What is Order Breakdown
Order breakdown is the process of dividing a large purchase order into smaller, executable production batches. Each batch has a specific quantity, size, color, date, and line. Without breakdown, the order is just a number. With breakdown, the order becomes a plan.
What to Break Down
Quantity by size. Quantity by color. Quantity by style. Quantity by fabric lot. Quantity by shipment date. Quantity by line allocation.
Practical Example 1 — Basic Breakdown
Order: 30,000 pieces of a basic T-shirt in sizes S, M, L, XL and colors white, black, navy. Size ratio 2, 4, 3, 1. Color ratio equal. Total 12 combinations. Break into 12 smaller batches.
Practical Example 2 — Shipment Split
Buyer wants 3 shipments of 10,000 pieces each in months 1, 2, 3. Break the order into 3 shipment batches. Each batch needs its own production plan.
Practical Example 3 — Line Assignment
Two lines are assigned. Break the order into 2 halves of 15,000 pieces each. Assign Line 1 to half A and Line 2 to half B. Coordinate cutting and finishing accordingly.
Practical Example 4 — Fabric Constraint
Fabric for navy is delayed by 2 weeks. Break the order so navy ships in the second batch. White and black can ship in the first batch.
Steps in Breakdown
Read the order details carefully. Check size and color ratios. Understand shipment requirements. Check fabric availability. Allocate to lines. Set batch dates. Document in the production plan.
Common Mistakes
Starting production without a breakdown. Breaking by size but not by color. Ignoring shipment splits. Not checking fabric availability. Not coordinating with merchandising.
When to Use It
Order breakdown is done for every new order. It is the first step in production planning.