Apparel Manufacturing Process Flow

© Rashmi Rao, Projects, Madura Clothing

Madura ClothingProcess Improvement Initiative

Apr, 2011

Process SOP Docket – CCPL

2© Rashmi Rao, Projects, Madura Clothing

Table of Contents

Version Control Sheet

Glossary of Process Elements

Key Process Stakeholders and Roles

L0 Process Workflow

L1 Process Summary

L1 Process Detailing


Table of Contents




L0 Process Workflow

L1 Process Summary




REVIEWED BY# Name Brand Designation Date

1 Abhishek Kumar Madura Clothing Projects Manager

2

3

4

5

AMENDMENT LOG# Version Number Amended By Date

1 Version 1 Rashmi. Rao. M 6-05-2011

2

3

4

5

Process Name FCL & CCPL Process Mapping

Version V1.0

Prepared By Rashmi. Rao. M

Published On


Table of Contents




L0 Process Workflow

L1 Process Summary



Processes have been designed to cover Process Maps, Policies, Templates, KPIs and RACI Charts

Process MapsProcess Maps

RACI ChartsRACI Charts

Cross-functional Touch Points

Cross-functional Touch Points

PoliciesPolicies

KPIsKPIs

“How is the process carried out and by which functions ?”Captures the basic operational flow and the steps to be followed

“What guidelines are to be followed in running the process ?”Captures key decisions/rules guiding the functioning of the process

“How can the success of the process be measured ?”Captures the metrics against which performance can be measured

“Who plays what role in the execution of the process ?”Captures roles and responsibilities of the persons directly involved

“Which other functions need to be involved in process execution?”Captures the areas where other functions are to take the process ahead

Process Documentation Scope

Input / Output Templates

Input / Output Templates

“What analyses and formats are used to support the process ?”Captures standardized formats of documents used in different process steps

Glossary of Shapes used in this Document

L2 processes within L1 process

Output Interfaces

External process

Inter-linked L1 processes

Stored DataDecision EventInput

Interfaces T - Template

Notes (1) : R – Responsible | A – Accountable | C – Consulted | I – Informed


Table of Contents




L0 Process Workflow

L1 Process Summary



Key Stakeholders – Roles / Designations

Designation Role DescriptionReporting Authority

Head – Manufacturing • Head of In-house Manufacturing (Madura Clothing) • President

General manager • Heads individual domains such as shirts, trousers and suits, IE• Head -

Manufacturing

Factory Manager • Heads the factory, responsible for general management • GM

Technical manager • Responsible for the technical part of the factory • GM

Manager-WCM • Head WCM• Head -

Manufacturing

Manager-HR • Head HR

• Head - Manufacturing And HR-VP

Manager-Finance • Head Finance• Head -

Manufacturing

Asst manager- project • Head projects• Head -

Manufacturing

Asst manager-WCM • Responsible for• Head -

Manufacturing

Asst Manager- HR • Head OD• Head -

Manufacturing




Central Planners• Plans and allocates available manufacturing capacity for executing work orders – is liaison

between manufacturing and brands• Head –

Manufacturing

Production officer • Responsible for managing production • Factory Manager

Store In-charge• Responsible for management of fabric / trims warehouse - inwards, storage and issue- to own

and outsourced factories• Factory Manager

Sampling In-charge • Responsible for sample production • Factory Manager

Pattern Master • Responsible for pattern-making / CAD marking for in-house production • Factory Manager

Merchandising executive• Ensure production capacity availability for third Party Business and Product Costing of Styles ,

Ensure on-time delivery to customers .Retaining Customer and Vendor for sustained Business .• Head -

ManufacturingProduction planning

executive• Responsible for factory production planning • Factory Manager

CAD In-charge • Responsible for making markers style wise and fabric consumption planning • Factory Manager

Cutting Officer • Responsible for managing cutting and fusing • Factory Manager

Finishing In-charge • Responsible for packing and finishing • Factory Manger

Quality Officer • Responsible to set and maintain the quality systems in factory. • Factory Manager

Ware-House In-charge • Responsible for Dispatch • Factory Manager

Senior Industrial Engineer

• Responsible for productivity and efficiency • Factory Manager

HR executive • Responsible for recruitment, induction, canteen , security and legal compliance • Manager – HR

Payroll and compensation Officer

• Responsible for timely payment and benefits administration. • Manager – HR

IT In-charge • Responsible to maintain the IT Infrastructure in the factory • Factory Manager




