PPC Production Planning & control in Apparel Industry New Strategy

PPC Production Planning ,Today the textile and apparel industry in India is experiencing a significant transformation, calling for professionals who can lead positive changes within factories. Specifically, in the PPC Production Planning & control Department, possessing robust expertise and a profound understanding of modern concepts is imperative. Without a strong foundation in these concepts, making impactful changes becomes challenging, and success in one’s career may remain elusive.

Within the apparel industry, different departments having distinct responsibilities, each requiring specific skills. For instance, the quality department demands exceptional problem-solving skills, while the realm of designing thrives on boundless creativity.

Similarly, in the PPC Production Planning & control Department, analytical skills take center stage. Effective planning serves as the backbone of the supply chain, a facet that has often faced challenges in the Indian industry, especially in the northern regions, with a few notable exceptions among significant export houses. Strengthening the planning processes becomes crucial for enhancing overall efficiency and addressing existing gaps in the supply chain. As the industry continues to evolve, professionals with strong analytical acumen in the Planning Department will play a pivotal role in driving positive changes and contributing to the success of the sector.

The efficient utilization of resources is paramount for success. These resources encompass manpower, machinery, fabrics, trims, and more. Of particular importance are manpower and machinery, the two pivotal factors that the PPC Production Planning & Control department must ensure are utilized to their maximum potential, aiming for a 100% utilization rate.

Time is a critical element in the production process, with each style having its designated lead time – be it 120 days, 90 days, 60 days, or even as short as 30-45 days in the fast fashion sector. This time frame represents the entire product cycle, spanning from order booking to the shipment of goods. The PPC Production Planning & Control Department takes the responsibility of ensuring that the Planned Cut Dates (PCD) are met on time.

The intricate activities within the factories, from the arrival of fabric to the final packing, must unfold within a specific timeframe, typically ranging between 20 to 40 days, aligning with the designated shipment date. Excelling in analytical skills is crucial for the PPC Production Planning & Control professionals to navigate and synchronize these timelines effectively.

The ability to arrange things JIT (just in time )(making sure all the parts come together at the right time)and the utilization of resources and adhere to precise timelines underscores the pivotal role of the PPC Production Planning & Control Department in the seamless and timely execution of production processes.

PPC Production Planning & control Objectives

“PPC Production Planning & control objectives and strategies are not just benchmarks, they are a commitment to excellence, precision, and unwavering dedication to delivering quality apparel to the Buyers on time”

1. 100% Adherence to T&A: From Fabric Inhouse to Shipment Dispatch – Time and Action (T&A) plans are carefully crafted, serving as our guiding roadmap. The goal is clear here 100% adherence in all department like Cutting, Sewing and Finishing also. This not only enhances operational efficiency but also reinforces our commitment to delivering on time and every time.

2. 100% Accountability on Pieces – In the complicate world of production, accountability is non-negotiable. Each piece is carefully tracked, ensuring that nothing is left to chance. This level of precision not only streamlines operations but also lays the foundation for a robust quality control process

3. Work in Progress (WIP) Optimization – Efficient WIP management is pivotal. Our strategy involves maintaining a delicate balance, ensuring that the factory operates at an optimal WIP level.

• Cutting to Sewing feeding should be minimum 4 days
• Sewing to Finishing feeding should be minimum 1.5 days
• Trims & Accessory stores should be minimum to 6 days
• Finished Goods should be minimum to 6 days

4. Rigorous Monitoring against Target Across Departments -Monitoring is the cornerstone of PPC Production Planning & Control strategy. Should carefully monitor 100% performance against target track of every department. This proactive approach allows us to identify bottlenecks, streamline processes, and maintain a consistent pace.

5. Advanced T&A Circulation – To stay ahead, T&A plans have to be circulated one week prior across all departments. This foresight ensures that every team is aligned with the production schedule, fostering a collaborative and synchronized workflow.

6. On-Time Shipment:– Dedication to on-time delivery is unwavering. PPC strive for 100% on-time shipment, recognizing its pivotal role in customer satisfaction and maintaining factory reputation as a reliable manufacturer.

7.Factory Style Plan: Agility in Three Weeks – In the fast-paced fashion industry, agility is key. Factory style plan is designed to be executed in less than or equal to three weeks, ensuring that factory can swiftly adapt to market dynamics and emerging trends.

8. Planning TBA Deviation: While flexibility is crucial, PPC aim to keep the Planning Time Before Actuals (TBA) deviation less than or equal to 5%. This allows PPC Production Planning & Control to adapt to changes without compromising on the efficiency and timelines of production processes.

These are the key responsibilities that may seem basic, but the job is remarkably intriguing. It’s not about routine tasks; instead, it demands the full engagement of your intellect. In PPC Production Planning & Control, plans are bound to face challenges, and that’s where the real job begins. You don’t just follow the plan; you constantly evaluate, reevaluate, and ask crucial questions.

“Why is the plan deviating, and what’s causing it?” becomes a fundamental inquiry. This leads to the exploration of alternate solutions and, in turn, sparks creativity. It’s a dynamic process of continuous improvement. Each deviation from the plan is an opportunity to enhance and optimize. You don’t just manage production; you orchestrate it with a constant eye on efficiency.

In the PPC Department, you are occupied with problem-solving, strategizing, and finding better ways to execute tasks. It’s not just about meeting deadlines; it’s about doing it smartly and innovatively. This makes PPC one of the most interesting and intellectually stimulating roles in the entire garment industry. It’s where your brainpower truly shines as you navigate the complexities of PPC production planning & control.

In a factory, it’s not uncommon for people to feel stuck in a routine, doing the same tasks day in and day out without a clear sense of what they’re gaining from the experience. In PPC, you won’t find yourself trapped in a cycle of repetitive tasks. The nature of the job ensures that each day brings new challenges and opportunities for learning. It’s a dynamic role that keeps you on your toes, especially when the company recognizes the pivotal role that the PPC production planning department plays in the overall production process.

JOB Description

A PPC executive must ensures

• Material Planning
• Capacity Planning (Click here to know more about Capacity Planning)
• Timely preparation and circulation of weekly schedule/ T & A plan to all departments
• Identifying and circulating Man power and Machinery requirement for production departments
• Line plan for sewing lines
• Timely amendment of deviations/ changes in the plan
• Style forecast for minimum 3 weeks or a month
• Weekly factory review meeting are conducted
• Daily Internal team meetings to be conducted
• PP meeting should be conducted
• Bulk Pattern and Fabric Requisition
• On time Cutting to Packing Process from Start to Finish
• Accurate data collection
• Size set Ready and Approvals
• On time requisition of Fabric and Trims
• Recommitments dates in daily report
• Internal Discipline

Monitor reports

Reports to be followed:

KPI’s

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