What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing

What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing

What is WIP? What does WIP mean in Apparel Industry? WIP means Work In-progress or In-process, an inventory system in the Garments manufacturing process in cutting, sewing and finishing but not for raw materials warehouse or finished goods warehouse. WIP for manufacturing floor the quantity between input and output what backlogged in production. In this article we will see the details of What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing.

What is WIP, WIP Calculation, Reducing, Reporting in Garments Manufacturing

WIP Calculation of Cutting, sewing, Washing, and Finishing

  • Cutting WIP = Total cut quantity – Total quantity inputted to sewing section

For example, Cutting section cut total 10,000 pieces for style# 5572819 and 7520 pieces have been inputted to the sewing department, then cutting room WIP will be =(10,000-7520) =2480 pieces.

  • Sewing Line WIP = Total pieces (GMTS Qty) inputted to the line – Total number of garments sewing output completed

For example, if a sewing Line totals 7520 pieces have been got input for style#5572819 and total 3500 pieces are produced from the line. Sewing line WIP is (7520-3500) = 4020 pieces.

Limiting washing WIP is very much important because most factories don’t have own washing facility. So they have to send Garments to another factory for washing. Delaying in washing can effect on time delivery.

  • Washing WIP= Total Garments sent to washing – Total Garments received from washing

Finishing, the last stage of Garments manufacturing, garments manufacturer challenge limiting washing and finishing WIP. Every factory especially follows up washing and finishing WIP to maintain on-time delivery to the customer.

  • Finishing sections WIP = Total Garments received from washing – Total packed quantity

WIP Report Format for the Apparel Industry

It is very easy reporting WIP, doesn’t need to make a format for checking WIP, you can keep WIP calculation in a production report. Here excel reporting format uploaded to download for all of you.

Cutting and Sewing WIP

Daily Production Report – Sewing
Line Name Style Order Quantity Al. Quantity Input Date Day Input Ttl Input Day Output Total Output Input Balance Output Balance Line WIP
A 808-8126 18211 19571 28-May-18 15401 1440 15300 4170 4271 101
A & B 808-8129 11897 12851 31-May-18 579 12413 1552 12407 438 444 6
B 834-4100 3000 3242 7-Jun-18 1263 3122 1208 2140 120 1102 982
C 808-2844 6570 6936 30-May-18 6714 925 6095 222 841 619
E 899-4241 30912 21278 22-May-18 2108 21278 1300 18330          – 2948 2,948
F 899-4241 30912 10444 4-Jun-18 2108 10444 1600 9590          – 854 854
G 808-8514 3060 3444 9-Jun-18 1099 305 305          –          – 794
H RM1005109 3202 3425 9-Jun-18 889 1996 600 600 1429 2825 1,396
I RM1020409 4115 4445 6-Jun-18 4384 1205 3540 61 905 844
J RM1020509 5854 6243 4-Jun-18 6174 1500 5961          –          – 213

Washing and Finishing WIP Report

Total Sent to Wash Day Receive from Wash Total Receive from Wash Work in Process in Wash
25401 7 25192 209
17234 61 17112 122
10082 54 10057 25
13065 33 13050 15
16154 44 16150 4
2173 82 2137 36
Total Wash Receive Day Poly Total Poly Poly Balance/Finishing WIP
79274 1200 3500 75774
19545 320 1850 17695
531 55 111 420
104 100 100 4
4664 1800 3855 809

Download WIP report format in excel chart

How to Limit excessive Work In-process (WIP) in Garments production Floor

  1. Reducing bottleneck and productivity improvement
  2. Adding machines and improving workforce
  3. Proper Layout and machine allocation
  4. Follow Kanban board in the production floor
  5. Keeping accurate production flow chart/ sequence
  6. Producing a good quality product and stopping re-work

Problems of Excessive WIP for Apparel Industry

  1. Transit areas become obstructed and blocked
  2. Garments gathering in the workplace
  3. Garments inadequate to maintain a good appearance
  4. Hamper normal production flow
  5. Poor housekeeping

This Content also have an answer of below points

  • How to find out WIP in the Apparel industry
  • Limiting WIP in the Apparel industry
  • WIP follow up in the Apparel industry
  • WIP calculation of Cutting
  • WIP calculation of Sewing
  • WIP calculation of Washing
  • WIP calculation of Finishing

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam