Fabric Consumption Part 3

Assignment Report Fabric Consumption for Knitted T-Shirt & Woven Shirt
1. INTRODUCTION
A merchandisers job is to plan production related tasks & make sure that everything gets
completed on the required date. Merchandisers need to have a variety of skills in their role,
including analytical skills, communication skills and organizational skills.
Order received
T-shirt - 6 colours, per colour/6000 pieces= 36,000 pieces
Shirt - 3 colours, per colour/4000 pieces= 12,000
1
Department of Fashion Management Studies NIFT,Shillong
2. FABRIC CONSUMPTION
Fabric consumption means the length or weight of fabrics needed for making a single piece
of garment. Fabric consumptions are measured in two different units for knits and for
woven fabric.
2.1 FABRIC CONSUMPTION FOR KNITTED T-SHIRT
Fig.2.1 Front view of T-shirt Fig.2.2 Back view of T-shirt
To determine the fabric consumption of knitted T-shirt, we need average of body length,
body width (chest), sleeve length, sleeve round. Table 2.1 represents the size chart for
knitted T-shirt along with average measurements.
XS (cm) S(cm) M(cm) L(cm) XL (cm) AVERAGE

LENGTH 66.04 71.12 73.66 76.2 78.74 73.152
WIDTH 41.91 45.72 50.8 55.88 60.96 51.054
SLEEVE
LENGTH 17.78 19.05 20.32 21.54 22.86 20.31
SLEEVE
WIDTH 27.94 28.87 29.85 29.85 32.05 29.712
RATIO 1 1 2 2 1
Table 2.1: Size Chart for Knitted T-Shirt
2
2.1.1 CALCULATIONS
Total Fabric Consumption for T-shirt is the summation of fabric consumption for front &
back, fabric consumption for sleeves and fabric consumption for rib.
𝑳 ∗ 𝑩 ∗ 𝟐 ∗ 𝑮𝑺𝑴
▪ Fabric consumption for front & back = 𝟏𝟎𝟎𝟎𝟎
𝟕𝟑.𝟏𝟓𝟐 ∗𝟓𝟏.𝟎𝟓𝟒 ∗ 𝟐 ∗𝟏𝟖𝟎
= = 134.45 gm
𝟏𝟎𝟎𝟎𝟎
𝑳 ∗ 𝑩 ∗𝟒 ∗ 𝑮𝑺𝑴
▪ Fabric consumption for sleeve = 𝟏𝟎𝟎𝟎𝟎
𝟐𝟎.𝟑𝟏 ∗𝟐𝟗.𝟕𝟏𝟐 ∗𝟒 ∗𝟏𝟖𝟎
= = 43.45 gm
𝟏𝟎𝟎𝟎𝟎
𝑳 ∗ 𝑩 ∗ 𝑮𝑺𝑴
▪ Fabric consumption for rib = 𝟏𝟎𝟎𝟎𝟎
𝟐𝟓.𝟐 ∗𝟏.𝟎𝟓 ∗𝟐𝟕𝟎
= = 0.7144 gm
𝟏𝟎𝟎𝟎𝟎
• Total Fabric Consumption for T-shirt = 134.45 + 43.45 + 0.7144 = 178.6122 gm
= 178.6122 * 1.03 = 183.97057 gm = 0.184 kg
Tabular representation of the calculation is as follows
Table 2.2 Fabric Consumption for Knitted T-shirt (front & back)
Fabric Consumption for

Knitted
T-shirt(front&back)
Formula =
(L*W*2*GSM)/10,000
Body
Chest, W Total
Length, No. of parts GSM 10,000
(cm) Fabric(g)
L (cm)
73.152 51.054 2 180 10,000 134.4492795
Table 2.3 Fabric Consumption for Knitted T-shirt(sleeves)

Knitted T-shirt(sleeves)
Formula =
(L*W*4*GSM)/10,000
Body
Chest, W Total
Length, No. of parts GSM 10,000
(cm) Fabric(g)
L (cm)
3
20.31 29.712 4 180 10,000 43.44845184
Table 2.4 Fabric Consumption for Knitted T-shirt(rib)