Lab In-charge • Ensure effective lab quality system and processes are adhered to the standard • Factory Manager

WCM Executive • Assist in implementation of 8 dimensions of WCM • Manager – WCM

Maintenance Officer • Responsible for preventive maintenance and breakdowns • Factory Manager

Safety Officer• Responsible for establishing and complying safety, health and environment rules / norms in

factories.• Manager – HR

Utility Officer • Ensure upkeep of all electrical installations ,UPS, generators, boilers,STP,vapour • Factory Manager

Vapour Phase supervisor

• Coordinating with production and finishing department to meet timelines as per the plan for Vapor phase production

• Factory Manager

Embroidery In-charge• Develop embroidery designs as per brand requirement and coordinate with cutting and sewing

department to meet timelines for production. • Factory Manager

MIS executive• Collect and compile all Management information reports for factories and Highlight the deviations

for the necessary actions to all concerned• Factory Manager

Central MIS• Ensure Accuracy of financial and operation al reports as per timelines , analysis of variances and

highlight deviations to FMs and HOM• Head -

Manufacturing

Accounts officer• To ensure correct and timely accounting and reporting of financial transactions, as per the

SOPs of the company and to ensure financial control and financial proprietary so as to facilitate meeting legislative requirements and optimizing shareholders value.

• Manger - Finance


Table of Contents




L0 Process Workflow

L1 Process Summary



Macro level process

Stores Planning CAD Cutting Sewing & finishing

Quality

People

Finance and Accounts

Maintenance and IT

Core and Supporting processes

Core Processes Enablers

1 3 4 5 6

9

10

11

12

Business Strategy &

P&B

0

Warehouse

7

Merchandising and IE 8

Storage Value creation Deliver

Lab

2


L1 Processes(FCL)

L1 processes

FCL

1. Stores

2. Lab

3. Centralized Planning

4. Factory Planning

5. CAD

6. Cutting

7. Sewing

8. Finishing

9. Warehouse

10. IE

11. Maintenance

12. Vapour Phase


L1 Processes in Stores

L1 processes

Stores

1. Stores

1. Receipt of material in stores

2. Issue of materials

3. Material requisition, indent, purchase

order follow up

4. Receipt, verification & issue of

products purchased

5. Approval of new supplier

6. Supplier evaluation & re-evaluation


Process Map : Receipt Of Material In Stores

Manufacturing (Store)


Output Interfaces

External process




Receipt of materials with supplier invoice /DC

1

Start

Entry in Goods Inward Register

3

Quantity confirmation 4

Entry of material in identified location in

stores

7 Updation of stock in

SAP system

6

Preparation of goods receipt note

5

Inspection2

Entry in Goods Inward Register

3

Preparation of Rejected Goods Return note

6

Quantity confirmation 4

Updation of quantity in SAP 5 Rejected material placed in

identified location

7

Rejected material sent back to supplier with DC

8

Not OK

OK

End

Fabric: P.O, supplier name, material code, ordered qty.,

Received qty., Visual parameters, laboratory test & design approval from brand

Trims: P.O, supplier name, material code, ordered qty.,

Received qty., Visual parameters, lining, buttons &

labels, items overview


Process Map : Issue Of Materials

Manufacturing (Store) INFORM BRAND &

CORRECT BOM

End


Output Interfaces

External process




Download of production order and BOM through sap

1

Start

Issue of material2 Receipt of material requisition

from production for sewing and packing accessories

3

Amendment of production order and BOM as per cad

consumption

5 Issue of 10 cm fabric to cad for marker

consumption

3 Receipt of cad consumption

4

Updation of issued qty in sap

8

Issue of materials to production as per PPC(cut

qty)

