Production Planning & Merchandising: Southeast University

Southeast University
Department of Textile Engineering
Production Planning &

Merchandising

Merchandising
Prepared By:
Prepared by : Mazadul
Hasan sheshir
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Merchandising
Study
On
Merchandising
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Merchandising
Acknowledgement
For the successful execution of this report, first we would like to
thanks to the almighty. Next, with warm gratitude we would like to
remember all of them whose enthusiastic supports have
contributed largely on the timely accomplishment of my entire
internship program.
We are pleased to get a fabulous opportunity to carry on our
internship program with one of the finest garment manufacturer of
the country namely FCI situated in Old DEPZ.We are very much
grateful to Prof. Sayed Fakhrul Hassan, Chairman of Textile dept. of
Southeast University for making this arrangement in such a
garment of the country. We herewith thankfully remember the
name Md. Moniruzzaman (Deputy Manager) and Md. Habibur
Rahman (Personnel), Azharul Islam, General Manager (Marketing &
Merchandising) Padma Polycotton who has helped us attaining our
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internship in Garments sector
and guided me by providing4
Merchandising
Introduction
Company profile
Padma poly cotton knit fabrics ltd.
Situated at Tejgaon industrial area

Year of established in 1995
Main section
1. Knitting section
2. Dyeing & finishing section
3. Garments section( includes sewing, cutting, finishing
unit)
Major buyer: Europe & USA (S.oliver, Defacto etc.)
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FCI BD Ltd.
Situated at Dhaka Export Processing Zone in Savar
Year of Established 1996

1. Major section
2. Sewing section
3. Cutting section
4. Finishing section
Major buyer: M&S, Zara, Nike and Alexon etc.
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Planning:
Planning is exercise of intelligent anticipation in order to establish
how an objective can be achieved, or a need fulfilled, in
circumstances which are invariable restrictive.
Planning is an act of prediction, the accuracy of which varies
enormously depending upon the kind of objective, kind of
circumstances, the skill of the planner and his techniques and
chance.
There are three types of planning:

1.Production planning relating the qualities of sale.
2.Production planning relating to the method.
3.Production planning relating to time.
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Production
Production is the process by which goods and services are created. Production
systems combine materials, labors, and capital resources in an organized way with
the objective of producing some goods or service. Production system may occur in
factories, banks, stores, hospitals etc. In all instances, some input to the system is
being processed within the system to produce a goods or services as an output; we
are in fact dealing with the operations phases of any enterprise.
Objectives of Production Planning
To determine capacity of all manufacturing departments and to plan systematically

coordinated
To translate orders received from sales department into orders on the works department and
to ensure steady plans of production activities.
To promote fuller utilization of plants.
To assist labor towards right and greater earnings.
To train staff in the effective performance of their duties
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Merchandising
Merchandising
Merchandising is a process through which products are planned,
developed, executed and presented to the buyer. It includes
directing and overseeing the development of product line from
start to finish. Marketing and merchandising department: A team
of merchandisers and marketers work together under a profit
controls head. Merchandisers handle the foreign buyers. The
teams are made according to the buyers being handled.
Type of merchandising done in garment

exports
Marketing merchandising.
Product merchandising.
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Merchandisers responsibility
Product Development
Market and product Analysis
Selling the concept
Booking orders
Confirming Deliveries
Designing and Sampling
Costing
Mediating production and quality departments
Giving shipping instructions and following shipping,
Helping documentation department
Taking responsibility for inspections and
Following up the shipment.
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10
Background
Mainly we found this reports on production planning &
merchandising
01. A study book about production planning

-Mintu Sarker &
Taslima Akter. (3rd batch,SEU)
02. A study book about production planning and merchandisingpritam das & Kamrul,
4thbatch, SEU
03. A Study on production planning and merchandizing in a
garments industry- Md. Mahfuzur Rahman Khan & Md. Kamrul
Hasan Joarder, 5th Batch.SEU.
04. A Study on Production planning and Merchandising of
Garments industry-6th Batch.SEU
All the report is written by them following our topic on production

planning & merchandising
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11
Theirs Findings
Company profile
Planning & Production

