Planning Flow After Order Confirmation
Delivery Backward Planning
Planning always starts from the ex‑factory shipment date and moves backward. Typical sequence:
- Ex‑factory date
- Final inspection & packing
- Sewing completion
- Sewing start
- Cutting
- Fabric in‑house & relaxation
Rule: If sewing dates are not frozen first, no other plan will work.
Capacity Planning Immediately After Confirmation
Purpose
Capacity planning confirms whether the factory can complete the order without risking delivery or excessive overtime.
Key Inputs
- Order quantity
- SMV (Standard Minute Value)
- Line size and manpower
- Planned efficiency
- Available factory calendar
Excel‑Style: Capacity Calculation Template
Sheet Name: Capacity_Calculation
| Parameter | Value |
| Operators per line | 50 |
| Working hours/day | 10 |
| Planned efficiency | 65% |
| SMV | 9.5 |
Logic Used:
- Daily minutes = Operators × Hours × 60
- Earned minutes = Daily minutes × Efficiency
- Daily output = Earned minutes ÷ SMV
This sheet decides:
- Number of sewing days required
- Number of lines to be booked
Master Production Planning (MPP)
After capacity feasibility is confirmed, planners create the Master Production Plan.
Excel‑Style: Master Plan Template
Sheet Name: Master_Order_Plan
| Buyer | Style | Order Qty | SMV | Sewing Start | Sewing End | Lines Required |
| H&M | Knit‑TS‑01 | 120,000 | 9.5 | 05‑May | 17‑May | 8 |
Purpose of MPP
- Locks production dates
- Communicates plan to sourcing, IE, QA and production
- Prevents last‑minute rescheduling
Line Loading Planning
Line loading ensures balanced utilization and reduces bottlenecks.
Excel‑Style: Line Loading Template
Sheet Name: Line_Loading_Plan
| Line | Style | Qty Assigned | Planned Days | Status |
| Line 1 | Knit‑TS‑01 | 12,000 | 6 | Active |
| Line 2 | Knit‑TS‑01 | 12,000 | 6 | Active |
| Line 9 | Buffer | — | — | Free |
Best practice: Always keep buffer capacity for risks and recovery.
Material Planning After Order Confirmation
Material planning starts parallel to capacity planning, not after sewing starts.
Excel‑Style: Material Planning Template
Sheet Name: Material_Plan
| Material | Consumption | Required Qty | PO Date | In‑House Date | Status |
| Fabric | 0.18 kg/pc | 22,250 kg | 03‑Mar | 10‑Apr | On Track |
| Thread | 120 m/pc | 120,000 pcs | 20‑Mar | 15‑Apr | Planned |
Key focus areas:
- Fabric arrives before PP meeting
- No sewing start without material readiness
Pre‑Production Planning (PPP)
PPP ensures the style is technically ready before bulk production.
Key PPP Activities
- PP sample approval
- PP meeting with IE, QA, production
- Operation breakdown & SMV validation
- Line layout and machine requirement planning
Output of PPP
- Approved operation bulletin
- Balanced line layout
- Production‑ready confirmation
Daily Production Control
Planning is incomplete without execution control.
Excel‑Style: Daily Control Template
Sheet Name: Daily_Output_Control
| Date | Line | Planned Output | Actual Output | Efficiency | Gap |
| 06‑May | L1 | 2,000 | 1,850 | 60% | ‑150 |
| 07‑May | L1 | 2,000 | 2,020 | 66% | +20 |
Planners must act daily to:
- Adjust manpower
- Balance operations
- Prevent accumulation of delay
Wrong Planning vs Correct Planning
| Area | ❌ Wrong Planning Practices | ✅ Correct Planning Practices |
|---|---|---|
| Planning Timing | Planning starts after fabric arrival | Capacity planned immediately after order confirmation |
| Capacity Impact | Causes capacity clashes | Smooth capacity allocation |
| Efficiency Assumption | Over-estimated (80–90%) | Realistic assumptions: Knit (55–65%), Woven (45–60%) |
| Execution Reality | Plan works only on Excel | Plan works on actual factory floor |
| Buffer Management | No buffer lines or days | Buffer included (extra line/day) |
| Production Flow | One issue delays entire factory | Issues absorbed without major disruption |
| Learning Curve | Ignored | Learning curve properly considered |
| Startup Efficiency | Not planned | Low start-up efficiency is planned |
| Control Method | Weekly firefighting | Daily production control & tracking |
| Overall Feel | Urgent, stressful operations | Calm, controlled operations |
Key Takeaways
- Order confirmation triggers capacity first, not material first
- Excel‑based planning must reflect factory reality
- Buffer and realism are cheaper than overtime
- Good planners prevent problems weeks before shipment
Conclusion
The most critical success factor in garment manufacturing is planning after order confirmation. Factories that employ structured capacity planning, realistic Excel-based master plans, disciplined tracking of materials and daily control of production achieve on time delivery at lower cost and less stress. Strong planning doesn’t make noise — it makes results.”
