apparel manufacturing process flow
DESCRIPTION
Apparel, Clothing, Manufacturing, Process, FlowTRANSCRIPT
© 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
3© 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
4© Rashmi Rao, Projects, Madura Clothing
Version Control Sheet
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
5© 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
6© Rashmi Rao, Projects, Madura Clothing
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
7© 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
8© Rashmi Rao, Projects, Madura Clothing
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
9© Rashmi Rao, Projects, Madura Clothing
Key Stakeholders – Roles / Designations
Designation Role DescriptionReporting Authority
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
10© Rashmi Rao, Projects, Madura Clothing
Key Stakeholders – Roles / Designations
Designation Role DescriptionReporting Authority
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
11© 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
12© Rashmi Rao, Projects, Madura Clothing
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
13© Rashmi Rao, Projects, Madura Clothing
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
14© Rashmi Rao, Projects, Madura Clothing
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
15© Rashmi Rao, Projects, Madura Clothing
Process Map : Receipt Of Material In Stores
Manufacturing (Store)
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
16© Rashmi Rao, Projects, Madura Clothing
Process Map : Issue Of Materials
Manufacturing (Store) INFORM BRAND &
CORRECT BOM
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
17© Rashmi Rao, Projects, Madura Clothing
Process Map : Material Requisition, Indent, Purchase Order Follow Up
Manufacturing (Store)
Revise
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
18© Rashmi Rao, Projects, Madura Clothing
Process Map : Receipt, Verification & Issue Of Products Purchased
Manufacturing (Store)
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
19© Rashmi Rao, Projects, Madura Clothing
Process Map : Approval Of New Supplier
Manufacturing (Store)
Rejected
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
20© Rashmi Rao, Projects, Madura Clothing
Process Map : Supplier Evaluation & Re-evaluation
Manufacturing (Store)
Withdraw supplier approval and amend approved supplier
list
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
22© Rashmi Rao, Projects, Madura Clothing
Process Map : Lab
Lab
Yes
No
End
Result Approved?
6
Receipt of sample1
Start
Manufacturing (Store)
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
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
23© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Centralized Planning
L1 processes
Centralized Planning
1. Centralized Planning
24© Rashmi Rao, Projects, Madura Clothing
Process Map : Centralized Planning
End
Risk Analysis for Quality feasibility with A4
size swatches
1
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
25© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Factory Planning
L1 processes
Factory Planning
1. FCL Factory Planning Process
26© Rashmi Rao, Projects, Madura Clothing
Process Map : Factory Planning
End
Receipt of BCDS1
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
27© Rashmi Rao, Projects, Madura Clothing
L1 Processes in CAD
L1 processes
CAD
1. FCL CAD Process
1. Sample development
2. For regular production
3. Sample Pattern development
28© Rashmi Rao, Projects, Madura Clothing
Process Map : CAD (Sample Development)
Brand (Merchandiser & designer)
CAD
(Sampling Section)
Receipt of sample indent
1
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
29© Rashmi Rao, Projects, Madura Clothing
Process Map : CAD (For Regular Production)
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
30© Rashmi Rao, Projects, Madura Clothing
Process Map : CAD (Sample Pattern Development)
CAD
End
Receipt of specification sheet from brand to make proto (development) sample
1
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Start
Development of pattern in PDS as per specification
2
Print pattern using plotter3
Make hard Pattern4
31© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Cutting
L1 processes
Cutting
1. FCL Cutting Process
1. Cutting(Plain fabric)
2. Cutting(Stripes & checks fabric)
32© Rashmi Rao, Projects, Madura Clothing
Process Map : Cutting (Plain Fabrics)
Receipt of CAD marker & lay plan
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
33© Rashmi Rao, Projects, Madura Clothing
Process Map : Cutting (Stripes & Checks Fabrics)
Receipt of CAD marker & lay plan
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Start
Manufacturing (Fabric/Trims Stores)
Manufacturing (Cutting)
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
34© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Sewing
L1 processes
Sewing
1. FCL Sewing Process