7

Yes

No

Verification of material requisition

with BOM 4

Preparation of cutting order

6


Process Map : Material Requisition, Indent, Purchase Order Follow Up


Revise

End


Output Interfaces

External process




Receipt of Material requisition slip

1

Start

Stock verification of material

Enquiry sent to approved supplier through mail

3

Follow up with supplier 4

Receipt of quotation from supplier

7 Verification of quotation

Inform supplier for revised quotation

Approval of quotation by Factory Manager

9

Material indent raised by Purchase as per budget

10

Approval by Stores-in charge & Department in charge

11

Approval by Accounts Officer

13

Verification by A/c officer as per budget

Final approval by Factory Manager

14

Preparation of Purchase Order in Tally

15

Verification of PO

by Stores in charge as per

indent

Approval by Stores-in charge and Final approval

by Factory Manager

16

Purchase Order sent to supplier and obtain

acknowledgement through mail

17

Follow up with supplier 18

Yes

No

Yes

In stock

Not in stock

Yes

No

8

2

12

15

Material collected as per requisition

Sufficient material in stock inform process owner

Revise

No


Process Map : Receipt, Verification & Issue Of Products Purchased


End


Output Interfaces

External process




Receipt of material from supplier with invoice as per PO

1

Start

Preparation of inspection report

4

Preparation of GRN by Purchase in Tally

5 Store material in allocated

area, provide identification and maintain traceability

records

7

Approval of GRN by Accounts and Final approval by Factory

Manager

6

No

Yes

Verification of quantity by Security & purchase

2

Incoming inspection for

quality by concerned dept.

3

No

Yes

Submission of GRN along with PO to accounts department

& take acknowledgement

8 Physical transfer of

material to the concerned process owner through material requisition and take acknowledgement

9

Entry of issue in Tally 10Material sent back to supplier

Inform supplier & accept the material


Process Map : Approval Of New Supplier


Rejected

End


Output Interfaces

External process




Identification of new supplier1

Start

Compile Data about ability of supplier

2

Select the supplier For Evaluation

3

Procure samples from suppliers

5

Visit the supplier4

Creation of supplier ledger in Tally

8

Approve, establish and

maintain records of approved supplier – by AO

7

Yes

No

Assess quality and cost of the

product6


Process Map : Supplier Evaluation & Re-evaluation


Withdraw supplier approval and amend approved supplier

list

End


Output Interfaces

External process




Prepare supplier list1

Start

Define the Criteria for Evaluation/re-evaluation Such as Quality, delivery & service

2

Fix weight age for each of the Criterion as mentioned

above for each supplier

3

Communicate rating to supplier as per grade

A -90-100, B -80-90, C- 60-80, D-BELOW 60.

6

Rate performance once in 6 months. Statistically analyze

performance of suppliers for continual improvement

5

Monitor Performance based on evaluation

4

Continue appraisal & re-appraisal

11

Retain the supplier In Approved supplier List

10

Yes

No

Evaluate Effectiveness

9

Obtain Acknowledgement from supplier

7

Monitor the corrective action by the supplier (Whenever Necessary)

8

Communicate to supplier

If graded D, remove from approved supplier list.

If graded C, inform supplier in writing for improvement for the next

three consecutive PO’s


L1 Processes in Lab

L1 processes

Lab

1. FCL Lab Process


Process Map : Lab

Lab

Yes

No

End

Result Approved?

6

Receipt of sample1

Start


Sourcing / PDQA

Fabric , trims, garments

Enter detail in register

Decide type of Test Package, cut & distribute to concerned technician

Carry out Test as per standard test method (AATCC, ASTM, ISO)

Prepare hand written draft report/ Enter test details in register

Send back test report signed copy to Lab, photocopy forwarded to store

Discard tested & untested sample as per Lab sample retention policy

Keep all test reports in Box File in sequence/ Keep record in register

Fabric ,trims, garments

Yes

No

Approved?8


Output Interfaces

External process




2

3

4

5

Bulk - Enter result in SAP & accept. Other cases: Send PDF report to concerned Person

9

10

11

Send test report along with tested specimen to QA Manager-RM for final

approval

7


L1 Processes in Centralized Planning

L1 processes

Centralized Planning

1. Centralized Planning


Process Map : Centralized Planning

End

Risk Analysis for Quality feasibility with A4

size swatches

1


Output Interfaces

External process




Start

Brand

PPC(Factory)

Month-wise plan at Style code level

2

WO Creation3

No

YesStatus Visibility4

BCDS Process implementation with Cut-of

date

5

WO Download and Review with Factory Capacity blocked

6

Trims & Fabric Avblty after

Testing

7WO Cancellation/ change in order

qty in case of partial fabric or trims avblty within 1 wrkng day by

brand SC

Gold Seal Avblty8

WO Cancellation by brand SC

Correct Costing & Routing

9

Costing rectification by brand SC

10 Fortnight Plan for cutting, sewing & dispatch based on line capacity, Garment styling11

Marker Preparation12

Cross verification of Fab consm BOM v/s Marker & trims BOM

(In case +-5%)13

Correct BOM14

Fabric ready17

WO release18

Milestone confirmation against Plan for Cutting,

Sewing, Finishing and dispatch

19

Brand commitment date follow-up

20

Variance analysis & TECO

21

No Yes

No

Yes

Correcting BOM

NoTrims checking

16

BOM & WO print15

Yes


L1 Processes in Factory Planning

L1 processes

Factory Planning

1. FCL Factory Planning Process


Process Map : Factory Planning

End

Receipt of BCDS1


Output Interfaces

External process




Start

OCR14

Brand

PPC(Factory)

