Garments production is a complicated business. It is a business path where so many guys have to perform to achieve targets. It is hard working track where every minute is counted. A garments merchandiser has to face a lot of problems from receiving order to shipment of that. today we will discuss about the right garments order execution process in this article. Our topic is t-shirt.

1. TOPIC: SHIPMENT MANAGEMENT PROCESS OF T-SHIRT ON THE BASED ON
COST
SUBMITTED BY:
AMIYO ROY

2. INTRODUCTION
Garments production is a complicated business.
It is a business path where so many guys have to
perform to achieve targets. It is hard working track where
every minute is counted. A garments merchandiser has
to face a lot of problems from receiving order to
shipment of that. today we will discuss about the right
garments order execution process in this article. Our
topic is t-shirt.

3. ORDER CONFORMATION PROCESS
Order conformation process have some step & follow those step we take
order and conform order .This process give in below.
 Inquiry of a product: First of all, merchandising manager
has to contact the buyer representative and send their
profile. They also assure them of making buyer required
sample or offer their self-made sample or collect the
product from the buyer.
 Lead time/Space Availability: Lead time is duration from
order placing to receive the finished goods. This channel is
included value chain model to supply chain management.
 Costing: Costing of garments is a necessary task for RMG
merchandiser, especially in soft-line.
 Order Confirmation: Buyer releases the order
confirmation after some fair bargaining and many stages of
sampling in comparison to other vendors.

4.  Approval of order from the buyer: In this process, a merchandiser has to
take approval of order as per the costing given by him/her, also make time
and action (T/A) plan.
 Buyer bank given master L/C to the Buying house: Master L/C is the
contract, given to bank, which covers the total value of an export order.
 Back to back (B/B) L/C is given to the suppliers: Here, commercial
department of buying house deals with the open up of B/B, L/C and
merchandiser deals with the follow up of materials on time.
 Fit sample sent to the buyer for the fit approval:
In this process, merchandiser has to co-ordinate with sample section for
making fit sample.
 Pre-production (P.P) sample submitted to the buyer:
Here, pre-production (P.P) sample should make from production line by using
original fabric and accessories and submitted to the buyer for P.P approve.

5. T&A IN GARMENT INDUSTRY
Time and Action Calendar or T&A, a popular tool used in apparel
manufacturing industry is a technique for tracking and following up of
important milestones in preproduction processes to ensure timely
delivery within stipulated delivery date.
A time and action calendar is a most effective communication tool
that proves it to be useful to this task.
T&A is especially useful when a buyer wants to know the status of
execution of an order.

6. Structure of T&A
Normally merchandisers prepare a plan of the order in a
spreadsheet by listing down the key processes in first
column and planned date of action for each process in the
next column.
– Process flow of an order with the list of task which
need to be performed
– Production capacity of cutting, sewing, washing and
finishing
– For sewing – batch wise and product wise capacity
(production per day per batch)
– Lead time of activities, e.g. raw material lead time,
sampling lead time, etc.
– Shipment date or planned ex-factory date

7. Sample T&A for T-shirt
manufacturing order
 Fabrics booking will be done with in 4th Jan both
foreign & local.
 Supplier will start production of fabrics.
 We will ask for sample fabrics for size set samples
at 10thJan with available color but with actual
construction.
 They will ask for counter samples & in house test
fabrics at 24thJan.
 We will take all accessories approval before order
placing just after projection.
 We will first start production with local fabrics
 than after foreign fabrics in-house.
 we will minimize local fabrics line & start foreign
fabrics line at full speed.

9. IMPORTANCE of T&A
The importance of T&A can be summarized.
 It helps to streamline the pre-production activities.
 Easy understanding of order processing.
 Clear understanding of timelines given by buyer.
 It gives the clear idea about the minor or sub
activities that need to perform during order
processing at different level.
 TNA gives the idea about the status of running
order and talks about delay or deviation, if any
 TNA gives the dates at which raw material need to
be sourced, in a way it helps to optimize the
inventory.
 TNA also reduces the risk of delivery delay.