35© Rashmi Rao, Projects, Madura Clothing
Process Map : Sewing(Shirts)
PPC
Manufacturing (Finishing)
Manufacturing (Sewing)
Manufacturing (Fabric/Trims Stores)
End
Production plan & line plan
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Start
Manufacturing (Cutting)
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
36© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Finishing
L1 processes
Finishing
1. FCL Finishing Process
37© Rashmi Rao, Projects, Madura Clothing
Process Map : Finishing
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Start
Manufacturing (Finishing)
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
38© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Warehouse
L1 processes
Warehouse
1. FCL Warehouse Process
39© Rashmi Rao, Projects, Madura Clothing
Process Map : Warehouse
Receipt of finished products
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
41© Rashmi Rao, Projects, Madura Clothing
Process Map : IE SHIRTS
Industrial Engineering(IE)
(Factory)
Merchandising
Receipt of gold seal1
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
42© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Maintenance
L1 processes
Maintenance
1. FCL Maintenance Process
1. Preventive maintenance
2. Breakdown maintenance
3. Critical spares
43© Rashmi Rao, Projects, Madura Clothing
Process Map : Preventive maintenance
Maintenance Dept
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
44© Rashmi Rao, Projects, Madura Clothing
Process Map : Breakdown maintenance
Maintenance Dept
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
45© Rashmi Rao, Projects, Madura Clothing
Process Map : Critical Spares
Maintenance Dept
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
46© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Vapourphase
L1 processes
Vapourphase
1. FCL Vapourphase Process
47© Rashmi Rao, Projects, Madura Clothing
Process Map : Vapour Phase
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
48© Rashmi Rao, Projects, Madura Clothing
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
49© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Stores
L1 processes
Stores
1. CCPL Stores Process
1. Fabric Store
2. Trims Store
3. Regular Purchase
4. Indent Purchase
50© Rashmi Rao, Projects, Madura Clothing
Process Map : Fabric Stores
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
51© Rashmi Rao, Projects, Madura Clothing
Process Map : Trims Stores
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
52© Rashmi Rao, Projects, Madura Clothing
Process Map : Regular Purchase
Suppliers
Manufacturing (Store)
Supply
Yes
No
ReportEnd
Garments Production – In-house Factories (4b.3)
Material
Quality Approved4
Visual checking 3
Material Return Dispatch5
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Material return
RN(Receipt Note) in system
6
Material issue
7
Receipt of material indent
1
Start
PO Raise2
53© Rashmi Rao, Projects, Madura Clothing
Process Map : Indent Purchase
Suppliers
Management
Manufacturing (Store)
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
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Material return
RN(Receipt Note) in system
6
Material issue
7
Approval from FM
PO RaiseReceipt of material
indent 1
Start
54© Rashmi Rao, Projects, Madura Clothing
L1 Processes in IE
L1 processes
IE
1. CCPL IE Process
1. IE(Trousers)
2. IE(Jackets)
55© Rashmi Rao, Projects, Madura Clothing
Process Map : IE (Trousers)
Industrial Engineering(IE)
Factory
Merchandising
Receipt of gold seal1
2
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Start
Gold seal
End
Man/M/c allocation7
Conduct method study
8Design workplace
layout
9
Prepare final OBD & freeze SMV 10
Analyze daily production report
11 Calculate factory efficiency on daily basis
12
Time study for bottle necks
13
Coordinate with supervisors & create awareness of their
operators performance
14 Coordinate with operators & encourage to practice
effective methods15
Initiate continual improvement activities
16
Prepare factory efficiency & other MIS
17
YesNo
Costing3
FM approval
4 Updation activity code in SAP
Prepare OBD2
5
Costing mail to be send for brand
6
56© Rashmi Rao, Projects, Madura Clothing
Process Map : IE (Jacket)
Industrial Engineering(IE)
Factory
Merchandising
Receipt of gold seal1
2
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Start
Man/M/c allocation
Conduct method study
Gold seal
Design workplace layout
Prepare final OBD & freeze SMV
Analyze daily production report
Coordinate with operators & encourage to practice
effective methods
Prepare factory efficiency & other MIS
End
Initiate continual improvement activities
7
8 9
10
11 Calculate factory efficiency on daily basis
12
Time study for bottle necks
13
Coordinate with supervisors & create awareness of their
operators performance
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
58© Rashmi Rao, Projects, Madura Clothing
Process Map : Lab
Lab
Yes
No
End
Result Approved?