BCDS

Stores

Production

IE

WO & BOM4

Block line based on expected efficiency & allotted capacity

9

Plan based on delivery requirement

8

Schedule for garment treatment

13

TECO15

Dispatch on scheduled date

13

Highlight to brand & get gold seal

BOM correction as per actual

6

Milestone confirmation (CO11N)

11

Highlight to brand & correct

Highlight to brand & correct

Check with IE dept

Yes

Yes

Yes

Yes

Yes

No

No

No

No

Check gold seal & fabric availability

2

Swatch collection & risk analysis

3

Check fabric, trims &

consumables available as per

BOM

5

Is OPBD available

7

Is Garment treatment

12

Follow up12

Reschedule with higher authorities approval

Yes

No

Check for fabric & trims availability

Schedule for cutting & loading

10

No

Schedule for pilot runNew style

Pilot run & follow up


L1 Processes in CAD

L1 processes

CAD

1. FCL CAD Process

1. Sample development

2. For regular production

3. Sample Pattern development


Process Map : CAD (Sample Development)

Brand (Merchandiser & designer)

CAD

(Sampling Section)

Receipt of sample indent

1


Output Interfaces

External process




Start

Merchandising Dept Sample indent

No Yes

Sending fabric requisition to stores3

Sample cutting 4

Approval

Updation of indent details in system

2

Folding & packing as per indent details

10Stitching5

Buttoning & button hole6 Pressing9

Trimming/Spot wash7

Dispatch11

Check the W/O creation for the Indent in SAP

2. a

Check the availability of

Fabric, Trims & Accessories in

stores

2. bFinal

inspection 8

Inform the brand merchandiser Correction

Grading & Final12

Gold Seal Sample ready for production

End

13

14

No

Yes

No

Pattern available / Make the new pattern2. c

Manual hard pattern

Rework / Inform to brand

Yes

No

Yes


Process Map : CAD (For Regular Production)


Output Interfaces

External process




Start

CAD

Stores

Cutting

Yes

Issue to cuttingEnd

Marker verification

9

10

Marker preparation as per ratio6

WO with swatches

Brand

Sampling Dept

Check for availability of gold seal no & brand

name in WO

Check for availability of

pattern & gold seal sample

Prepare the ratio as per WO qty5Measure fabric repeat & width

before preparation of marker

4

Check with brand

Check with sampling dept

Yes

Yes

NoNo

Calculate the consumption7

Issue consumption to stores

Print marker from plotter8

Stripe & checks markers sent to manual cutting

Solid & pin stripe markers sent to Gerber cutting

NoMake changes

Receipt of WO1

32

11

11


Process Map : CAD (Sample Pattern Development)

CAD

End

Receipt of specification sheet from brand to make proto (development) sample

1


Output Interfaces

External process




Start

Development of pattern in PDS as per specification

2

Print pattern using plotter3

Make hard Pattern4


L1 Processes in Cutting

L1 processes

Cutting

1. FCL Cutting Process

1. Cutting(Plain fabric)

2. Cutting(Stripes & checks fabric)


Process Map : Cutting (Plain Fabrics)

Receipt of CAD marker & lay plan


Output Interfaces

External process




Start

Receipt of fabric & trims

Manufacturing (Fabric/Trims Stores)

Manufacturing (Cutting)

CAD

Fabric & accessoriesCutting order

Spreading3

No

Relay

Lay inspection4

1Cutting(Auto cutting-

Gerber cutting)

5

Numbering7

YesInspection9

Issue to sewing

12

Recut

No

Panel Inspection

10

No

RecutFusing8

Bundling11

End

2

CAD marker

Lay Plan

Confirmation of cut qty in SAP

6 Relay of front

panel8

Ready cutting9


Process Map : Cutting (Stripes & Checks Fabrics)

Receipt of CAD marker & lay plan


Output Interfaces

External process




Start



CAD

Fabric & accessoriesCutting order

Spreading6

No

Relay

Lay inspection7

1

Band Knife Cutting(For small parts)