Knitted T-shirt(rib)
Formula =
(L*W*GSM)/10,000
Body
Chest, W Total
Length, L GSM 10,000
(cm) Fabric(g)
(cm)
25.2 1.05 270 10,000 0.71442
• Fabric consumption for each colour
Sky blue: 0.184 * 6000 = 1106.22 kg
Grass green: 0.184 * 6000 = 1106.22 kg
Lavender:0.184 * 6000 = 1106.22 kg
Lemon yellow: 0.184 * 6000 = 1106.22 kg
White: 0.184 * 6000 = 1106.22 kg
Purple: 0.184 * 6000 = 1106.22 kg
Total Fabric Consumption in kg = 6637.32kg
2.2 FABRIC CONSUMPTION FOR WOVEN SHIRT
Fig.2.3 Front view of Shirt Fig.2.4 Back view of Shirt
4
To determine the fabric consumption of woven shirt, we need average of body length, body
width (chest), sleeve length, sleeve round, collar length, collar width, placket length, placket
width, cuff length, cuff width, yoke length and yoke width. Table 2.5 represents the size chart
for woven shirt along with average measurements.
Table 2.5: Size Chart for Woven Shirt
XS(cm) S(cm) M(cm) L(cm) XL(cm) AVERAGE
SHOULDER 42.5 44.6 46.4 48.25 50.75 46.5

LENGTH 73 74.5 76.25 77.5 78.75 76
WIDTH 47.75 51.5 54.5 57.75 61.5 54.6
SLEEVE
LENGTH 64 65 66 66.7 67.3 65.8
SLEEVE
WIDTH 27.94 28.87 29.85 29.85 32.05 29.712
RATIO 1 1 2 2 1
2.2.1 CALCULATIONS
Total Fabric Consumption for Shirt is the summation of fabric consumption for front & back,
fabric consumption for sleeves, fabric consumption for collar, fabric consumption for placket,
fabric consumption for cuff and fabric consumption for yoke.
▪ Fabric consumption for back & front
𝐿∗𝐵∗2 76 ∗54.6 ∗ 2
= 𝑓𝑎𝑏𝑟𝑖𝑐 𝑤𝑖𝑑𝑡ℎ ∗𝑓𝑎𝑏𝑟𝑖𝑐 𝑢𝑛𝑖𝑡 = 60 ∗2.54
= 54.46 cm
▪ Fabric consumption for sleeve
𝐿∗𝐵∗2 65.8 ∗29.712 ∗ 2

= 𝑓𝑎𝑏𝑟𝑖𝑐 𝑤𝑖𝑑𝑡ℎ ∗𝑓𝑎𝑏𝑟𝑖𝑐 𝑢𝑛𝑖𝑡 = 60 ∗2.54
= 25.66 cm
𝐿∗𝐵 38.735 ∗6.35

▪ Fabric consumption for collar = 𝑓𝑎𝑏𝑟𝑖𝑐 𝑤𝑖𝑑𝑡ℎ ∗𝑓𝑎𝑏𝑟𝑖𝑐 𝑢𝑛𝑖𝑡 = = 1.614𝑐𝑚
60∗2.54
5
𝐿∗𝐵 67.056 ∗4.572

▪ Fabric consumption for placket = 𝑓𝑎𝑏𝑟𝑖𝑐 𝑤𝑖𝑑𝑡ℎ ∗𝑓𝑎𝑏𝑟𝑖𝑐 𝑢𝑛𝑖𝑡 = = 2.012𝑐𝑚
60∗2.54
𝐿∗𝐵∗2 25.4∗6.35 ∗ 2
▪ Fabric consumption for cuff = 𝑓𝑎𝑏𝑟𝑖𝑐 𝑤𝑖𝑑𝑡ℎ ∗𝑓𝑎𝑏𝑟𝑖𝑐 𝑢𝑛𝑖𝑡 = = 2.12𝑐𝑚
60 ∗2.54
𝐿∗𝐵 38.1 ∗14.732

▪ Fabric consumption for yoke = 𝑓𝑎𝑏𝑟𝑖𝑐 𝑤𝑖𝑑𝑡ℎ ∗𝑓𝑎𝑏𝑟𝑖𝑐 𝑢𝑛𝑖𝑡 = = 3.683𝑔𝑚
60∗2.54
Total Fabric Consumption for shirt = 54.46 + 25.66+ 1.614 + 2.012 + 2.12+ 3.683 = 89.54cm
= 0.89m
Tabular representation of the calculation is as follows
Table 2.6 Fabric Consumption for Woven Shirt (front & back)

Woven Shirt(front&back)
Formula = (L*W*2)/(fabric
width * fabric unit)
Body
Chest, Fabric Fabric Total
Length, No. of parts
W (cm) width(cm) Unit Fabric(cm)
L (cm)
76 54.6 2 60 3 54.45669291
Table 2.7 Fabric Consumption for Woven Shirt (sleeves)

