Planning I, II & III – Orders, Changeovers and Yarn
Planning I — the loom plan
Every booked quality gets a row: its construction, the looms assigned, their speed and efficiency, the A-grade percentage, and the quantity. From these the plan computes daily output, the days needed, and — counting from the start date — the finish, packing (+2 days), arrival in Karachi (+4 days) and the dispatch deadline (vessel date − 4 days). Late is finish − dispatch + 2: negative numbers mean the order is safe.
| A | B | C | D | E | F | G | H | I | J | K | L | M | N | O | P | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 1 | Quality | PPI | Eff | A % | RPM | Widths | Looms | Qty (m) | Daily yd | Days | Start | Finish | Packed | In Karachi | Vessel | Late |
| 2 | 60×60/161×114, 68", 4/1 | 1,518 | 43.2 | 43.2 | 45.2 | 49.2 | (2.8) | |||||||||
| 3 | 60×60/161×114, 68", 4/1 (2nd lot) | 1,012 | 43.2 | 44.2 | 86.4 | 88.4 | 92.4 | (6.6) | ||||||||
| 4 | 60×60/161×114, 98", 4/1 | 1,139 | 12.0 | 12.0 | 14.0 | 18.0 | (24.0) | |||||||||
| 5 | 60×60/161×114, 114", 4/1 | 1,265 | 25.9 | 34.9 | 36.9 | 40.9 | (19.1) |
Planning II — loom changeovers
A second sheet lists, for every calendar day, how many looms run each quality. When a lot finishes its looms are re-beamed — a changeover takes a day or more — and the daily total must never exceed the looms in the shed. The pattern below is the kind of allocation the workbook produces for the four qualities above (looms per day):
| Day | 1 | 5 | 10 | 20 | 30 | 40 | 50 | 60 |
|---|---|---|---|---|---|---|---|---|
| 68" lot 1 | 6 | 6 | 6 | 6 | 6 | 6 | – | – |
| 68" lot 2 | – | – | – | – | – | – | 4 | 4 |
| 98" | 6 | 6 | 6 | – | – | – | – | – |
| 114" | – | – | 8 | 8 | 8 | 8 | 8 | – |
| Total running | 12 | 12 | 20 | 14 | 14 | 14 | 12 | 4 |
Idle looms on days 20–60 are the opportunity for new bookings — Planning IV takes this up with a month-long simulation.
Planning III — yarn working
The yarn sheet converts each quality into warp and weft pounds per yard and, with the adjusted loom speed, into production and bags per loom per day. Multiplying by the looms running each day (from the changeover sheet) gives the daily warp and weft requirement, which is summed by month and compared with yarn already booked.
| A | B | C | D | E | F | G | H | I | J | K | L | M | N | O | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 1 | Quality | Warp | Weft | Ends | Picks | Width | Wp crimp | Wf crimp | Wp lb/yd | Wf lb/yd | RPM | Eff | Prod yd | Warp bags | Weft bags |
| 2 | 60×60/161×114, 68" | 0.2368 | 0.1677 | 263.9 | 0.625 | 0.442 | |||||||||
| 3 | 60×60/161×114, 98" | 0.3412 | 0.2416 | 197.9 | 0.675 | 0.478 | |||||||||
| 4 | 60×60/161×114, 114" | 0.3860 | 0.2811 | 164.9 | 0.637 | 0.464 | |||||||||
| 5 | 60×60/161×114, 122" | 0.4131 | 0.3008 | 164.9 | 0.681 | 0.496 |