9

Numbering11

YesInspection13

Issue to sewing

16

Recut

No

Panel Inspection

14

No

RecutFusing12

Bundling15

End

CAD marker

Lay Plan

Confirmation of cut qty in SAP

10

Relay of front panel

12

Ready cutting13

Receipt of fabric & accessories

2

Verification of centre line in marker

3

Pin setting based on repeat size

4Verification

5

Straight Knife Cutting8

No

Yes

Yes

Yes


L1 Processes in Sewing

L1 processes

Sewing

1. FCL Sewing Process


Process Map : Sewing(Shirts)

PPC

Manufacturing (Finishing)

Manufacturing (Sewing)


End

Production plan & line plan


Output Interfaces

External process




Start


IE

Alteration / Rework

Cut panels

Trims

Line plan

Receive line plan2

Receive cut parts3

Trims receipt4

Load small parts5

Sleeve ready

Assembly7

Trimming8

EOL inspection

9

Issue to finishing10

Yes

No

BackCuff make Front readyCollar ready

Receive production plan

1


L1 Processes in Finishing

L1 processes

Finishing

1. FCL Finishing Process


Process Map : Finishing

End


Output Interfaces

External process




Start


Extra thread trimming1

Loose thread removed in thread sucking machine

2

Buttoning the shirt 3

Pressing the inner side – bottom, front placket, side & pocket

4

Outside full pressing 5

Rework

Attach price tag, collection tag, collar support and butter fly

7

Insertion of collar traveller 8

Pre iron9

Shirt folding with tissue paper, and back support (card board), metal &

plastic clip

10 Placement of price sticker, collar size tag, bar code sticker on swing tag &

product box

11

Issue to warehouse13

Packing inside poly bag

12

Final Inspection 6

Yes

No


L1 Processes in Warehouse

L1 processes

Warehouse

1. FCL Warehouse Process


Process Map : Warehouse

Receipt of finished products

End


Output Interfaces

External process




Start

Stores

Factory Warehouse

Central warehouse

Finishing Section Garments

Verification of barcode & size sticker

Replace barcode & size sticker

No

Yes Size wise packing in inner

carton box

Packing trims

Sealing of carton box Create carton

stickers in YPDMR34

Print delivery Chelan in YSOLR41

Size wise packing in outer carton box as per location

Location wise scanning

Repack

GRN to be done in SAP

STO to be created in ME27

Delivery created in VL04

Picking & packing in VL02N

Loading

Dispatch

TECO – Final confirmation & analyse

variance

Do PGI in VL02N

Check WO status

1

4

3 6

7

8

10

9

11 12

13

14

15

16

15

5

2

No

Yes

Yes


L1 Processes in IE

L1 processes

IE

1. FCL IE Process


Process Map : IE SHIRTS

Industrial Engineering(IE)

(Factory)

Merchandising

Receipt of gold seal1


Output Interfaces

External process




Start

Gold seal

End

Man/M/c allocation5

Conduct method study

6 Design workplace

layout

7

Prepare final OBD & freeze SMV

8

Analyze daily production report

9 Calculate factory efficiency on daily basis

10

Time study for bottle necks

11

Coordinate with supervisors & create awareness of their

operators performance

12 Coordinate with operators & encourage to practice effective

methods

13

Initiate continual improvement activities

14

Prepare factory efficiency & other MIS

15

Prepare OBD2

Fixing CM, creating activity type /rate and SAP updation3

Plan for resources based on targets and

styling

4


L1 Processes in Maintenance

L1 processes

Maintenance

1. FCL Maintenance Process

1. Preventive maintenance

2. Breakdown maintenance

3. Critical spares


Process Map : Preventive maintenance

Maintenance Dept

End


Output Interfaces

External process




Prepare a maintenance checklist

Carry out maintenance as per plan

Maintain records of preventive maintenance

Start

Prepare yearly plan for preventive maintenance

Prepare a master list 2

3

4

5

6

Identify each equipment and machine used for production/ service provision with

an inventory number

1


Process Map : Breakdown maintenance

Maintenance Dept

End


Output Interfaces

External process




Start

Statistically analyze the causes for break down of critical machines and use the

data for continual improvement

6

Carry out maintenance as per plan at periodic intervals

5

Identify reasons for breakdown of equipment and initiate corrective action

4

Register all break downs, malfunctioning, trouble shooting for each equipment in

History card

3

Rectify the breakdown2

Receipt of information regarding breakdown of equipment/machinery from concerned

department

1


Process Map : Critical Spares

Maintenance Dept

End


Output Interfaces

External process




Purchase arranges for material Receipt of material

Entry of material into stock ledger Identify and list out critical spares for critical equipments

Start

Fix minimum quantity for each of the critical spares based on consumption and

lead time of supply

Requirement is sent to purchase through materials requisition

Receipt of material

Store Material in the Allocated Area, Provide Identification And Maintain

Traceability Records.