Woven Shirt(sleeves)
Sleeve Sleeve
Fabric Fabric Total
Length, Round, No. of parts
width(cm) Unit Fabric(cm)
L (cm) W (cm)
65.8 29.712 2 60 3 25.6568189
Table 2.8 Fabric Consumption for Woven Shirt (collar)
Fabric Consumption for Woven

Shirt(collar)
Formula = (L*W)/(fabric width *
fabric unit)
Length, Width, Total
Fabric width(cm) Fabric Unit
L (cm) W (cm) Fabric(cm)
6
38.735 6.35 60 3 1.613958333
Table 2.9 Fabric Consumption for Woven Shirt (placket)

Shirt(placket)
Formula = (L*W)/(fabric width *
fabric unit)
67.056 4.572 60 3 2.01168
Table 2.10 Fabric Consumption for Woven Shirt (cuff)

Woven Shirt(cuff)
Sleeve Sleeve
Fabric Fabric Total
Length, Round, No. of parts
width(cm) Unit Fabric(cm)
L (cm) W (cm)
25.4 6.35 2 60 3 2.116666667
Table 2.11 Fabric Consumption for Woven Shirt (yoke)

Shirt(yoke)
Formula = (L*W)/ (fabric width *
fabric unit)
38.1 14.732 60 3 3.683
▪ Fabric consumption for each colour

Black: 0.088 * 4000 * 1.03 = 3688.99 m
Maroon: 0.088 * 4000 * 1.03 = 3688.99 m
Olive green 0.088 * 4000 * 1.03 = 3688.99 m
Total Fabric Consumption in meter = 11066.997 m
7
3. TRIM CONSUMPTION
Size Label-Size label indicates the size of the garments. Size labels are indicated as S, M, L, XL,
where S for small, M for medium, L for large, and XL for extra large.
Wash Care Label-Wash care symbols are signs that appear on the care label of our clothes.
These signs give us information on how the garment should be washed, dried and ironed.
Main Label-Main labels indicate a Brand name or Brand Logo of the company that sources
and sells clothes.
Mobilon Tapes-Mobilon Tapes are ideal for stretch prevention on shoulder lines in knit
fabrics, for shape retention in lace materials, as shoulder straps, in lingerie, as stretch tapes
sewn inside shoulder straps,etc.
Buttons-Buttons are small hard objects sewn on to shirts, coats, or other pieces of
clothing.They vary in sizes, colors, materials and shapes, and can be placed on different types
of garment, serving a decorative function to add a fashionable statement to clothing.
3.1 T-SHIRT(Wash Care Label,Main Label,Cardboard Tags)
Table 3.1 Wash care label
number of
Wash Care pieces+3%
Label(polyster)= wastage
= 6000+3%
= 6180
6 colours 37080
Table 3.2 Main Label
number of
Main Label(polyster)= pieces+3%
wastage
= 6000+3%
= 6180
6 colours 37080
8
Table 3.3 Cardboard Tags

number of
pieces+3%
Cardboard Tags= wastage
= 6000+3%
= 6180
6 colours 37080
3.2 Size Label for T-shirt

Total Shirts = 6000
Total Shirts/ Sum of ratios =857.14
3% wastage = 25.71
Addition of wastage = 882.86
Table 3.4 Size Label for T-shirt
Table 3.4 For 1
Size Ratio colour For 6 colours
XS 1 883 5296
S 1 883 5296
M 2 1766 10596
L 2 1766 10596
XL 1 883 5296
3.3 SHIRT(Wash Care Label, Main Label, Cardboard Tags)

Table 3.5 Wash Care Label (polyster)
number of
Wash Care pieces+3%
Label(polyster)= wastage
= 4000+3%
= 4120
3 colours 12360
Table 3.6 Main Label

number of
pieces+3%
Main Label(polyster)= wastage
= 4000+3%
= 4120
3 colours 12360
9
Table 3.7 Cardboard Tags

number of
pieces+3%
Cardboard Tags= wastage
= 4000+3%
= 4120
3 colours 12360
3.4 Size Label for T-shirt

Total Shirts = 4000
Total Shirts/ Sum of ratios = 571.43
3% wastage = 17.14
Addition of wastage = 588.57
Table 3.8 Size Label for Shirt
For 1
Size Ratio colour For 3 colours
XS 1 589 1767
S 1 589 1767
M 2 1178 3534
L 2 1178 3534
XL 1 589 1767
3.5 Buttons (shirt)
Size Ratio=1:1:2:2:1
No. of shirts per size = 5000/7 = 571.429
Table 3.9 Total Button Consumption
No. of shirts per No. of pieces Total button

