TB Planner — production planning

One order book, followed end to end — merchandising & materials → the fabric pipeline that usually owns the calendar → the sewing plan → line balancing. Change efficiency, overtime, operators or line assignment and every number recalculates. Illustrative data; a working model of your process.

Order book → material need — marker-based consumption + scrap, per order

BOM detail —

Fabric by colour

Trims, thread & packing (per order)

Fabric pipeline — critical path — yarn → knit → dye → finish, backward from fabric-in-house

The pipeline usually owns the calendar. Yarn-order-by is the real trigger date — miss it and no amount of overtime on the line recovers the ship date.

Fabric-loss controlling — yarn issued → finished received; the dyeing-loss skim, caught

Dyeing loss is where BD factories get robbed. Expected process loss ≈ 12 % (knit+dye+finish); anything past the band is a shortfall — skimmed fabric and/or "shity" quality. Caught only by daily controlling with trustworthy people on the ground — the TB on-ground edge. Reconcile yarn issued vs greige vs finished, every order, every day. MANDATORY. On big orders even 0.5 % of 10 t = 50 kg quietly diverted — the only real defence is 1:1 bale & roll numbering + covert marking, verified on the floor by your own people ("fabric boy").

Production plan — Cutting → Sewing → Finishing → Packing vs required ship date

Order · buyer · line

Cutting Sewing Finishing Packing Today / WIP Ship Late

Line balancing is the sharpest lever on the floor — and, in practice, under-done in BD. Move operators onto the bottleneck and watch output/day and balance efficiency climb.