10. Factors need to be considered
while preparing T&A:
 Production capacity of plan
 Style type of merchandise
 Festivals of manufacturing country
 Holidays
 Shipment details
 Festivals of country from where raw material is imported
 Logistics facilities
 Lead time estimated by buyer
 Style complications
 Fabric and trims manufacturing complications
 Buffer required from each department
 Political stability of the country
 Flexibility of freight forwarder
 Response time from buyer at different stages
 Lead times of various activities like L/C payment, custom
clearance, etc.
 Cut off dates for shipments

11. Fabric Consumption:
Fabric consumption is an important factor in
garments merchandising. Profit of an order
mostly depends on it. As a result, fabric
consumption should be done accurately after
receiving the order. As its vast importance on
garments merchandising, today I will discuss
about the knit fabric consumption formula for T-
Shirt.

12. Method of Knit Fabric
Consumption:
Knit fabric consumption should be done by using the following formula-
Fabric consumption per dozen, (All measurements in cm)

13. Note:
 Types of fabric and fabric GSM will be confirmed by the buyer.
 For body length and sleeve length, approximate sewing allowance
(12cm) should be needed at body hem, shoulder joint, sleeve hem and
armhole joint.
 For chest width, approximate sewing allowance (6cm) should be
needed at both side seams.
 And approximate fabric wastage in various stages is 10%.
Example:
Suppose, one of the buyer has provided you the
following measurement chart of a basic T-Shirt by
mentioning the order quantity and fabric GSM.
(Where Fabric is 100% cotton single jersey and fabric
GSM is 160 and order quantity is 10000pcs). Then
calculate the fabric consumption for this order.

14. Solution:
Here, we will follow the measurement chart for XL size.
Fabric GSM- 160,
Total order quantity- 10000
Body length or shirt length- 79cm
Sleeve length- 43cm
½ Chest width- 61cm
Now, all the measurements are applied on the following formula-
Fabric consumption per dozen, (All measurement in cm),

15. = 3.45 + 10% (in kg)
= 3.795 kg per dozen.
So, fabric needed for 10000pcs (833.33 dozen) garments is 3162.5kg.

16. Costing (CM,FOB)
Introduction:
Calculating cost of making (CM,FOB) for any
garment items is an important factor in garments
merchandising. Every garments merchandiser
should know the actual calculating method of it.
Other-wise, factory may fall in huge loss. As its
importance in garments merchandising, today I
will present an easy method for calculating cost of
making (CM) for any garment items.

17. HOW TO CALCULATE COST OF MAKING (CM) OF GARMENTS?
Before calculating cost of making (CM) for any garment items,
a garment merchandiser should confirm the following matters:
1. Factory total expenditure per month (running), it includes factory rent, electricity
bill, water bill, commercial cost, transportation, worker & staff wages etc.
2. Total number of operators.
3. SAM of a garment.
4. Targeted production per hour from the existing layout (excluding alter and reject).
5. Total working day per month.
6. Total working hours per day.
Now by applying following formula, a garment merchandiser can easily
calculate the actual cost of garments making.

18. NOW ONE EXAMPLE IS ENOUGH TO REMOVE ALL THE
CONFUSIONS FROM THE ABOVE DISCUSSION.
Example: Suppose, H.N apparels has received an order of basic T-Shirt
item.
Where, H.N apparels total expenditure on an average- 2,00,000 taka
Total number of operator- 20
SAM of a garment- 28
Total working day per month-26
Total working hours per day-08 hours
Overtime- 01hour

19. NOW CALCULATE THE COST OF MAKING (CM) OF THE
MENTIONED ITEM
Available Minute = working days × No. of operator ×(working duration+ overtime) ×
60
= 26×20×(8+1) ×60
= 2,80,800 minutes
Minute cost = 2,00,000/2,80,800
= .71 taka
CM of a garment = SAM of a garment × minute cost
= 28× 0.71
= 19.88
= 20 taka

20. CALCULATE FOB
100% Cotton poplin, Width 57/58, Price $1.75 per yards, consumption 1.75 yards/pcs, Cost of
making $0.80 pcs, Trims and Accessories cost $.66 pcs, Wash $0.12 pcs, Over head cost 3%,
Commercial and Shipping cost 2%, Trading Commission 5%, Company profit 6%. Calculate
FOB?
Now calculate FOB:
Fabric Cost (1.75×1.75) = $ 3.06
CM(cost of making) = $ .080
Trims and Accessories = $ 0.66
Wash = $ 0.12
Material Cost = $ 4.64
Add overhead cost ($4.64×3%) = $ 0.14
Total = $ 4.78
Add commercial & shipping(78×2%) = $ 0.10
Total = $ 4.88
Add Trade commission (4.88×5%) = $ 0.24
Total = $ 5.12
Add profit (5.12×6%) = $ 0.31
FOB = $ 5.43
So the FOB is $5.43

21. PRODUCTION PROCESS
Process flow for T-shirt making: The manufacturing process of t-
shirt starts from designing a t-shirt, sourcing of fabrics and ends after
selling the t-shirt to retailers. It is considered that design part is
completed as buyer’s end and as a manufacturer you get order of a
given style. For such orders, order processing involves following process
flow.