Planning
Types of production
planning
Object & procedure of
production planning
Qualification &
responsibilities of a
merchandiser
Work study & method
study
Objects of their work
Flow chart of production

planning
Description of production
planning
Procedure of production
planning
Garments export
procedure
Process of line balancing
SMV calculation & analysis
Sequence of product
development
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Our Findings
Mainly we are focusing on
merchandising in details & work of a
merchandiser in production planning
in every stage of garment section.
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13
Methodology
Flow process of garments manufacturing:

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14
Description of Export procedure:
Pricing:
It is also called costing. Fabric cost, Accessories cost, CM cost, Overhead cost,
Transportation cost etc is included here
Space booking
Space booking is very important for production. While getting approval,
space booking is must for storing fabric and accessories
P.O. sent by buyer
Full meaning of P.O is purchase order. It is sent by buyer when order is
confirmed. P.O contains order no, date, supplier description, buyer name &
address, factory name & address, product description, packing description,
terms & conditions & various instructions.
Master L/C sent by buyer
L/C means letter of credit. It is a very important document. Master L/C is sent
by buyer and it is made by bank. L/C contains all the payment & other
terms
Making of T & A calendar
It means time & action calendar. In this calendar all the planning actions are
done by which works run to meet the delivery date.
Fabric & accessories booking:
Fabric & accessories are bookedProduction
according
to T & A calendar. It is done by
Planning &
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merchandiser.
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BTB opening:
BTB means Back to back L/C. It is opened against the master L/C. For fabric &
accessories booking it is essential and it is done for security.
Fabric & trims in house:
Textile
Fabric & trims are come toDepartment
the store,of
store
in Engineering
charge check them if there is any
damage of box & then in house them.
Checking inventory & making inventory report:
Then inventory is checked again and make a report. This report goes to the
commercial department & merchandiser.
PP meeting:
PP meeting stands for pre-production meeting. It is done before bulk production of
an order. Following Persons are present in this meeting.
Merchandisers.
Production manager.
Cutting master.
Quality controller.
Production planning officer.
Production planning manager
Pattern checking & trial cutting:
After PP meeting pattern is checked again and trial cutting is done to check, the
cutting is correct or wrong.
Bulk cutting:
Merchandising
Bulk5/24/15
cutting is done for bulk production.
From here bulk production is start. 16
Numbering, sorting & bundling:

Cutting pieces are numbered, sorted & then bundled for easy
production.
Production line set up:
It is also called line balancing. It is very important for bulk production.
The objectives of line balancing are given below:
Higher productivity
Proper work flow
Quality product
Fair distribution of workers
Cost savings
In-time delivery to buyer
Increase efficiency etc.
Bulk Production:
It includes:
Sewing
Ironing
In-line inspection etc.
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Finishing:
After bulk production finishing is done.
Final inspection booking:
Booking is required forDepartment
final inspection.
In a inspection industry, time
of Textile Engineering
is very sensitive matter. So before finale inspection one needs to
book the inspection table for a particular order.
Final inspection:
During final inspection, present 3rd party QC:
SGS
ITS
Moody
Bureau VERITAS etc.
IC (Inspection certificate):
The international inspection group gives a certificate of their
inspection.
Truck loading & transport to the port:
Cargo Company takes the vessel to the port by truck or other.
Hand over the goods to the logistic firms:
Production
&
They
handover it to the logistic
firmPlanning
at port
and after loading to the
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Merchandising
ship get the bill of lading.
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Merchandisers work in design section:
Results & discussion:
We have found that Bangladesh is lacking of quality fashion

designers. Economy of Bangladesh mostly depends on RMG sector
but there is not sufficient opportunity for good fashion designers.
So there is good possibility of improving our industry if we can
improve our fashion as well as design sector.
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Production planning in pattern section:
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21
Merchandiser work in pattern section:

Pattern
master makes the
garments pattern.
Merchandiser only checks that the pattern is according
to buyers recommendation or not. He/she send buyer
information if any modification of pattern is possible.
Result & discussion:
Theoretical and practical section has a huge difference
in pattern section. Those we have learned in
theoretically are not implemented in this section
directly; they use their own easy method to make a
pattern.
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Spreading:
After ratio break down planning of spreading is done. In
this planning mainly the method of spreading is
Department
of Textile
Engineering of fabric will be
selected by which
method
spreading
done such as normal, one way, slitting, zigzag etc.
A sample of Spreading machine inspection of Padma poly cotton is

given below
Result & discussion: Spreading quantity depends on

buyer requirements. In the above table we have seen
that the variation of spreading is different because
there are different kinds
of buyer. Another reason is
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Merchandising
manual spreading is used
in some tables. Thats why
Cutting:
Cutting plan is done here. How the cutting process will be run and
quality will be maintained discussed here. Some cutting plan is
given below:
Result & discussion: In cutting section cutting pieces are varying

for following reasons, such as Number of pieces.
Number of layer.
Cutting fault.
Manual spreading.
From above it is seen that table 1 & 3 cutting man keep
consistency because they are more professional than others. Other
reason is fabric lay are manually spreaded in table 2 & 4 and their
Production
Planning &
cut
pieces found much more
faults.
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Merchandising
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25
Merchandiser work in cutting section:
Merchandiser does the ratio breakdown for marker for marker

planning and then he sends it to CAD section for producing an
efficient marker. He helps to make decision of fabric spreading. In
cutting his main job is to help in making the flow process of
cutting. Sometimes when cutting supervisor cannot solve any
problem then a merchandiser try to solve it.
Though it is the duty of merchandiser to make ratio breakdown

sheet, we have seen it is done by line in charge practically. In
case of spreading manual & normal spreading is done. Manual
spreading is done because spreading machine is very costly &
manual spreading method is appropriate for Bangladesh. Every
marker is checked before starting a cutting in this factory and
sometimes it is found Production
that there
Planning &is measurement mistake in
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26
Merchandising
marker, and then is fixed manually. It is the fault of CAD operator.
Production planning in sewing section:
In sewing section before starting production some planning is done. This

planning includes line balancing, No of machine required for each part, No
of operator, planning of inspection. When to start, production per day, and
Department
Textileetc
Engineering
fabric & accessories arrival
fromofstore
is discussed here.
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27
Merchandiser work inDepartment
sewing section:
of Textile Engineering
First of all in sewing section merchandiser do the line balancing to assure
maximum production in short time. He/she selects the machines &
number of machines required for on order. If buyer gives the S.M.V sheet,
then merchandiser checks if it is appropriate for the factory. If it is not
appropriate, then merchandiser bargains with buyer to modify S.M.V. Its
his duty to reduce S.M.V for factory production, because more the S.M.V
lowers, higher the production.
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SMV:
SMV stands for standard minute value. It is very
important for garments especially in production
section. It is mainly done to control the speed of
production.
SMV Calculation:
Normal Time: Average observed time performance
rating.
SMV = Basic time + (Allowances Basic time)
= Basic time (1 +Allowances Time)
Target =
Efficiency
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29
Planning in store section:
Store section is also very important for factory as cutting, sewing and like
other section.
If improper planning is done for Store section then followings can be

occurred:
Less material (Accessories/Trims/Fabric) can be stored (If not counted

properly).
Quality of stored materials may not be correct (If inspection is done
incorrectly).
Stored materials can be damaged due to improper maintenance (Improper
Temperature/Dust/faulty materials control).
Materials can be stoles if security is not maintained correctly.
Merchandiser work in Store section:
Merchandiser is responsible to book fabric and accessories from other supplier

and he checks the arrival of fabric and accessories in due time. He will be
responsible it goods are not come in correct time.
Result
& discussion:
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Production planning in finishing section:
Merchandiser work in finishing section:

In finishing section merchandiser helps to do the planning of a particular order and
sometimes his duty is to come in finishing section to check that finishing is running
in correct or faulty method.