Incoming inspection

6

1

2

3

4 5

7

8 9

Yes


L1 Processes in Vapourphase

L1 processes

Vapourphase

1. FCL Vapourphase Process


Process Map : Vapour Phase

End


Output Interfaces

External process




StartSend to finishing

Spot washSecond quality

Second quality

Yes

Creases

No

StainsDamage

To pressing

Yes

Yes

YesYes

No

Check for stains, damage

& unwanted creases

2

Check the processed

shirts6 Spot

wash

Receipt of pressed shirts from finishing

1

Place the shirts on VP production trolleys (80 to 100 Pcs each with 2” – 2.5” gap. If the qty is less use dummy

shirts)

3

Set the programme number4

Load the trolleys in the chamber & run the programme

5

7


L1 Processes(CCPL)

L1 processes

CCPL

1. Stores

2. IE

3. Lab

4. Factory Planning

5. CAD

6. Cutting

7. Sewing

8. Finishing

9. Warehouse

10. Maintenance

11. Vapour Phase


L1 Processes in Stores

L1 processes

Stores

1. CCPL Stores Process

1. Fabric Store

2. Trims Store

3. Regular Purchase

4. Indent Purchase


Process Map : Fabric Stores


Output Interfaces

External process




Start

Fabric Suppliers Fabric Production and Supply

Bulk Fabric

Receipt of fabric1

Manufacturing (Fabric Store)

Document verification

2

NoGIR

3

Inform/Mail to brand

Sourcing

PO and Order Management - Fabric (4a.4)

Yes

Bale opening4

Design approval

Swatch for design approval

Fabric Discrepancy Report (FDR)

Visual, Lab & Shade batching Report

Lab testing5

T

Yes

No

Quality Approved?

7

Fabric Rejection Advice (FRA) + sampleT

Approvals/ Advice

Accept?Yes

No

End

Garments Production – In-house Factories (4b.3)8

Fabric Return Dispatch

9

Fabric Return

GRN in system

10Material issue to CAD & Cutting

11

Fabric shortage

Visual & Shade batching

6


Process Map : Trims Stores


Output Interfaces

External process




Start

Fabric Suppliers Trims Production and Supply

Trims

Receipt of trims1

Manufacturing (Trims Store)

Document verification

2

NoGIR

3

Inform/Mail to brand

Sourcing

PO and Order Management - Fabric (4a.4)

Yes

Sample approval

Master sample approval for first time

material receipt

Visual & Lab Report

Visual & lab testing4

Yes

No

Quality Approved?

5

Trims Rejection Advice (TRA) + sampleT

Approvals/ Advice

YesNo

End

Garments Production – In-house Factories (4b.3)Accept?6

Trims Return Dispatch

7

Trims Return

GRN in system

8 Material issue to cutting, sewing &

finishing dept

9


Process Map : Regular Purchase

Suppliers


Supply

Yes

No

ReportEnd

Garments Production – In-house Factories (4b.3)

Material

Quality Approved4

Visual checking 3

Material Return Dispatch5


Output Interfaces

External process




Material return

RN(Receipt Note) in system

6

Material issue

7

Receipt of material indent

1

Start

PO Raise2


Process Map : Indent Purchase

Suppliers

Management


Supply

Collect quotations- Meeting with

suppliers- Comparative

analysis

No

Yes Yes

No

Report

End

Garments Production – In-house Factories (4b.3)

Material

Supplier approved?2

Quality Approved?4

Visual Checking3

Material Return Dispatch5


Output Interfaces

External process




Material return

RN(Receipt Note) in system

6

Material issue

7

Approval from FM

PO RaiseReceipt of material

indent 1

Start


L1 Processes in IE

L1 processes

IE

1. CCPL IE Process

1. IE(Trousers)

2. IE(Jackets)


Process Map : IE (Trousers)