22. STEPS BY STEP GUIDE FOR ORDER PROCESSING
Here are the steps to be followed for making t-shirts (from order receiving to
shipment).
 Once you receive the t-shirt sample with the order, analyze the garment and list
down all detailing (construction, workmanship, seam, fabric used, trims attached
etc). Estimate consumption of fabric and trims per garment.
 Make bill of materials (BOM) after receiving the order. Include all items in the
BOM.
 Source Fabrics and trims as per requirement.
 After receiving fabrics and trims, check for quality and quantity of sourced items.
Fabric and trims need to be checked as per specification (quality standards). For
the confirmation for fabric properties you might need to send fabric sample to the
testing labs. Test fabric shrinkage.

23.  Develop patterns for the style. Pattern grading to be done for different
sizes. Make sample marker with actual garment patterns and find
average consumption of fabrics.
 Make two/three sample garments and follow all processes to be
followed
in bulk production (e.g. washing and finishing). Check these samples
after finishing. According to checking report of the sample do correction
if needed.
 This process will stop you making mistakes in patterns and shrinkage
related issue in fabrics. Just to be safe from losing fabric and also
maintaining quality of the final product.
 Start bulk process
 Lay fabric on the table as per marker length. Cut multiple layers at a time to
save time in cutting. You can even layer multiple colors together. Just keep
in mind to check size ratio.
 Make marker on the top layer. Cut fabric as per pattern. Cut quantity to be
as per size ratio in the in order. You can cut some extra garment for buffer.
Like if some defective or rejected garment are made in the following
processes.

24.  Check cut panels randomly for fabric defects and cutting is done
according to the pattern.
 Make bundles of cutting (if required). Or you can feed complete layers to
the sewing operator.
 Set a group of tailors for stitching garments. Define sequence of the
operations to be followed by tailors. Sew garments maintaining stitching
quality.
 Check stitching quality during sewing and at the end of sewing. Do
correction of defective garment found in the line. Repair work (alteration and
part changing job) can be done separately or by same tailors.
 Send stitched garment to finishing section. Trim uncut threads.
 Remove stains before pressing garments with steam iron (if stains are
found in garments). If needed wash garments for cleaning and removing
stains and getting wash effect.
 Press garments.
 Fold garments. Attach hang tags and price tags to garments. Pack
garments into poly bags. Pack garments according to customer
requirement.
 check finished and packed garment randomly for quality assurance.
 Store packed garments for shipping to your buyers.

25. SHIPPING TECHNIQUE
Production and shipment system:
Production goes through different kind of steps. It needs many quality
checking and approval to be perfect. It is run by those system is called
production system likes knitting, dyeing, printing, sample making,
cutting, sewing etc.

26. Shipping management maintained such features:
 Able to track individual transactions or gross quantities
 Manages planned and actual transactions.
 External material transfers can be balanced against internal facility
movements.
 Able to manage data multiple cargoes, cargoes with multiple shipment,
shipments with split ownership.
 Able to manage multiple versions of transaction quantities and qualities.
 Integrated with real-time instrumentation.
 Handles all supply chain movements including. Ship, truck and pipeline.
The latest track and trace technologies:
Modern trace and track systems that focus on the IT-based
solutions. It is monitoring and recording of shipment movements
from origin to destination. In the apparel manufacturing industry,
garment products are tracked in terms of geographic location and
time-delays. In this modern tracing system, buyers and
manufacturer know the status and physical conditions of the goods.

27. HERE I HAVE MENTIONED SOME LATEST TRACK AND TRACE TECHNOLOGIES FOR
SHIPMENT:
Global Positioning System (GPS)
 Java Mobile Cell Tracking
 Mobile Phone Approximated (AGPS)
 Radio frequency identification (RFID)
Web-based telephone Track

28. THANK YOU