equipment policy, replacement and work flow. The preplanning function of PPC is concerned with decision making with respect to methods, machines and workflow with respect to available scope and capacity. The planning function deals with analysis of 4M&#8217;s i.e. Machines, Methods, Materials and Manpower. Control phase is effected by despatching, inspection and expediting material control, analysis of work in process. Finally, evaluation makes the PPC cycle complete and corrective actions are taken through a feedback from analysis. A good communication and feedback system is essential to enhance and ensure effectiveness of PPC.<\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-270\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-131.png\" alt=\"\" width=\"575\" height=\"422\" srcset=\"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-131.png 575w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-131-300x220.png 300w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-131-65x48.png 65w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-131-225x165.png 225w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-131-350x257.png 350w\" sizes=\"auto, (max-width: 575px) 100vw, 575px\" \/><\/p>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter size-full wp-image-271\" src=\"http:\/\/hsp07.epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-132.png\" alt=\"\" width=\"635\" height=\"552\" srcset=\"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-132.png 635w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-132-300x261.png 300w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-132-65x57.png 65w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-132-225x196.png 225w, https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-content\/uploads\/sites\/251\/2019\/05\/Untitled-132-350x304.png 350w\" sizes=\"auto, (max-width: 635px) 100vw, 635px\" \/><\/p>\n<ol start=\"7\">\n<li><strong> Summary<\/strong><\/li>\n<\/ol>\n<p style=\"text-align: justify\">In order to maximize the profits and optimize the utilization of resources, each apparel industry must continuously adjust and adapt its products and services to the changing requirements of customers. To be successful and to stay in business each company must be structured in such a way that best serves its needs.<\/p>\n<\/div>\n<table>\n<tbody>\n<tr>\n<td><strong>you can view video on Apparel Industry &#8211; Organizational set up &#8211; Planning and product selection &#8211; production planning and control <\/strong><\/td>\n<td><a href=\"https:\/\/youtu.be\/kajr39AxJjU\" target=\"_blank\" rel=\"noopener\"><img loading=\"lazy\" decoding=\"async\" class=\"alignnone wp-image-120\" src=\"http:\/\/epgpbooks.inflibnet.ac.in\/wp-content\/uploads\/2018\/11\/download.png\" alt=\"\" width=\"36\" height=\"36\" \/><\/a><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>&nbsp;<\/p>\n<div>\n<p><strong>References<\/strong><\/p>\n<p>&nbsp;<\/p>\n<ul>\n<li style=\"text-align: justify\">Grace I Kunz, Ruth E Glock, &#8221; Apparel Manufacturing &#8211; Sewn Product Analysis&#8221;, 4th edition, Prentice hall, ISBN-13: 978-0131119826.<\/li>\n<li style=\"text-align: justify\">Karl T. Ulrich, Steven D. Eppinger, &#8221; Product design and development&#8221;, 5th edition, McGraw-Hill, 2012 ISBN 978-0-07-340477-6.<\/li>\n<li style=\"text-align: justify\">Jay Diamond, Ellen Diamond, Sherri Litt, &#8221; Fashion Retailing &#8211; A Multi channel Approach&#8221;, 3rd edition, Fair child books, 2015 ISBN 9781609019051.<\/li>\n<li style=\"text-align: justify\">Martand Telesang, &#8221; Industrial Engineering and Production Management&#8221;, 2nd edition, S.Chand Publisher, 2006 ISBN -13 9788121917735.<\/li>\n<li style=\"text-align: justify\">B.S.Goel, &#8221; Production Operation Management&#8221;, K.K.Mittal for Pragati Prakashan, Meerut.<\/li>\n<\/ul>\n<\/div>\n<p>&nbsp;<\/p>\n","protected":false},"author":8,"menu_order":22,"template":"","meta":{"pb_show_title":"on","pb_short_title":"","pb_subtitle":"","pb_authors":["mrs-b-geetha-manohari"],"pb_section_license":""},"chapter-type":[],"contributor":[66],"license":[],"class_list":["post-263","chapter","type-chapter","status-publish","hentry","contributor-mrs-b-geetha-manohari"],"part":3,"_links":{"self":[{"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/pressbooks\/v2\/chapters\/263","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/pressbooks\/v2\/chapters"}],"about":[{"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/wp\/v2\/types\/chapter"}],"author":[{"embeddable":true,"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/wp\/v2\/users\/8"}],"version-history":[{"count":6,"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/pressbooks\/v2\/chapters\/263\/revisions"}],"predecessor-version":[{"id":275,"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/pressbooks\/v2\/chapters\/263\/revisions\/275"}],"part":[{"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/pressbooks\/v2\/parts\/3"}],"metadata":[{"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/pressbooks\/v2\/chapters\/263\/metadata\/"}],"wp:attachment":[{"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/wp\/v2\/media?parent=263"}],"wp:term":[{"taxonomy":"chapter-type","embeddable":true,"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/pressbooks\/v2\/chapter-type?post=263"},{"taxonomy":"contributor","embeddable":true,"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/wp\/v2\/contributor?post=263"},{"taxonomy":"license","embeddable":true,"href":"https:\/\/ebooks.inflibnet.ac.in\/hsp07\/wp-json\/wp\/v2\/license?post=263"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}