Size size Line of buttons consumption
XS 571 15L 11 6286
S 571 16L 11 6286
M 1143 16L 12 13714
L 1143 17L 13 14857
XL 571 17L 13 7429
10
3.6 Mobilon Tape for T-shirt (0.5cm)
Length= 28 inches= 71.12 cm

= 71.12*6000
= 4260
Wastage 127.8
Adding Wastage = 4388
Total for 36000 pieces= 26328
26328
= metres
11
4. BILL OF MATERIAL
A bill of materials is a list of the raw materials, sub-assemblies, intermediate assemblies, sub-
components, parts, and the quantities of each needed to manufacture an end product. It is the
complete list of all the items that are required to build a product. A BOM may be used for
communication between manufacturing partners to a single manufacturing plant.
12
Buyer ARYA S
PO number ####
Style Number 0709CORE
Item SS24
Delivery Date ####
Up date:
TOTAL
COMPONENT COMPONENT COLORWAY PER PC ORDER CONSUMPTION
SIZE REMARKS
IMAGE NAME NAME CONSUMPTION QUANTITY FOR 6000 PCS
(3% wastage)
FABRIC
Main Fabric Sky Blue 28.8" 0.184 kg ### 1106.22 kg
Grass Green 28.8" 0.184 kg ### 1106.22 kg
Single Jersey,
Lavender 28.8" 0.184 kg ### 1106.22 kg
95% cotton,
5% Spandex, Lemon
28.8" 0.184 kg ### 1106.22 kg
GSM 180 Yellow
Purple 28.8" 0.184 kg ### 1106.22 kg
White 28.8" 0.184 kg ### 1106.22 kg
TRIMS
Moblin Tape Transparent 28" 0.71 m ### 25728
LABELS/HANGTAGS
Brand Label Paper Print 3" x 1/2" 1 ### 37080 pcs
Wash care
Fabric print 3" x 1/2" 1 ### 37080 pcs
label
0.5cm x
Size Label Fabric print 1 ### 37088 pcs
3.81cm
Cardboard
Paper Print 1 ### 37080 pcs
Tag
PACKAGING
Poly Bag Transparent 10"x14" 1 36000 pcs 37080 pcs

Carton Box
Corrogated
Diameter 10"x14" 10 pcs per box 900 pcs 927 pcs
Box
600x400x300
13
5. TIME & ACTION PLAN
It is basically a planing sheet of the given tasks required in a production broadly classified into
6 main blocks including the dates of completion. It involves Booking details, Fabric flow,
Sampling, Testing, Production, Misc.
Table 5.1 Time & Action Plan for T-shirt
IN
### ALERT COMPLETED
PROCESS
STYLE 0701core
QTY (UNITS) 36,000
Sky blue, Grass Green, Lavender, Lemon yellow, White,
COLORS
Purple
FABRIC
QUALITY 180 GSM ( for Rib - 270)
Merchant Chandni
FACTORY F2
SEASON Summer"23
BOOKING DETAILS PLANNED ACTUAL Remarks

FABRIC BOOKING ####
SIZING ####
FABRIC FLOW
FABRIC BOOKING ####
Size APPROVAL ####
FABRIC Cutting Start ####
FABRIC Cutting End ####
SAMPLING
1ST FIT SAMPLE ####
COMMENTS ####
2ND FIT SAMPLE ####
COMMENTS ####
3RD FIT SAMPLE ####
COMMENTS ####
FIT TO FINAL DUE DATE ####
Production sample ####
SUBMIT
TESTINGS
FPT ####
14
GPT ####
PRODUCTION &
SHIPPING
SEWING START ####
SEWING COMPLETION ####
MISC
WASH CARE APPROVAL ####
PACKING/FOLDING ####
APPROVAL
Table 5.2 Time & Action Plan for Shirt
IN
## ALERT COMPLETED
PROCESS
STYLE 0301core
QTY (UNITS) 12,000
COLORS BLACK,MAROON,OLIVE GREEN
FABRIC
QUALITY 180 GSM
Merchant Chandni
FACTORY F1
BOOKING DETAILS PLANNED ACTUAL Remarks

FABRIC BOOKING #####
SIZING #####
FABRIC FLOW
FABRIC BOOKING #####
Size APPROVAL #####
FABRIC Cutting Start #####
FABRIC Cutting End 5-Feb
SAMPLING
1ST FIT SAMPLE 1-Dec
COMMENTS 4-Dec
2ND FIT SAMPLE 6-Dec
COMMENTS 8-Dec
3RD FIT SAMPLE #####
COMMENTS #####
FIT TO FINAL DUE DATE #####
15
Production sample #####

SUBMIT
TESTINGS
FPT #####
GPT #####
PRODUCTION &
SHIPPING
SEWING START 1-Feb
SEWING COMPLETION 4-Feb
MISC
WASH CARE APPROVAL #####
PACKING/FOLDING 6-Feb
APPROVAL
16
6. PRODUCTION PLANNING
Production planning includes the lines of production, no. Of workers, per line production
capacity per day, total production to be done & days required for the production completion.
Table 7.1 Production planning for T-shirt
Production planning For

Tshirt
Line 4
Workers 30
Production capacity/Day/Line 1500
Total production to be done 36,000
Total time 6 Days
Table 7.2 Production Planning for Shirt
Production planning for shirt

Line 4
Workers 24
Production capacity /Day 1000
Total production to be done 12,000
Total time 3 Days
17

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Assignment Report Fabric Consumption for Knitted T-Shirt & Woven Shirt

2.1 FABRIC CONSUMPTION FOR KNITTED T-SHIRT

Fig.2.1 Front view of T-shirt Fig.2.2 Back view of T-shirt

XS (cm) S(cm) M(cm) L(cm) XL (cm) AVERAGE

• Total Fabric Consumption for T-shirt = 134.45 + 43.45 + 0.7144 = 178.6122 gm

= 178.6122 * 1.03 = 183.97057 gm = 0.184 kg

Tabular representation of the calculation is as follows

Fabric Consumption for

Table 2.3 Fabric Consumption for Knitted T-shirt(sleeves)

Fabric Consumption for

20.31 29.712 4 180 10,000 43.44845184

Table 2.4 Fabric Consumption for Knitted T-shirt(rib)

Fabric Consumption for

• Fabric consumption for each colour

Sky blue: 0.184 * 6000 = 1106.22 kg

Grass green: 0.184 * 6000 = 1106.22 kg

Lavender:0.184 * 6000 = 1106.22 kg

Lemon yellow: 0.184 * 6000 = 1106.22 kg

White: 0.184 * 6000 = 1106.22 kg

Purple: 0.184 * 6000 = 1106.22 kg

Total Fabric Consumption in kg = 6637.32kg

2.2 FABRIC CONSUMPTION FOR WOVEN SHIRT

Fig.2.3 Front view of Shirt Fig.2.4 Back view of Shirt

Table 2.5: Size Chart for Woven Shirt

XS(cm) S(cm) M(cm) L(cm) XL(cm) AVERAGE

SHOULDER 42.5 44.6 46.4 48.25 50.75 46.5

▪ Fabric consumption for back & front

▪ Fabric consumption for sleeve

𝐿∗𝐵∗2 65.8 ∗29.712 ∗ 2

𝐿∗𝐵 38.735 ∗6.35

𝐿∗𝐵 67.056 ∗4.572

𝐿∗𝐵 38.1 ∗14.732

Tabular representation of the calculation is as follows

Fabric Consumption for

Table 2.7 Fabric Consumption for Woven Shirt (sleeves)

Fabric Consumption for

Table 2.8 Fabric Consumption for Woven Shirt (collar)

Fabric Consumption for Woven

38.735 6.35 60 3 1.613958333

Table 2.9 Fabric Consumption for Woven Shirt (placket)

Fabric Consumption for Woven

Table 2.10 Fabric Consumption for Woven Shirt (cuff)

Table 2.11 Fabric Consumption for Woven Shirt (yoke)

▪ Fabric consumption for each colour

Table 3.2 Main Label

Table 3.3 Cardboard Tags

3.2 Size Label for T-shirt

3.3 SHIRT(Wash Care Label, Main Label, Cardboard Tags)

Table 3.6 Main Label

Table 3.7 Cardboard Tags

3.4 Size Label for T-shirt

3.5 Buttons (shirt)

No. of shirts per No. of pieces Total button

3.6 Mobilon Tape for T-shirt (0.5cm)

Length= 28 inches= 71.12 cm

Poly Bag Transparent 10"x14" 1 36000 pcs 37080 pcs

5. TIME & ACTION PLAN

Table 5.1 Time & Action Plan for T-shirt