Factory

Merchandising


2


Output Interfaces

External process




Start

Gold seal

End

Man/M/c allocation7


8Design workplace

layout

9

Prepare final OBD & freeze SMV 10



12


13



14 Coordinate with operators & encourage to practice

effective methods15


16


17

YesNo

Costing3

FM approval

4 Updation activity code in SAP

Prepare OBD2

5

Costing mail to be send for brand

6


Process Map : IE (Jacket)


Factory

Merchandising


2


Output Interfaces

External process




Start

Man/M/c allocation


Gold seal

Design workplace layout

Prepare final OBD & freeze SMV


Coordinate with operators & encourage to practice

effective methods


End


7

8 9

10


12


13



14

15

16

17Costing

FM approval

YesNo

3

4

Prepare OBD

Updation activity code in SAP

Costing mail to be send for brand

2

5

6


L1 Processes in Lab

L1 processes

Lab

1. CCPL Lab Process


Process Map : Lab

Lab

Yes

No

End

Result Approved?

6

Receipt of sample1

Start


Sourcing / PDQA

Fabric , trims, garments

Fabric ,trims, garments

Yes

No

Approved?8


Output Interfaces

External process




Enter detail in register2

Decide type of Test Package, cut & distribute to concerned technician

3

Carry out Test as per standard test method (AATCC, ASTM, ISO)

4

Prepare hand written draft report/ Enter test details in register

5

Bulk - Enter result in SAP & accept. Other cases: Send PDF report to concerned Person

Send back test report signed copy to Lab, photocopy forwarded to store

9

Keep all test reports in Box File in sequence/ Keep record in register

10

Discard tested & untested sample as per Lab sample retention policy

11

Send test report along with tested specimen to QA Manager-RM for final

approval

7


L1 Processes in Factory Planning

L1 processes

Factory Planning

1. CCPL Factory Planning Process


Process Map : Factory Planning

CAD

Receipt of BCDS

End

1


Output Interfaces

External process




Start

WO dispatch8

Daily update WO’s created

Brand

PPC(Factory)

BCDS

Stores

ProductionGold seal review

IECommunicate for work place

design

Check for trims availability

2

Release plan3 Weekly Dispatch plan4

Give Brand Commitment fortnightly

5WO release

6

Follow up WO’s in different sections

7

Consumption

OTIF, Through Put & other reports

9


L1 Processes in CAD

L1 processes

CAD

1. CCPL CAD Process

1. Sample development

2. Production Marker development


Process Map : CAD (Sample Development)

Brand sourcing

CAD

End

Receipt of sample indent & control sheet

1


Output Interfaces

External process




Start

Merchandising Dept

Sample indent & control sheet

Pattern making2

No

Yes

No Yes

Digitizing / Manual marker3

Sample development 4

Approved sample5

Grading / Final model development

6

Develop size set sample7

Sample ready for production

9

Approval8


Process Map : CAD (Production Marker Development)


Output Interfaces

External process




Start

CAD

Stores

Cutting

Avg consumption

3

Receipt of control sheet5

1

Yes

No

End

Approved gold seal, measurement

chart & pattern availability

2

Marker verification

7

Issue to cutting8

Yes

Marker preparation6

WO detail received with consumption

WO detail with lay plan 1

Prepare control sheet4


L1 Processes in Cutting

L1 processes

Cutting

1. CCPL Cutting Process


Process Map : Cutting


Output Interfaces

External process




Start



CAD

Fabric & accessoriesControl sheet

No

Yes

Return to stores

Change fusing parameters

No

Yes

No

Yes

Table planning & spreading

6

No

Yes

Relay

Lay inspection?7

Prepare lay plan & accessory sheet

1

Cutting8

No

YesCut panel Inspection

9

Recut

Sorting10

Numbering11

BUNDLE INSPECTION

Yes

15

Issue to sewing

16

Recut

No

Issue fab requisition slip

Panel Inspection

12

No

Recut

Fusing13

Bundling14

End

Receipt of fabric & trims2

Check fusing bond

strength / thermal

shrinkage

4

Check for fab code &

width before spreading

5

Marker making

Control sheet

review?

