Name: Planning and Production Strategy BTS CY25
Uploaded: 2024-11-26
Duration: 3 min 47 s
Description: The planning and production strategy for the upcoming Back to School season. The BTS surge production season is from sew week 51 to sew week18 next year..

[Audio] The planning and production strategy for the upcoming Back to School season. The BTS surge production season is from sew week 51 to sew week18 next year.. 

Scene 1

Planning and Production Strategy BTS CY25

Week-51 to Week-18 Surge Production Period

[Audio] As seen from past few surge seasons, these are the key reasons for combining demand and planning in batches.
Reserve capacity for service while deliver event on time Zero Air ship or additional logistic expense Zero TKS Minimize changeover to maximize IM capacity and reduce Subcon Ensure material availability for production Maximize textile capacity Reduce Inventory and prevent warehousing challenges. 

Scene 2

Reserve capacity for service while deliver event on time
 Zero Air ship or additional logistic expense
 Zero TKS
 Minimize changeover to maximize IM capacity and reduce Subcon
 Ensure material availability for production
 Maximize textile capacity
 Reduce Inventory and prevent warehousing challenges

[Audio] Last three BTS seasons, we planned in Batches. In year 2022, we did not have any Material Pre-positioning. However, starting from 2023 BTS season, we had only 15% material pre-positioning. This year Back to school season had more than 70% material pre-positioned styles. In 2022 and 2023 we planned at standard lead time but this year we planned batches at pre-positioned lead time. Batch planning at MPP lead time resulted in yarn shortages and difficulty to respond to print surge.. 

Scene 3

BTS Planning and Production – past three years

Year Batch Demand Planned M Dz Capacity Allocation MPP Lead Time Production Timeline Remark BTS22 3 5.2 70% MUW event 80% FUW event 0% Standard Material LT WK52-15 (15 wk)
 BTS23 3 4.1 70% MUW event 70% FUW event 15% Standard Material LT WK01-16 (15 wk)
 BTS24 4 4.3 50% MUW event 50% FUW event 71% MPP LT WK51-18 (19 wk) Yarn shortage in Jan and Print shortage in Mar-Apr

[Audio] Building on past experiences, in the upcoming BTS season we need to plan four batches and 70% of CPS capacity as part of each batch. It is important to plan each batch at standard lead time and to make that happen, we may need to reserve demand for MPP lead time weeks.. 

Scene 4

BTS Planning and Production – proposal for upcoming season

BTS25 4 As per allocation 70% by Critical Ratio (Men’s, Kids) 70% by Event (Women’s) 100% Standard Material LT WK51-18 (19 wk)

[Audio] Above is the calendar for the four batches in the upcoming BTS season. Each batch has an Event Introduction cut-off and a work order week. The capacity allocation process is meant to reserve demand for MPP weeks when we go ahead to plan a batch at standard lead time. If a growth team is on IBP, we measure available capacity at less than standard lead time for each work center. We map available capacity with IBP demand. Then we identify Critical ratio for standard lead time and start Batch planning from that critical ratio. We do allocate 70% CPS capacity by work center in each batch plan.. 

Scene 5

Timeline and Process – BTS Batch Planning CY25

Measure available Capacity at less than standard LT weeks by WC

Identify CR for Standard LT and start Batch planning

Allocate 70% CPS by WC to Batch Planning starting from the CR identified

For Growth Team on DPr, Plan events by DPr priority sequence to fill 70% CPS by WC in Batch sew weeks.

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[Audio] For better understanding, we can pick the first batch plan as an example and see how the capacity allocation process may look like. The slide details the conditions and process to execute batch plan for both MPP styles and non-MPP styles.. 

Scene 6

1st batch Plan Wk46 
 IM: MPP LT sew wk47 >> Plan per normal R1 (1 round)
 IM: Batch Plan sew wk51-05 (7 rounds to meet 70% of CPS) 	2.1 Non MPP styles 	2.2 MPP styles convert back to normal LT. Identified Start CR/Dpr rule by Mega WC level (Start CR/Dpr rule is calculated by available capacity during wk46-50)
 3.   HYS Subcon (WM_G10/WM_G40/GIRL_G10/GIRL_G40): Batch Plan sew wk51-05 (7 rounds to meet 100% of CPS) 	2.1 Non MPP styles 	2.2 MPP styles convert back to normal LT. Identified Start CR/Dpr rule by Mega WC level (Start CR/Dpr rule is calculated by available capacity during wk46-50)
 **ROH PP to provide the Start CR/Dpr rule on batch planning week

[Audio] The key take aways for Winston Salem would be Demand introduction per batch. Try to introduce Kids demand evenly across Batches. Special material events must follow LLT timeline for event exposure. (note – Asia will share more details on special materials to watch out) And the key take aways for Asia would be
Align material capacity and IM plant production per surge period strategy. Order higher MPP TIL for prints. (note – with HAA prints moving out of Vietnam mills, we must have an improved print constraint in H1 next year). 

Scene 7

Demand introduction per batch.
 Try to introduce Kids demand evenly across Batches.
 Special material events must follow LLT timeline for event exposure. (note – Asia will share more details on special materials to watch out)

Align material capacity and IM plant production per surge period strategy.
 Order higher MPP TIL for prints. (note – with HAA prints moving out of Vietnam mills, we must have an improved print constraint in H1 next year)

The planning and production strategy for the upcoming Back to School season. The B-T-S surge production season is from sew week 51 to sew week18 next year.

avatar

As seen from past few surge seasons, these are the key reasons for combining demand and planning in batches.
Reserve capacity for service while deliver event on time

Zero Air ship or additional logistic expense

Zero T-K-S

Minimize changeover to maximize IM capacity and reduce Subcon

Ensure material availability for production

Maximize textile capacity

Reduce Inventory and prevent warehousing challenges

Last three B-T-S seasons, we planned in Batches. In year 2022, we did not have any Material Pre positioning. However, starting from 2023 B-T-S season, we had only 15% material pre positioning. This year Back to school season had more than 70% material pre positioned styles. In 2022 and 2023 we planned at standard lead time but this year we planned batches at pre positioned lead time. Batch planning at M-P-P lead time resulted in yarn shortages and difficulty to respond to print surge.

Building on past experiences, in the upcoming B-T-S season we need to plan four batches and 70% of C-P-S capacity as part of each batch. It is important to plan each batch at standard lead time and to make that happen, we may need to reserve demand for M-P-P lead time weeks.

Above is the calendar for the four batches in the upcoming B-T-S season. Each batch has an Event Introduction cut off and a work order week. The capacity allocation process is meant to reserve demand for M-P-P weeks when we go ahead to plan a batch at standard lead time. 
If a growth team is on I-B-P--, we measure available capacity at less than standard lead time for each work center. We map available capacity with I-B-P demand. Then we identify Critical ratio for standard lead time and start Batch planning from that critical ratio. We do allocate 70% C-P-S capacity by work center in each batch plan.

For better understanding, we can pick the first batch plan as an example and see how the capacity allocation process may look like. The slide details the conditions and process to execute batch plan for both M-P-P styles and non M-P-P styles.

The key take aways for Winston Salem would be 
Demand introduction per batch.

Try to introduce Kids demand evenly across Batches.

Special material events must follow L-L-T timeline for event exposure. (note – Asia will share more details on special materials to watch out)

And the key take aways for Asia would be
Align material capacity and IM plant production per surge period strategy.

Order higher MPP TIL for prints. (note – with H-A-A prints moving out of Vietnam mills, we must have an improved print constraint in H1 next year)