What is Line Loading
Line loading is the process of assigning styles to production lines with specific dates and quantities. It is the day-to-day core of production planning. A good line loading plan maximizes capacity utilization, minimizes changeovers, and delivers on time.
Key Inputs
Confirmed orders with delivery dates. Line capacities. SMV of each style. Skill of each line. Fabric in-house dates. Buyer priority.
Practical Example 1 — Simple Loading
Order 1: 15,000 pieces, delivery 30 days. Order 2: 10,000 pieces, delivery 45 days. Line 1 has capacity 5000 pieces per day. Load Order 1 on Line 1 for days 1 to 3. Load Order 2 for days 4 to 6.
Practical Example 2 — Style Grouping
Two orders have similar SMV and skill requirements. Group them on the same line. One changeover instead of two. Saves 8 hours of setup.
Practical Example 3 — Buffer Loading
Load Line 1 at 90 percent capacity. Leave 10 percent for rush orders. Load Line 2 at 100 percent because it has a stable ongoing order. Balance risk across lines.
Practical Example 4 — Fabric Delay
Fabric for Order 1 is delayed by 3 days. Shift Order 1 to start on day 4. Load a smaller order in the gap days to avoid idle line.
Line Loading Board
A simple board with rows for each line and columns for each day or week. Cards or color blocks show the assigned order. Update weekly. Post in the planning room.
Common Mistakes
Overloading all lines at 100 percent. Not accounting for fabric in-house. Ignoring SMV differences. Not leaving buffer. Not updating when orders change.
How to Improve Line Loading
Use a simple Excel sheet. Update weekly with confirmed orders. Coordinate with fabric in-house. Track actual performance daily. Adjust for absenteeism.
When to Use It
Line loading is done weekly and updated daily. It is the heart of PPC work.