This is the finale section before dispatching goods to ship. Outlook is a great factor
in RMG sector. If all the quality is good but finishing is faulty then customer will not
pay attention to it, so buyer will reject the goods before shipment. So it is wise to do
as buyer requirement & it is better if it is possible to modify the requirement to
increase outlook quality, but for this one must take advice from buyer.
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Merchandising section:
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32
Confirmation & T & AC Make
Fit sample confirmation & T & AC Make
Fit sample Approval
Lab-dip submission
Lab-dip approval
Receiving the Master L/C
Yarn/Fabric/Trim Booking
BTB L/C opening for Booking Accessories/Trims
PP sample submission
PP sample approval
Trims submission
Trims approval
Yarn/Fabric/Trims in house
Inventory of received Yarn/Fabric/Tri
Bulk Fabric/Test reports submission
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Bulk Fabric/Test reports Merchandising
approval
33
Objective of the study

Broad objective:
The broad objective of this report is to analyze the entire departmental
work process of Garments (woven/knit) industry and addressing related
departmental shortcomings in light of marketing.
Specific objectives:
To address the broad objectives, there should have some specific
objectives. These are:
To find out how all departments of Garments factory operates.
To analyze critically all aspects of the departmental work procedures.
To analyze how all departments coordinate among themselves.
To find out major existing and potential controllable and uncontrollable
shortcomings of all departments and their effects on overall marketing
of the organization.
To find ways to overcome the shortcomings in light of marketing tools
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and concepts.
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Limitations of the study
Major limitations of this study are outlined below:

All personnel are always very much busy and work under
extreme pressure for their nature of job and huge volume of
the business. Thus they couldnt give me sufficient time.
Since all their buyers are located outside of the country
therefore it was not possible to measure their image from
customers point of view.
Due to time and cost restriction, the study is concentrated
in selected major departments.
The study has been conducted based on observing and
interview of the employees.
Limited sample size for interview.
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Findings:
Production planning & merchandising work is huge task. We try our

best to work as much as possible. Mainly we observed the garments
section in the factory. In garments section we observed mainly the
marker, spreading, cutting, merchandising & finishing section. We
have found that where the automatic production process is used
there is much production than manual production process. Skill
worker is one of the main issues to effective production process.
Administrative tools also play a vital role for effective production
planning.
Is further work is necessary:

Production planning & merchandising is a lot of work, we cannot
touch the all of thing because of short time. There are lots of things
which are studying more on production planning & merchandising.
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36
References:
[1]-----http://padma-group.com/padmapolycotton/index.php
[2]-----http://www.fcibd.com/services.php
[3]-----http://www.fcibd.com/products.php
[4]-----Production planning & control (pdf)
[5]-----Practice of garments Merchandising & Management by Engr
Md. Faruk Hosen
[6]-----From class sheet
[7]----- Practice of garments Merchandising & Management by Engr
Md. Faruk Hosen
[8]----- http://www.textileschools.com
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37

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Southeast University

Department of Textile Engineering

Production Planning &

Production Planning &

Production Planning &

Production Planning &

Padma poly cotton knit fabrics ltd.

Situated at Tejgaon industrial area

Production Planning &

Situated at Dhaka Export Processing Zone in Savar

Year of Established 1996

Production Planning &

There are three types of planning:

Production Planning &

Objectives of Production Planning

To determine capacity of all manufacturing departments and to plan systematically

Production Planning &

Type of merchandising done in garment

Production Planning &

Production Planning &

01. A study book about production planning

All the report is written by them following our topic on production

Planning & Production

Flow chart of production

SMV calculation & analysis

Production Planning &

Flow process of garments manufacturing:

Production Planning &

Description of Export procedure:

Numbering, sorting & bundling:

Production Planning &

Production Planning &

Merchandisers work in design section:

Results & discussion:

We have found that Bangladesh is lacking of quality fashion

Production Planning &

Production planning in pattern section:

Production Planning &

Merchandiser work in pattern section:

Production Planning &

A sample of Spreading machine inspection of Padma poly cotton is

Result & discussion: Spreading quantity depends on

Result & discussion: In cutting section cutting pieces are varying

Production Planning &

Merchandiser work in cutting section:

Merchandiser does the ratio breakdown for marker for marker

Result & discussion:

Though it is the duty of merchandiser to make ratio breakdown

Production planning in sewing section:

In sewing section before starting production some planning is done. This

Production Planning &

Production Planning &

Production Planning &

Planning in store section:

If improper planning is done for Store section then followings can be

Less material (Accessories/Trims/Fabric) can be stored (If not counted

Merchandiser work in Store section:

Merchandiser is responsible to book fabric and accessories from other supplier

Production Planning &

Production planning in finishing section:

Merchandiser work in finishing section:

Result & discussion: