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WIP Meaning And Calculation in Garments Industry
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| WIP |
WIP Meaning
Work in
progress (WIP) or in-process inventory
includes the set at large of unfinished items for products in a production
process. These items are not yet completed but either just being fabricated or
waiting in a queue for further processing or in a buffer storage. In garment
manufacturing WIP is generally measured in pieces (unit). WIP can be
measured Total pieces loaded in a
process minus total pieces out from that process is the WIP of that process.
Cutting
Room WIP:
When one
calculates cutting room WIP only stock cut pieces is considered as cutting WIP.
Fabric those are layered on table or received from fabric store for cutting is
not considered as WIP.
Cutting
WIP = Total
cut qty - Total qty sent to sewing,
For
example, Cutting room cut total 5000 pieces for style# A and 3000 pieces have
been issued to sewing department. Then cutting room WIP will be 2000 pieces.
Sewing Section WIP:
WIP level
of sewing section can be calculated for a line, for a floor or WIP between two
operations. You have to use specific formula for what you are calculating WIP
level.
Sewing Line WIP = Total pieces loaded to the line - pieces completed
For
example, To Line# X total 3000 pieces have been loaded for style# A and total
2500 pieces are out from the line. Sewing line WIP is 3000-2500 = 500 pieces
Finishing Room WIP:
Finishing room WIP = Total received from sewing - Total pieces packed
Production WIP
It means the volume of work that is under process in the
production processes. If it is sewing line WIP, it means the total number of
semi-stitched (unfinished) garments lying in the line. Garment cuttings are
loaded but not yet come out from the line. Garment pieces lied inside the line,
spread over the workstations of the line.
Cutting WIP = Total cut qty
- Total qty sent to sewing,
Sewing Line WIP = Total pieces loaded to the line - total Pieces completed
Finishing room WIP = Total received from sewing - Total pieces packed
Technically above calculation method is correct. But it that
method timeline is not defined. Total pieces loaded to the line since when? Is
it today or week-to-date or week-to-month loading quantity? If you consider it
week-to-date total pieces loading quantity, then at the start of the weel you
need to complete al garments and make zero WIP in the line. But that is not
possible to clear out the line in every week or in every month.
Then how to measure the WIP in garment production processes? Read the below
explanation and formula.
WIP calculation formula
WIP of a sewing line need to be calculated using the following formula:
Sewing line WIP = (Total
garments loaded today + Previous day's balance WIP - Today line output)
You need to record 3 data on the selected date -
1. production loading
quantity,
2. production output
quantity,
3. previous day's WIP quantity
(closing balance).
Same way you can prepare WIP for other sections. Like cutting
section WIP, Finishing section WIP.
The production recorders can easily keep previous day's WIP
records in their daybook and carry it forward as the opening balance for today.
This closing balance carries forward and becomes the opening balance for
everyday WIP calculations.
The physical registers are okay for recording and maintaining day
to day data. But not enough for data analysis and information sharing with
management. WIP report should be generated automatically and should be
available for view at any moment you need it.
We used the database they have from the real-time production
tracking system to get WIP report in Excel Sheet. See the below example of such
report.
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| WIP Report |
The WIP is showing till-date total production quantity which is optional for the WIP report.
If you have above-listed data in a SQL database, you can fetch data from the database and make production WIP report as you desired using the pivot table.
