ADVANCEMENT IN

PRODUCTION PLANNING AND

CONTROL

Submitted by
G.MANOMITHRA MFT/18/46
INTRODUCTION
• Automation has played an important role in the
apparel manufacturing operation.
• Increasing fast fashion in retail has increased the
speed of merchandise movement to market,
which leads to increase in efficiency mainly in
labor .
• The use of automation robotics and advanced
tools, equipment and computer software for
various operations will be the key for success of
garment industries in the future.
• Automated machines replace the
routine jobs done by workers
• This will help in contributing toward
 Low labor cost
 An efficient process,
 High-tech and better quality garments
 Lower cost
 Quick response to the consumer market in terms of current
designs and orders.
MANUAL LABOR IN PRODUCTION SYSTEMS
• Even in the highest-automated production systems, human
labor is needed in one or the other form.
• They will be required to manage and maintain the plant or
even any advanced production systems.
• In addition, there are many reasons or situations in which
manual labor is usually preferred over automation in
garment manufacturing.
Some of the reasons are
 Tasks are too technologically difficult to automate
 Short product life cycle
 Customized product
 Coping with ups and downs in demand
Reducing the risk of product failure
 AUTOMATION IN PRODUCTION SYSTEMS
• Automation is the use of technology with the
application of electronic,mechanical, and
computerized systems to operate and control
production.
• Automation in production can be of two different
categories:
 Automation of manufacturing systems in the
factory and
 Computerization of the manufacturing systems.
 REASONS FOR AUTOMATION AND
ADVANCED TOOLS
Companies mostly undertake projects in manufacturing
automation for various reasons Such as:
• To increase labor productivity
• To reduce labor cost
• To mitigate the effects of labor shortages
• To reduce or eliminate routine manual tasks
• To improve worker safety
• To improve product quality
• To reduce the manufacturing lead time
• To accomplish processes that cannot be done manually
• To avoid the high cost of not automating
STRATEGIES FOR AUTOMATION AND
PRODUCTION SYSTEM
There are 10 strategies which are practical and relevant
in the context of garment manufacturing.
• Specialization of operations
• Combined operations
• Simultaneous operation
• Integration of operations
• Increased flexibility
• Improved material handling and storage
• Online inspection
• Process control and optimization
• Plant operations control
• Computer-integrated manufacturing (CIM)
These are the strategies act as a checklist of the
possibilities for improving the production system
through automation
ADVANTAGES OF AUTOMATION
The benefits that are obtained from automation include:

• Fast planning and scheduling

• Reduced production time—increased efficiency in shop floor
operation
• Improved data collection
• Control of production at multi locations
• Reduced waste as the operations can be paperless
• Less human error and more repeatability
• Increase in accuracy
• Less employee costs—less safety issues and reduced payroll
• Higher production—increase in profitability
DISADVANTAGES OF AUTOMATION

The disadvantages of automation include:

• Less versatility—limitation on flexibility and

variety
• Larger initial investment—higher installation
costs
• Increase in unemployment
• Unpredictable costs—maintenance costs,
training employees and expensive spare parts
AUTOMATION IN MANUFACTURING
SYSTEMS
Automated manufacturing systems are applied on a physical
product replacing the labor-intensive work.
Examples of automated manufacturing systems include:
• Automated machine tools
• Transfer lines performing a series of machinery operations
• Automated assembly systems
• Manufacturing systems using industrial
robots to perform operations
• Automatic material handling and storage systems
• Automatic inspection for quality control
 The automation can be classified
into three basic types based on
the function of production
volume and product in a
manufacturing enterprise.

The three types of automated

manufacturing systems are:
 fixed automation,
 programmable automation, and
 flexible automation
FIXED AUTOMATION

It is a system in which the sequence of

processing operations is fixed in terms of
equipment configuration.
Features of fixed automation are as follows:
• Higher initial investment cost
• Higher production rates
• Reduced flexibility toward accommodating
product variety
 PROGRAMMABLE AUTOMATION
• In this type, the whole sequence of operations is controlled
by a program.
• A set of instructions coded that can be read and interpreted
by the system
Some features of programmable automation are as follows:
• Higher investment cost for the equipment
• Lower production rates in comparison to fixed
automation
• Flexibility to deal with changes in product configuration
• Suitability for batch production
FLEXIBLE AUTOMATION
• It is an extension of programmable automation
• It is capable of producing a variety of products with no
time loss for any changeovers from one style to the other
i.e., no loss in production time, while reprogramming the
system.
Features of flexible automation are as follows:
• High investment involved for custom design
• Production of variable products
• Medium rates of production
• Flexibility to deal with product design variations
ADVANCEMENTS IN PRODUCTION
PLANNING
• Production planning is the planning of
managing the machineries and people
in the due course of production.
• Instead of traditional method, the
contemporary PPC uses several
software including the ERP, to manage
the complex activity.
APPLICATION OF DIFFERENT
SOFTWARE AND PLANNING TOOLS
IN PPC
• Jobpack production suite
• PlanetTogether
• ProfitFab enterprise resource planning
• Resource Manager DB
• OmegaCube enterprise resource planning
• Quantum
• SIMATIC IT Preactor advanced planning and scheduling
• Delfoi planner
• Asprova
 CONCLUSION
• Traditional garment manufacturing was labor-intensive
,low quality and slow production cycle.
• For Increased demands for quality clothing, automation is
the approach that offers high-tech and better quality
garments with lower cost and quick response to the
consumer market in terms of current designs and orders.
• The future of garment industry will be brighter with the
applications of advanced tools and equipment in various
departments of garment manufacturing.
THANK YOU