6
Receipt of sample1
Start
Manufacturing (Store)
Sourcing / PDQA
Fabric , trims, garments
Fabric ,trims, garments
Yes
No
Approved?8
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
59© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Factory Planning
L1 processes
Factory Planning
1. CCPL Factory Planning Process
60© Rashmi Rao, Projects, Madura Clothing
Process Map : Factory Planning
CAD
Receipt of BCDS
End
1
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
61© Rashmi Rao, Projects, Madura Clothing
L1 Processes in CAD
L1 processes
CAD
1. CCPL CAD Process
1. Sample development
2. Production Marker development
62© Rashmi Rao, Projects, Madura Clothing
Process Map : CAD (Sample Development)
Brand sourcing
CAD
End
Receipt of sample indent & control sheet
1
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
63© Rashmi Rao, Projects, Madura Clothing
Process Map : CAD (Production Marker Development)
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
64© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Cutting
L1 processes
Cutting
1. CCPL Cutting Process
65© Rashmi Rao, Projects, Madura Clothing
Process Map : Cutting
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Start
Manufacturing (Fabric/Trims Stores)
Manufacturing (Cutting)
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
66© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Sewing
L1 processes
Sewing
1. CCPL Sewing Process
67© Rashmi Rao, Projects, Madura Clothing
Process Map : Sewing(Trousers)
PPC
Manufacturing (Finishing)
Manufacturing (Sewing)
Manufacturing (Fabric/Trims Stores)
End
Production plan
Receive production plan
1
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Start
Manufacturing (Cutting)
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
68© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Finishing
L1 processes
Finishing
1. CCPL Finishing Process
69© Rashmi Rao, Projects, Madura Clothing
Process Map : Finishing(Trousers)
Manufacturing (Finishing)
Manufacturing (Sewing)
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Start
Garments
Receive material1
Loose thread sucking2
Side seam iron3
Legger pressing4
Topper pressing5
Issue to FQC6
70© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Warehouse
L1 processes
Warehouse
1. CCPL Warehouse Process
71© Rashmi Rao, Projects, Madura Clothing
Process Map : Dispatch (TROUSERS)
Receipt of garments
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
72© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Quality
L1 processes
Quality
1. CCPL Quality Process
73© Rashmi Rao, Projects, Madura Clothing
Process Map : Quality(Trousers)
FQA
Sewing
CAD
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
Check operators for quality
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
74© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Sewing
L1 processes
Sewing
1. CCPL Sewing Process
75© Rashmi Rao, Projects, Madura Clothing
Process Map : Sewing(Jackets)
PPC
Manufacturing (Finishing)
Manufacturing (Sewing)
Manufacturing (Fabric/Trims Stores)
Receive plan
Issue to Finishing
Inspection
Yes
End
Section wise planning
1
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
Start
8
Receive material
Manufacturing (Cutting)
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
76© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Finishing
L1 processes
Finishing
1. CCPL Finishing Process
77© Rashmi Rao, Projects, Madura Clothing
Process Map : Finishing(Jackets)
Manufacturing (Finishing)
Manufacturing (Sewing)
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
78© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Warehouse
L1 processes
Warehouse
1. CCPL Warehouse Process
79© Rashmi Rao, Projects, Madura Clothing
Process Map : Dispatch (JACKETS)
Receipt of garments
End
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
80© Rashmi Rao, Projects, Madura Clothing
L1 Processes in Quality
L1 processes
Quality
1. CCPL Quality Process
81© Rashmi Rao, Projects, Madura Clothing
Process Map : Quality(Jackets)
FQA
Sewing
CAD
L2 processes within L1 process
Output Interfaces
External process
Inter-linked L1 processes
Stored DataDecision EventInput
Interfaces T - Template
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
Check operators for quality
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