A Comprehensive Study On Production Planning And Control For Denim Manufacturing

Submitted

By

Raquib Alam

Roll No-24

Introduction

• Production planning is done in order to solve anticipated possible difficulties and decide in advance as to how the production should be carried out in the best and economical way.

Company Overview- Arvind Mills Ltd

• It is world’s third largest and India’s largest Producer of Denim

• Established-1931A.D• Owner-Kasturbhai, Narottambhai and

Chimanbhai• CEO and Managing Director-Mr. Sanjay S.

Lalbhai

Company Overview- Arvind Mills Ltd

• Production of Denim-120 million meters of Denim Per annum

• Total Revenue-Rs 23.45 Billions• Revenues from different segments as follows:

• Source:- http://en.wikipedia.org/wiki/Arvind_Mills

Brands of Arvind

Research Background

Research Objective

• To translate orders received from sales department into orders on the works department and to coordinate different departments so that a fine balance of activities may be maintained.

• To find ways and means through which product manufacturing requirements such as materials and their necessary constituents may be available in right quality and quantity at the right time.

• To determine capacity of all manufacturing departments and to plan systematically

Production Planning and Control

• Concept Production planning and Control may be defined as

the technique of foreseeing every step in a long series of separate operations, each step to be taken at the right time and in the right place and each operation to be performed with maximum efficiency.

Production Planning and Control

• Purpose

Effectively utilize limited resources in the production of goods so as to satisfy customer demands and create a profit for investors.

Production Planning and Control

• Functions

Production Planning and Control for Denim Manufacturing

• Role of PPC for Denim Manufacturing

Process of Sales Order Execution

Dispatch Date Commitment

The dispatch date commitment is based on following factors-

• Current Load• Product Characteristic• Bottleneck areas

Capacity Planning

Capacity Planning (Spinning)

Capacity Planning (Dyeing)

Capacity Planning (Weaving)

Capacity Planning (Finishing)

Average Speed= 30 Metres/ min

Average Time =18 hours

Efficiency %= 0.80

Production capacity (Finishing) per Day= (Avg. Speed x Avg time x Efficiency)

Production capacity per day=(30 x 18 x 60 x 0.80) = 25920 metres

Yarn, Weaving and Process Outsourcing

• Yarn Outsourcing-Ring Yarn- 1000 tons (Source-Nahar Industries,

Vardhaman, Oswal, Abhishek, Etco, Ravali, Nitin, Nadan etc)

-Filament Yarn- 450 tons (Source- Reliance, Welspun, Alok, Taiwan, China etc)

-Lycra Yarn -130 tons (Source-Auro, Abhishek etc)

-Open end Yarn – 150 tons ( Source- Nahar, Abhishek etc)

-Linen Yarn- 20 tons ( Source-Jayshree, Germany)

-Dyed weft Yarn and melange- 10 tons (Source-Shirting, Winsome)

Scheduling Process

Plan Release

• The plan is forwarded to production department and execution of plan takes place.

• The production department follows the plan to optimize the production capacity.

Co-ordination and Control

Recommendations

• Total Productive Maintenance• Sequence of Operations• Termination of unnecessary process of

Finishing

Conclusion

• The production control activity is a chain of interrelated events that functions as a system.

• The decisions are made for different horizons in time and with different degrees of accuracy.

• To use limited resources effectively to produce goods that satisfy customer demands and create a profit for investors.

Thank You