Merchandising School: Method of Garments Costing for Knitted Polo Shirt (Factory Costing)

Method of Garments Costing for Knitted Polo Shirt (Factory Costing)

→ Introduction:

In garments merchandising, costing is a very important issue. As its importance in garments sector, today its seen that, some buying house make an another department only for costing. The main reason of that is to prepare accurate costing for any order. To make accurate costing you have to know the method of costing, by which you can solve any costing issue without any hesitation.

Method of Garments Costing for Knitted Polo Shirt:

Before starting of a knitted polo shirt garments costing, a knit garments merchandiser must be known about the following matters:

1. Yarn Price,

2. Knitting and Washing Cost,

3. Dyeing Cost,

4. Embroidery Cost,

5. Printing cost,

6. Accessories Cost,

7. Cost of Making (CM),

8. Commercial Cost,

9. Others Cost.

Important tips***

§ The 2nd duty is to calculate the fabric consumption and costing.

§ Normally, we calculate the grey fabric consumption.

§ After completing grey fabric consumption and costing, all the required fabric processing cost (knitting+ washing cost, dyeing cost) should be added with grey fabric cost. After that, we can achieve the actual fabric cost.

§ At last, all the others necessary cost should be added with actual fabric cost to achieve total cost of a garment.

Need verius consumption:

1. Body fabric consumption (Body & Sleeve )

2. Fabric consumption for pocket

3. Fabric consumption for Collar

4. Fabric consumption for Cuff

5. Fabric consumption for Half-moon

6. Fabric consumption for RIB

An example for the knitted polo shirt garments costing method are presented in the below:

Example:

Suppose,
One of the buyers named “Ha-Meem Group” forwards a knitted polo shirt item order (20000pcs) to you with following specification.

1. 100% cotton single jersey fabric for body parts (Body + Sleeve), Half-moon and Pocket. Where fabric GSM is 170.

2. 1 × 1 Rib fabric for collar and Cuff. Where the fabric GSM is 220.
Follow the below measurement chart.

3. Print on Pocket.

4. Embroidery on Back part.

Follow the below measurement sheet.

	Actual length	Allowance	Measurement with Allowance
Body length	65cm	6cm	71cm
Sleeve length	18cm	6cm	24cm
½ Chest width	50cm	6cm	56cm
Collar length	36cm	0cm	36cm
Collar width	7cm	3cm	10cm
Cuff length	20cm	4cm	24cm
Cuff width	3cm	2cm	5cm
Pocket length	11cm	3cm	15cm
Pocket width	8cm	3cm	11cm
Half-moon length	14cm	3cm	17cm
Half-moon width	7cm	3cm	10cm

Now, determine the garments costing (On FOB) for the above order.

Solution:

Fabric GSM- 170 for cotton single jersey,
Fabric GSM- 220 for 1 × 1 Rib fabric.

Let,

Yarn Price per kg- $3.90
Knitting and Washing Cost per kg- $1.50
Dyeing Cost per kg- $2.10
Printing Cost per dozen- $3.90
Embroidery Cost per dozen- $6.00
Accessories Cost per dozen- $2.00

Now, we have to calculate the fabric consumption for the above order.

Fabric Consumption:

1. Fabric consumption for Body parts (Body +Sleeve):
Here, we will follow the following formula (per dozen),

(Body Length + Sleeve Length + Seam Allowance) x (½ Chest + Seam Allowance) x 2 x GSM / 10,000 /1000 + 10% (Wastage and extra cutting) x Doz

={(71+24)×56×2×170 /10,000 /1,000/100×110×12

= 2.39 kg per dozen.

So, fabric consumption for Body parts (Body +Sleeve) is 2.39 kg per dozen.

2. Fabric consumption for Collar:
Here, we will follow the following formula (per dozen),

= Collar length × Collar width × 12 × GSM /10,000 /1,000

= 36 × 10 × 12 × 220 / 10,000 / 1000

= 0.10kg per dozen.

So, fabric consumption for Collar is 0.10kg per dozen.

