The four numbers
Requirement comes from confirmed orders multiplied by consumption per style. Subtract material in stock, subtract quantities already on open purchase orders, and what remains is the buy. Lead time decides when it has to be raised.
- Requirement from confirmed and planned orders
- Less material stock on hand, including leftovers from earlier lots
- Less open purchase order quantities not yet received
- Timing set by the supplier's real lead time, not the quoted one
Wastage belongs in consumption
Cutting wastage, shrinkage and rejection allowance are part of what a style actually consumes. Storing consumption net of wastage produces plans that survive contact with the cutting table.
Recalculate on every change
A plan made once a week is wrong for six days. When requirements read live from orders and receipts, the buyer sees the gap the moment it appears rather than at the next review.
Takeaway
Requirement, stock, open orders, lead time - kept live in one place, that is planning enough for most garment businesses.
Topics in this article
- material planning
- MRP
- trims
- fabric
- purchase order