3Yes



L1 processes

Sewing

1. CCPL Sewing Process


Process Map : Sewing(Trousers)

PPC




End

Production plan

Receive production plan

1


Output Interfaces

External process




Start


IE

Alteration / Rework

Cut parts

Trims

Line plan

Receive line plan2

Receive cut parts3

Trims receipt4

Load small parts5

Parts sewing6 Panels & parts

sewing

7

Sewing assembly8

Trimming9

EOL inspection

10

Issue to finishing11

Yes

No



L1 processes

Finishing

1. CCPL Finishing Process


Process Map : Finishing(Trousers)



End


Output Interfaces

External process




Start

Garments

Receive material1

Loose thread sucking2

Side seam iron3

Legger pressing4

Topper pressing5

Issue to FQC6



L1 processes

Warehouse

1. CCPL Warehouse Process


Process Map : Dispatch (TROUSERS)

Receipt of garments

End


Output Interfaces

External process




Start

Stores

Factory Warehouse

Central warehouse

Finishing Section

Garments

Final quality audit if qty >

80%

Rescreen

No

Yes

Re audit

Tagging of price tag with barcode

Packing

Appearance audit

Rescreen

No

Audit by buyer QC

Rescreen

No

Yes

Yes

Generate DC

Dispatch to WH

Receive details of confirmed orders which

are dispatched

Check for cost variance in SAP & TECO

Packing trims

1

2

53

4

6

7

8

9

10


L1 Processes in Quality

L1 processes

Quality

1. CCPL Quality Process


Process Map : Quality(Trousers)

FQA

Sewing

CAD


Output Interfaces

External process




Cutting

Check marker

Check laying

Check cutting

Check panels Check

bundling

Check fusingRe - laying

Re - cutting Change fusing parameters Re - cut

Check operators for quality

Issue red flag


Issue white flag

Issue green flagCheck critical

operations

Alterations

End of sections check for

quality output

Check as per traffic light

system

Final Audit

Choose single sampling plan as

per order size

100% inspection

Alterations

Final Audit for presentation

No

Yes

No

No

Yes Yes

Yes

Yes

YesYes

Yes

Yes Yes Yes

No

No

No

No

No

No



L1 processes

Sewing

1. CCPL Sewing Process


Process Map : Sewing(Jackets)

PPC




Receive plan

Issue to Finishing

Inspection

Yes

End

Section wise planning

1


Output Interfaces

External process




Start

8

Receive material


IE Receive style details and loading plan

Control sheet

Cut parts

Trim kit

Bundle wise loading

Processing (Body)

Sleeve assembly

Body assembly

Alteration / Rework

No

Processing (Lining)

Processing (Sleeve,)

2

3

4

4

4

5 67



L1 processes

Finishing

1. CCPL Finishing Process


Process Map : Finishing(Jackets)



End


Output Interfaces

External process




Start

Garments

Receive material1

Spot remover2

Shoulder & sleeve press

3

Left & right front press4

Button marking 6

Side & back press5

Button sewing (Front button)

7 Button sewing (Lining button)

8

Collar press9 Lining ironing &

fabric touch up12

Sleeve touch up11

Lapel pressing & touch up

13 Label attaching on sleeve14

Wrapping15

Issue to FQC16

Armhole touch up10



L1 processes

Warehouse

1. CCPL Warehouse Process


Process Map : Dispatch (JACKETS)

Receipt of garments

End


Output Interfaces

External process




Start

Stores

Factory Warehouse

Central warehouse

Finishing Section

Garments

Final quality audit if qty >

80%

Rescreen

No

Yes

Re audit

Put size ring for jacket/trouser with

hanger

Paring of jacket & trouser

Tagging of price tag with barcode

Packing

Appearance audit

Rescreen

No

Audit by buyer QC

Rescreen

No

Yes

Yes

Generate DC

Dispatch to WH

Receive details of confirmed orders which

are dispatched

Check for cost variance in SAP & TECO

Packing trims

1

2

3

4

5

6

7

8

9

10

12

11


L1 Processes in Quality

L1 processes

Quality

1. CCPL Quality Process


Process Map : Quality(Jackets)

FQA

Sewing

CAD


Output Interfaces

External process




Cutting

Check marker

Check laying

Check cutting

Check panels Check

bundling

Check fusingRe - laying

Re - cutting Change fusing parameters Re - cut


Issue red flag


Issue white flag

Issue green flagCheck critical

operations

Alterations

End of sections check for

quality output

Final Audit

Choose single sampling plan as

per order size

100% inspection

Alterations

Final Audit for presentation

No

Yes

No

No

Yes Yes

Yes

YesYes

Yes

Yes Yes Yes

No

No

No

No

No

No


END OF DOCUMENT

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Apparel Manufacturing Process Flow