3. Fabric consumption for Cuff:
Here, we will follow the following formula (per dozen),

= Cuff length × Cuff width × 2 × 12 × GSM / 10,000 / 1,000

= 24×5×2×12×220/10,000/1,000

= 0.06kg per dozen.

So, fabric consumption for Cuff is 0.06kg per dozen.

4. Fabric consumption for Pocket:
Here, we will follow the following formula (per dozen),

= Pocket length × Pocket width × 12 × GSM /10,000/1000 + 10 % Wastage

= 15×11×12×170/10,000/1,000

= 0.03kg per dozen.

So, fabric consumption for Pocket is 0.03kg per dozen.

5. Fabric consumption for Half- moon:
Here, we will follow the following formula (per dozen),

= Half-moon length × Half-moon width × 12 × GSM

= 17×10×12×170/10,000/1,000

= 0.03kg per dozen.

So, fabric consumption for Half- moon is 0.035kg per dozen.

Now, total amount of cotton single jersey fabric needed for this order is (per dozen),
= [{Fabric consumption for Body parts (Body +Sleeve) + Fabric consumption for Pocket + Fabric consumption for Half- moon} + wastage (10%)]
= {(2.17 + 0.03 + 0.03) kg + 10%}
= 2.23kg + 10%
= 2.45kg per dozen.

So, cotton single jersey Grey fabrics needed per dozen 2.45kg.

And,

Total amount of (1 × 1) Rib fabric needed for this order is (per dozen),
= {(Fabric consumption for Collar + Fabric consumption for Cuff) + wastage (10%)}
= {(0.10 + 0.06) kg + 10%}
= (0.16kg + 10%)
= 0.18kg per dozen.

So, 1 × 1 Rib Grey fabrics needed per dozen 0.18kg.

Total grey fabric needed to make the polo shirt is – (2.45+ 0.18 = 2.63kg) per dozen
As yarn price per kg is $3.90 then, total grey fabrics cost per dozen is (2.63kg × $3.90) = $10.26

So, Total grey fabrics cost per dozen is $10.26

Now, adding all the fabric processing cost (Knitting+ Washing Cost, Dyeing Cost) with grey fabrics cost, actual fabric cost will be determined.

So,
Actual fabric cost,
= Total Grey fabric cost + [{(knitting cost + washing cost) + dyeing cost} × Total grey fabric] per dozen
= [$10.26 + {($1.50 + $2.10) × 2.63}] per dozen
= $19.79 per dozen.

So, actual fabric cost per dozen is………. $19.73 ………………….. (A)
Printing Cost per dozen……………………… $3.90 ………………………. (B)
Embroidery cost per dozen ………………… $6.00 ……………………….. (C)
Accessories Cost per dozen……………….…$ 2.00 ………………………… (D)
Cost of making (CM)……………………………. $5.00 ………………………… (E)
Commercial cost …………………………………. $0.55 …………………………. (F)
Others cost …………………………………………. $0.25 ………………………… (G)

Here,
By adding A, B, C, D, E, F and G, we will get the total FOB cost of garments per dozen for the above order.

Total FOB cost per dozen = (A +B + C + D+ E + F + G)
= $ (19.73 + 3.90 + 6.00 + 2.00 + 5.00 + 0.55 + 0.25)
= $37.43 per dozen.

So, total FOB cost per dozen is $37.43

Normally, in case of factor costing, it should be think that, as we have received the order from a buying house (Here, we got the order from Ha-meem Group’s Buying House), so we have to pay 8%commission to them for that order.

So, in this condition, total FOB cost per dozen stands at-
= $37.43 per dozen + 8% commission
= $40.42 per dozen.

In factory costing, profit% for the factory (here-10%) should be added with total FOB cost per dozen.

So,
Total FOB cost per dozen with profit% stands at ($40.42 + 10%) = $44.46

Now, total FOB cost per pcs is ($44.46 / 12) = $3.71

So, factory cost (FOB) per pcs garment of the above order is $3.71

Variable function:

1. Fabric consumption

2. Fabric cost

3. Accessories cost

4. Print/Embroidery/Washing charge

5. C.M.(Cost of Making)

6. Freight (C & F)