How to calculate Weighted average SAM or weighted average SMV ?

Whenever there is a need to find the average SAM, It becomes quite clear that simple average doesn’t give us the right picture. This is because simple average divides the SAM equally between all the styles. This division is wrong because there will be some styles with bigger order Quantity and some styles with lesser order quantity and the effect of order quantity will not be reflected in the averaged SAM. Therefore we need to calculate weighted average SAM whenever there is need to find average. Continue reading “How to calculate Weighted average SAM or weighted average SMV ?”

Deciding factors for number of garments on a marker

Fabric consumption depends greatly on the number of garments on a marker because the more the number of garment patterns on a marker the better is the marker efficiency. So a 6 way marker will have better marker efficiency than a 4 way marker which means that fabric consumption will be lesser for higher way markers. Therefore, standardizing the number of ways is very important because only then we will be able to control the fabric consumption. Continue reading “Deciding factors for number of garments on a marker”

Lean Production Planning and control in apparel industry – What and how?

Production planning and control in apparel industry is a department which fixes production start  date(cutting start date) ,allocates the style to a sewing line and controls the processes such that the deliveries are met on time. As the name suggests there are two functions of this department

  1. Planning
  2. Control

Continue reading “Lean Production Planning and control in apparel industry – What and how?”

Does bigger ordering fabric width give better fabric consumption?

It looks like it is a known fact that “higher the width of fabric better will give better fabric consumption” but is it really the case?

This will be a discussion post. I just heard a merchandiser quoting that “fabric sourcing must probably order bigger width to save consumption”. It looks like it is a known fact that “higher the fabric ordering width better will be the fabric consumption” but is it really the case? Continue reading “Does bigger ordering fabric width give better fabric consumption?”

Difference Between Standard & Standardised work ?


The question “Difference Between Standard & Standardised work?” has been a confusion for quite a few people and I have seen people particularly pressing on the point that “Do not confuse Standard work with Standardised work”. I googled the difference and what I could understand from many blog posts was that Standard work means the work will not change whereas Standardized work means there is a scope of improvement. Continue reading “Difference Between Standard & Standardised work ?”

Process standardisation- A silver bullet for lean Manufacturing.

“Where there is no standard, there is no Kaizen” . Effective lean strategy should be made by keeping Standardisation as the focus point. This is because Standardised work forms the foundation for Kaizens & is also one of the 5S .

Process Standardisation is a simple technique but with high impact. It is more underestimated than misunderstood. Lean strategy in Garment industry is mainly centered around 5S & Kaizen but an effective lean strategy should be made by keeping Standardisation as the focus point. This is because Standardised work forms the foundation for Kaizens & is also one of the 5S . Taichi Ohno, The father of Toyota Production System himself has famously quoted :

“Where there is no standard, there is no Kaizen”

What is Process Standardisation in garment industry?

Continue reading “Process standardisation- A silver bullet for lean Manufacturing.”

A secret useful excel formula for merchandisers, planners and buyers

In this post I am going to tell you a useful excel formula for merchandisers, planners and buyers ( or every garment professional) which is going to save you a lot of time and will let your boss wondering about your speed and efficiency.

Many a times garment professionals have to copy a style information from one excel sheet to other. To do this, the normally adopted method is to open both the sheets, search the style number , select the style colour then copy the relevant data and paste it into the other sheet. Continue reading “A secret useful excel formula for merchandisers, planners and buyers”

Industrial Engineering Calculations in garment production factory


Industrial engineering calculations in garment production factory is the most powerful waste quantifying and reduction tool.

These calculations are important because without setting up a target it is highly unlikely that you will be able to achieve what is expected. Once the target is set and we know what is expected we can take steps to achieve the target production. It gives industrial engineers clear picture about the performance of sewing operators, supervisors and the sewing line. The things that an industrial engineer needs to calculate are: capacity, efficiency, performance and utilization. Continue reading “Industrial Engineering Calculations in garment production factory”

Doing things right the first time – literature review

Quality is free, what costs money is defects- all the activities resulting from not doing things right the first time. It is always cheaper and efficient to do things right the first time

Doing things right the first time(DRIFT)/Zero defect(ZD)

Doing things right the first time (DRIFT)/Zero defect(ZD) was coined was Philip Crosby in his book Quality is free. According to him Quality is free, what costs money is defects- all the activities resulting from not doing things right the first time. It is always cheaper and efficient to do things right the first time[1] Crosby’s response to the quality crisis was the principle of “doing things right the first time” (DRIFT). Continue reading “Doing things right the first time – literature review”