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    A Summer Internship Reporton Streamlining of process and Development ofStandard Operating Procedure for the Trims Storesubmitted in partial

    Fulfilment of the requirement for the award of Degree in

    Bachelor of Fashion Technology-Apparel Production

    Department of Fashion Technology

    NATIONAL INSTITUTE OF FASHION TECHNOLOGY

    CHENNAI

    MONTH BATCH

    Submitted by:Apoorva meshram

    (B.F.TECH,(AP))

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    INTRODUCTION TO STANDARD OPERATING PROCEDURE

    A Standard Operating Procedure (SOP) is a set of written instructions that document

    a routine or repetitive activity followed by an organization. It is a guideline that clearly

    spells out what is expected and required of personals. SOPs defines a standard

    procedure based on which a department is supposed to function.

    An SOP is a written document or instruction detailing all relevant steps and activities

    of a process or procedure. An SOP provides employees with a reference to common

    business practices, activities, or tasks. New employees use an SOP to answer

    questions without having to interrupt supervisors to ask how an operation is

    performed. The SOP used in any manufacturing process that could affect the quality

    of the product.

    SOPs are detailed written instructions to achieve uniformity of the performance of a

    specific function.

    Standard Operating Procedures (SOPs) should be transferred without every

    modification to insure the expected results. Every modification or divergence of a

    given standard, the Procedure should being served, while an investigation and

    results of the investigation documented according to the internal divergence

    procedure. All high-class processes and procedures should be put on in a Standard

    Operating Procedure.

    A Standard Operating Procedure is a document which describes the regularly

    recurring operations relevant to the quality of the investigation. The purpose of a

    SOP is to carry out the operations correctly and always in the same manner. A SOP

    should be available at the place where the work is done.

    A SOP is a compulsory instruction. If deviations from this instruction are allowed, the

    conditions for these should be documented including who can give permission for

    this and what exactly the complete procedure will be. The original should rest at a

    secure place while working copies should be authenticated with stamps and/or

    signatures of authorized persons.

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    INTRODUCTION TO TRIMS STORE

    Trims store is used to store all the trims needed in the manufacturing, finishing and

    packaging of trousers and jackets. Its basic function is the inspection and storage of

    trims before sewing starts and easy issue of trims according to the need.

    The acceptance of the raw materials or the accessories is generally done in terms of

    documents i.e., whatever it may be whether acceptance or revival, they are done

    according to the documents that have been received from the suppliers and the

    department also makes the document for anything they carry out within their roof.

    The basic purpose of existence of the store is to:

    Store the trims in inventory before sewing starts:

    The trims are received two to three months before the loading of an order.

    Meanwhile these trims are required to be stored, inspected quantitatively and

    qualitatively and kept ready for sewing. Trims store does the job of receiving the

    trims and storing them temporarily until the sewing starts.

    To inspect the trims before sewing starts:

    Before the issue of trims to the lines, they need to be checked for all possible defects

    so they do not cause quality problems in the end product. The quality of the trims

    has an effect on the quality of the garment being produced and can easily be a

    source for the rejection of the garment. So the quantity and quality of the trims

    received are checked according to set standards.

    The trims store follows 100% quantity checking of trims,

    For quality checking of trims it follows 2.5 Acceptance Quality Level (AQL)

    Keep them ready both qualitatively and quantitatively before sewing starts:

    The store does the quantity and quality checking of trims, but it is important to keep

    the trims ready before the sewing of the particular order starts. The trims need to be

    available to the sewing lines in time. Trims store ensures the availability of trims to

    the sewing line. The store is responsible for easy availability of all kinds of trims to

    the lines.

    The store manages stationary requirements of the industry:

    The trims store is responsible the stationary requirements of the industry. It takes the

    requisition from all the departments and manages monthly requirement according to

    the need of the industry.

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    TYPES OF TRIMS

    The trims include:

    - Sewing trims

    - Finishing and packing trims

    SEWING TRIMS FOR JACKET, TROUSERS AND VESTCOAT

    Main Label:

    It is the label containing the brand name and usually attached above the

    cigarette pocket in jackets and welt pocket in trousers.

    Hanger Loop Label:

    It is the label containing the brand name and usually below the collar band

    (neck) for hanging purpose of jackets.

    Size Label:

    The label contains the information about the size of the garments and usually

    attached below hanger loop label in jackets and waistband in trousers.

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    Washcare Label:

    The label contains wash care and ironing instructions usually attached at side

    seam of jackets and waist band in trousers.

    Fit Label:

    The fit label gives information about the fit of the trouser like slim fit, comfort

    fit, contemporary fit, smart fit and modern fit.

    Besom Tape:

    It is used to give strength and shape to welt pockets (lining) in jackets.

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    Bridal Tape:

    Bridal tape is used to attach shell fabric and canvas panel in jackets.

    Double Sided Fusible Tape With Paper:

    Used inside the lapel or collar in jackets to hold the shape of shell fabric while

    stitching. It is also used to fix knee lining in trousers.

    Double Sided Fusible Tape Without Paper:

    It is used with shoulder pad to give the strength and shape in jackets and to

    hold waist band lining in trousers. It is also used in side seam of waistcoats.

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    Armhole Tape:

    This tape is used in armhole of jacket to give shape and gives ease in

    stitching.

    Piping:It is a thin strip of fabric in roll form sewn between the lapel and lining of the

    jacket.

    Buttons:

    It is a small disc or knob sewn to a garment, either to fasten it by being

    pushed through a slit made for the purpose, or for decoration. They come in

    various sizes measured in ligne (L) (1l = 1/40 of an inch).

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    Usually the sizes used for jackets are 24L and 32L

    Sizes used for trousers are 24L and 27L

    Shoulder Pads:

    Shoulder pads are small pad made up of felt inserted to raise or give shape to

    the shoulder of the jacket.

    Belt Loop Fusing:

    It is the fusing used to make belt loop for trousers. Belt loop is attached to the

    waistband of trousers.

    Ban Roll:

    It is the fusing used in the waistband of trousers to give shape and hardnessto the waistband.

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    Hook And Bar:

    Hook and bar is attached to the waistband front of the trousers. It is used for

    the closure of the waistband in trousers.

    Zipper:

    A fastening device consisting of parallel rows of metal, plastic or nylon teeth

    on adjacent edges of an opening that are interlocked by a sliding tab.

    Slider:

    The sliding tab which is used to interlock the teeth in a zipper tape is called a

    slider.

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    Waist Band Lining:

    It is attached to the waistband in trousers for ornamentation and

    strengthening.

    Binding Tape:Binding tape is used in trousers for binding front and back rise and zipper fly.

    The use of binding tape changes according to the order.

    Sleeve Label:

    It contains the brand name and is attached to the sleeve of a jacket.

    Buckle:

    It is used in waistcoat for fastening of belt and is attached to the back of

    waistcoat to the belt. The fastening of belt provides some shaping and makes

    the vest look slimmer.

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    Threads:

    They are long thin strands cotton, nylon or other fibers used in sewing which

    come in various lengths and ticket numbers.

    Different tickets threads are used for different purposes.

    TICKET NUMBER USED FOR

    30 Button wrapping

    70 Button hole

    80 Button hole

    100 Top stitch

    120 Top stitch

    150 Lining

    160 Overlock surging

    180 Bottom hem

    240 Bottom hem

    360 Bottom hem

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    FINISHING AND PACKING TRIMS:

    Hangers:

    It is a shaped piece of wood, plastic, or metal with a hook at the top which is used for

    hanging garments.

    Danglers:

    It is made up of cardboard paper and hung loosely on the garment using

    button with strings. It contains information about brand, styles etc.

    Loop lock tag pin:

    loop lock tag pin is used to attach price tags to the garments.

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    U-Clip:

    It is a packing trim used for packing of trousers. A trouser is folded around the

    back clip board and u-clip is used to secure the trouser on the board.

    Button With String:

    It contains the brand name is inserted in keyhole in jackets.

    Polybags:

    Poly bags are used in the packing of trousers and jackets before they are

    packed in cartons.

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    Cartons:

    Cartons are cardboard containers which are used in the packing of garments.

    Barcode sticker:

    Size Rings:

    These are attached to the hook of the hangers and are used to display the

    size of the garment.

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    Gum tape: It is used to secure the cartons after packing of garments inside

    the cartons.

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    IMPORTANT TERMS

    TRIMS:

    Trims are defined as items that go into the production of the final garment and are classified

    as embellishments. Examples of trims include tags, labels, buttons, zippers, buckles, threadspacking material etc.

    RAL:

    RAL stands for orders related to Raymond and includes park avenue, Raymond, Parx etc. It

    stands for Raymond apparel limited.

    EXPORT ORDERS:

    It stands for orders to be exported like Levis, Palestorm, Metalan, Louis Philippe etc.

    QUALITY:

    It is the characteristic of the trims that will satisfy stated and implied needs and

    specifications. It states that the trims are free from defects, deficiencies, and significant

    variations which is important in achieving uniformity of output that satisfies specific

    customer or user requirements.

    QUANTITY:

    Quantity is an exact or specified amount of measure of trims.

    SLITTING MATERIAL:

    Slitting material is received from the fabric department. It consists of tapes which are cut

    from rolls of fabrics and fusing in the fabric department. It includes trims like Bridle tape,

    besom tape, banrol, belt loop fusing, binding tape, piping and knee lining.

    SWATCH CARD:

    These are cards to which sample of received trims are attached to get the approval of

    merchandiser in order to know the received trims matches the specifications of the ordered

    trims.

    GROSS:

    It is the quantity for the measurement of buttons. Each gross consists of 144 buttons.

    LOT:

    A lot is total number of garments required in a particular style for particular brand and

    garment. It is further divided into various POs based upon different colors and other

    variations.

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    BILL OF MATERIAL (BOM):

    A BOM is a list of all the trims which are required for a particular lot. It gives details about

    the quantity, types of trims, content of trims (in case of labels), consumption per garment and

    order quantity.

    PURCHASE ORDER (PO):

    A purchase order is a document issued by a buyer to a seller indicating types, quantities etc.

    for the products the seller will provide to the buyer.

    AQL:

    A statistical measurement of the maximum number of defective goods considered acceptable

    in a particular sample size. If the acceptable quality level (AQL) is not reached for a

    particular sample of goods, 100% checking of the material is done and the rejected goods arereturned to the supplier.

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    DELIVERY CHALAN (DC):

    It is the receipt of receiving of trims which is received along with the trims when they are

    delivered. It contains information about the quantity and types of material received. It also

    gives information about the buyer, order number and reference number of the material.

    STAGE:

    Stage is the software which manages all the information about the trims. It stores the

    information about the quantity of the trims received and inspected, gives location to the trims

    and maintains information about the balance trims. GRN and PO are prepared in stage.

    GRN:

    It is a document which is used to record the inward entry of the trims in the store. The

    document consists of the quantity of material received. It is prepared in stage.

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    MATERIAL REQUISITION SLIP (MRS):

    Material requisition slip is a document prepared at the time of issuing of materials from store

    to the production line. It is an authentic document without which the trims should not be

    issued. It helps in updating the stock. It states the types of trims and issued quantity.

    BIN CARD:

    All the trims which are allocated to a location have a bin card. A bin card containsinformation about the actual quantity of trims which are stored in the rack, the total quantity

    issued to the lines and the remaining amount left in the rack. It is updated against the material

    requisition slip.

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    CUT QUANTITY:

    Total number of garment quantity cut at a given time is the cut quantity. It specifies the

    number and sizes of a garment cut at a given time.

    CUTTING SLIP:

    Cutting slip tells the cut quantity at a given time. It is received from cutting department and

    the trims are issued according to the cutting slip.

    MATERIAL REQUISITION SLIP:

    MRS is a document prepared at the time when the material is issued from stores to the

    production line. Without MRS trims should not be issued to the lines. It contains the date,

    type and quantity of the trims issued.

    STATEMENT:

    Statement is prepared to keep track of quantity of trims. It is used to check whether all the

    trims are received and if not how many trims are yet to come.

    SIZE BREAKUP SHEET:

    This document is attached with the BOM and it tells the size breakup of garments in a

    particular lot i.e. how many garments of which sizes are there in a lot.

    THREAD SHEET:

    This sheet is also attached with BOM and it tells what quantity of what count thread is

    required for a particular lot.

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    SECTIONS OF STORE

    The trims store is divided into two parts:

    a) Sewing trims store

    b) Packing trims store

    Sewing trims store:

    It deals with storing and checking of all types of sewing trims. The store performs all

    the functions for the sewing trims from receiving of the trims to storage and issue.

    Packing trims store:

    Packing store deals with the storing and checking of all the packing trims. The trims

    are received and stored in incoming goods area of the sewing trims store. There they

    are checked for quality and quantity. GRN for packing trims is made and the system

    location in stage is given. Then the packing trims are transferred to the packing store

    where physical location to the material is given and BIN card is maintained. The

    issue for packing material is done in the packing store and it is updated in stage.

    INCOMING GOODS STORAGE AREA

    Incoming goods storage area consists of a single rack and specific floor sections of

    store. This area is used to temporarily store the goods when they are received. As

    soon as the trims are received they are stored in the incoming goods area to be

    checked for quality and quantity. Materials of large sizes like shoulder pads arestored on the floor in specific area highlighted with yellow tape.

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    It consists of a rack which is divided into 12 sections. Shoulder pads are stored on

    the floor. Packing trims are also stored in the incoming goods storage area except

    for materials like hangers, polybags, cartons and dividers which are of large sizes.

    These materials are directly taken to the packing store and checked for quantity and

    quality. Cartons, dividers and polybags are stored in specific floor locations in thepacking store.

    Cartons and hangers are also stored in fabric area due to lack of space in the

    packing store.

    RECEIVED TRIMS STORAGE AREA (SEWING TRIMS STORE)

    The storage area consists of seven racks. One rack is allocated to export orders and

    other 6 racks stores trims related to RAL (Raymond Apparel Limited) orders. Each

    rack is divided into 28 sections.

    RACK 1 - It stores trims related to export orders.

    The trims include:

    Labels

    Buttons

    Banrol

    Buckles

    Heel tape

    Armhole tape Satin tape

    Bridal tape

    Fusing with paper

    Fusing without paper

    Zippers

    Zipper sliders

    In this rack the trims are segregated according to order type. Trims of the same

    order are stored together.

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    RACK 2 - Stores zipper tapes and sliders

    The second rack stores zipper tapes and sliders for Raymond orders. This rack also

    has 28 sections. The zipper tapes and sliders are segregated according to their color

    and the matching zipper tapes and sliders are stored in a single rack.

    RACK 3 - Front: Labels and slitting material

    Back: Buttons

    The third rack stores labels, slitting material and buttons for Raymond orders. The

    trims are stored according to their type and color.

    Same buttons and slitting materials are stored together. Labels are stored according

    to the order.

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    RACK 4 Front: Labels

    Back: threads

    This rack stores labels and threads for Raymond order.

    Threads are stored according to their color and labels are stored according to the

    order.

    RACK 5 Threads

    The fifth rack stores threads for Raymond orders.

    The threads are segregated according to their color.

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    RACK 6 Threads

    The sixth rack stores threads for export orders. Here also the threads are

    distinguished based on their color.

    RACK 7 Waistband lining

    Waistband lining for both export and Raymond orders are stored in the seventh rack.

    Waistband lining comes in roll form and is kept in cartons based on the order.

    Waistband lining for an order is stored in a single carton and kept in the rack.

    All the racks are labelled which helps in easy searching of material. Bin cards aremaintained for each material and kept in the rack. They are updated against every

    issue which helps in keeping track of quantity of remaining material in rack.

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    RECEIVED TRIMS STORAGE AREA (PACKING TRIMS STORE)

    It consists 9 racks in total rest all are floor locations. 6 of the racks have 10 small

    sections and the rest 2 have 14 sections each.

    RACK 1- It stores danglers, size rings and sleeve tags. These are segregatedaccording to trims type and order for both export and Raymond orders. Trims for

    same order are kept together.

    RACK 2- It stores hanger chips and hang tags according to order for both Raymond

    and export orders.

    RACK 3/RACK 4- It stores danglers which are segregated according to order for

    both Raymond and export orders.

    RACK 5- It stores rings and gum tape sorted on the basis of order for both export

    and trims.

    RACK 6- It stores hang tags and size rings for Raymond and export orders.

    RACK 7- It contains joker tags and RFID stickers for both Raymond and export

    orders.

    RACK 8 (14 sections) - It stores U-clips and danglers for both Raymond and export

    orders.

    RACK 9 (14 sections) - It stores danglers, size rings, joker tags and RFID stickers for

    both export and Raymond orders.

    The packing store consists of a ground floor and first floor. The ground floor holds all

    the racks, cartons, polybags, dividers and chip board. The first floor holds all the

    hangers and dead stock. The dead stock is returned to the supplier.

    Cartons, polybags, dividers and hangers are stored on floor. Specific space is

    allotted to each the material and the material is stored order wise in the location. Bin

    cards are maintained for each kind of material. There is a general area for cartons in

    fabric store where all kinds of cartons can be kept due to lack of space in packing

    trims store.

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    QUANTITY AND QUALITY INSPECTION AREA

    Quality inspection area is where the quality and quantity inspection is done. It has

    three tables side by side for simultaneous quality and quantity inspection. The center

    table is used for quality inspection and other two are used for quantity inspection.

    Some amount of floor space is also allocated for keeping the material while

    inspection takes place.

    It contains a bulletin board which describes the 2.5 AQL system, the trims to be

    checked and measurement chart for buttons. There are racks attached to the table

    which is used to keep quantity register and quality checking reports.

    INSPECTED GOODS AREA

    Specific floor space is allocated for inspected goods in front of the quantity and

    quality checking area. After checking the goods are transferred to inspected goods

    area from where they are transferred to the location in racks.

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    REJECTED GOODS AREA

    The rejected goods from quality checking are stored in this area and the total

    quantity of the rejected goods is written on the carton.

    MATERIAL WITHOUT DC AREA

    The material which is received without DC is kept in this area to distinguish the

    material from other material and helps in easy identification and matching with DC

    when it arrives.

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    GRN AREA:

    It consists of two computers where the GRN and inspection report in stage in

    prepared. The GRN of both packing and sewing trims is done in the sewing trims

    store itself. The goods are segregated after quality checking and packing trims are

    transferred to packing store.

    SYSTEM ISSUES AREA

    A computer is allocated for updating the amount of trims issued in stage. The

    quantity issued is subtracted from the actual available quantity to show the remaining

    quantity.

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    PHYSICAL ISSUE TABLE

    There is a specific table allotted for the issue of trims where again the quantity of

    required trims are checked and issued. The issue is done against the material

    requisition slip.

    W/B LINING SHRINKAGE MACHINE

    The store does the shrinkage of waistband lining before it goes to the line. A

    separate area is allocated for the shrinking machine.

    LABEL CUTTING MACHINES

    The store also does cutting of labels for RAL orders which come in the form of roles.

    A label cutting machine is kept in the store for this purpose.

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    STATIONERY AREA

    Separate racks and cupboards are allocated to stationary material. There are two

    cupboards and five racks for stationary material. The stationary material include files,

    folders, white pencils, gum tapes, sketch pens, stamps, markers, papers, registers,

    punching machines, calculators, numbring stickers etc.

    RETURN RACK

    Return rack is used to store all the excess trims which are returned from the sewinglines. The return rack is also used to store dead stock.

    It contains of total 15 racks.

    The trims are store according to item type. Material is also issued from the rack

    when there is a requirement.

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    FUNCTIONS OF TRIMS STORE

    The main functions of the trims store are:

    Receiving trims:

    The trims store receives the trims and tallies the physical quantity and invoice of the

    goods received.

    Temporary storage of the incoming goods

    As soon as the trims are received they are temporarily stored in the incoming goods

    area to be checked for quality and quantity. Materials of large sizes like shoulder

    pads are stored on the floor.

    Quantity check for the incoming trims

    The trims store does 100% quantity inspection of trims is done based on the unit of

    measurement of a particular trim. The physical quantity and invoice of the goods

    received is tallied.

    Buttons are measured in gross. (1GROSS = 144 BUTTONS)

    Tapes and waistband lining in meters.

    Labels, tags, cartons, polybags, pins etc in pieces.

    Quality check as per AQL 2.5

    Quality inspection is done after the quantity inspection. A worker specially trained for

    quality checking is assigned for checking of trims. Quality is checked on predefined

    aspects of trims which vary according to the trims type. For quality checking the trims

    store follows Acceptance Quality Level 2.5.

    AQL specifies the maximum number of defective goods considered acceptable in a

    particular sample size. If the acceptable quality level (AQL) is not reached for a

    particular sample of goods, 100% checking of the material is done and the rejected

    goods are returned to the supplier.

    Storing of goods in respective location

    The goods are stored according to trim type in specific racks. A statement for

    balance material is maintained and follow up for balance material is done.

    Issue the material to the sewing and finishing department

    The store issues the trims against the requisition slip received from lines. The

    requisition slip states the requirement of trims in the sewing line. It is signed against

    the issue and the goods are issued.

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    Update in bin card and stage

    After the issue the bin card is updated to keep track of the number of trims remaining

    in racks and the same is updated in stage.

    Receive returns from sewing lines

    The leftover trims from the sewing lines are returned to the trims store. They are

    stored in separate racks. Common trims such as threads, armhole tapes etc which

    can be used in future orders are kept in the store. Rest of the trims is returned to the

    supplier.

    The material is returned against return material requisition slip.

    The returned numbers are updated in bin card and stage.

    Maintaining monthly stock report

    A monthly stock report is maintained to keep track of the stock in hand. The month

    end is report is made for every month from 26 th of first month to the 26th of the next

    month. It contains the information like the item code, type of material, its size, color

    etc. It gives details about the opening stock, the trims issued and the remaining stock

    which is known as the closing stock of the store.

    Waistband lining shrinkage

    For trousers the shrinkage of waistband lining is done before it is send to the lines.

    This is important because if previous shrinkage is not done the waistband lining

    shrinks while ironing and causes unwanted puckering.

    Label cutting

    Sometimes labels are received in roll form from the suppliers. In such cases cutting

    of labels in individual pieces is done in the trims store. The labels usually are of RAL

    orders and sometimes export orders.

    Attachment of barcode sticker

    The barcode sticker needs to be attached at the back of the hangtag. The store does

    the work of attaching the barcode sticker to the hang tag and then provides it to the

    lines.

    Management of stationary requirements

    There are a lot of stationary requirements of the industry like papers, staples,

    calculators, stamps etc. The store manages all these requirements. It receives

    requisition for the materials from all the departments and provides stationary

    accordingly.

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    MATERIAL FLOW PROCESS

    INCOMING MATERIAL

    UNLOADING

    TAKEN TO TRIMS STORE USING THE LIFT

    STORED IN INCOMING GOODS STORAGE AREA

    100 % QUANTITY CHECKING OF MATERIAL

    2.5 AQL QUALITY CHECKING OF MATERIAL

    STORAGE IN RACKS

    ISSUED ACCORDING TO REQUIREMENT

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    RETURN OF MATERIAL FROM SEWING DEPARTMENT

    STORED IN RETURN MATERIAL RACKS

    RETURNED TO SUPPLIER OR KEPT FOR FUTURE USE

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    MATERIAL FLOW PROCESS IN DETAIL

    a) After the material is received it is unloaded and taken to the trims store using

    trolleys and lift. Usually the material is received from Silver Sparks Apparel

    Limited. The trims are received in cartons with Delivery Chalan.

    b) As soon as the material reaches the trims store, it is temporarily kept in the

    incoming goods storage area and awaits quantity and quality check.

    c) Material is transferred to checking area where it is checked for possible

    defects and variation in quantity

    d) After checking of materials the quality passed material is kept in accepted

    goods area and rejected material is kept in the rejected goods area.

    e) From accepted goods area the material moves to the racks where it is stored

    till the issue.

    f) The trims are issued to the sewing lines against material requisition slip. Thetrims left in the sewing line are returned to the store. These trims are stored in

    the return racks from where they are either send to the supplier or kept in the

    store for future use.

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    PREVIOUS SOP OF THE STORE

    Collection of DC from security with seal

    Entry in DC inward book

    Material stored in incoming goods storage area

    100% Quantity Check Entry in material inward register

    Quality checking 2.5 AQL

    Material stored in inspected goods area Material stored in rejected goods area

    Preparation of swatch cards Material returned to supplier for

    replacement

    Approval of swatch cards In case of rejection material returned

    to supplier for replacement

    Preparation of statement against BOM

    A

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    Cross checking with DC quantity

    Preparation of Purchase Order PO number stored in PO book

    GRN preparation Attached with DC

    QC pass report made in STAGE Attached with DC

    A

    System location given to material

    Physical shifting of material against

    location report

    Updating of bin card on the inward of

    material

    Issue of trims to lines against cutting slip

    Updating of bin card on outward of

    material

    B

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    Receiving of excess material from lines

    against requisition slip

    Storing of trims with respect to the location

    of issue

    B

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    PROCESS IN DETAIL

    Receiving of material

    The process starts with arriving of the trims to the trims store. The material is usually

    received from Silver Sparks Apparel limited in trucks. The material is also received

    from other suppliers which mostly include stationary material and sometimes trims.

    Collection of dc from security with seal

    The material received is accompanied by a Delivery Chalan which is made in SSAL.

    It is the receipt of receiving of trims which is received along with the trims when they

    are delivered. It contains information about the quantity and types of material

    received. It also gives information about the buyer, order number and referencenumber of the material.

    When the material is received, it is taken for unloading and DCs are submitted at the

    security where the entry of DC number is done in the DC register and security seal is

    put on the DC. The security seal gives information about the in time of the material

    and the date of material received.

    After the seal is been put to the DC, it is collected by the trims store worker for

    documentation purpose.

    Entry in dc inward book

    When the DC is received the entry of DC number and lot number is done in the DC

    inward register date wise to know what all DCs are received on a particular date.

    Material stored in incoming goods storage area

    As soon as the material reaches the trims store, it is temporarily stored in the

    incoming goods storage area for quantity and quality checking. Only after the

    checking the documentation can be done and a more permanent location can be

    allocated to the trims.

    Received material cannot directly go for quantity and quality as there is a large

    quantity and everything cannot be checked at the same time. So the material is

    stored temporarily in the incoming goods storage area and is taken one by one for

    checking. Material which is urgently required is given preference over other

    materials.

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    100% quantity check

    The trims store does 100% quantity inspection of trims is done based on the unit of

    measurement of a particular trim. The physical quantity and invoice of the goods

    received is tallied.

    Buttons are measured in gross. (1GRASS = 144 BUTTONS)

    They are received in packets.

    Tapes and waistband lining in meters and number of rolls.

    Tapes and waistband lining is received in the form of rolls.

    Labels, tags, cartons, polybags, pins etc in pieces.

    These are received in packets.

    Threads in tubes and cones.

    Threads are received in boxes.

    Shoulder pads are measured in pairs.

    These are received in cartons.

    Sealed packets have the exact quantity as mentioned, therefore only the number of

    packets are counted. 100% quantity checking for loose packets is done.

    For quantity checking of tapes and waistband lining, numbers of rolls are counted.

    For quantity checking of threads number of boxes and tubes/cones are counted.

    After quantity checking, the DC is passed to the quality checking worker for quality

    checking.

    Entry in material inward register

    After the checking of trims the quantity received entered in the quantity inward

    register. The quantity of the received material is tallied with the DC quantity.

    Quality checking 2.5 AQL

    Quality inspection is done after the quantity inspection. A worker specially trained for

    quality checking is assigned for checking of trims. Quality is checked on predefined

    aspects of trims which vary according to the trims type. For quality checking the trimsstore follows Acceptance Quality Level 2.5.

    AQL specifies the maximum number of defective goods considered acceptable in a

    particular sample size. If the acceptable quality level (AQL) is not reached for a

    particular sample of goods, 100% checking of the material is done and the rejected

    goods are returned to the supplier.

    The sample size for different quantity of goods can be known by the 2.5 AQL chart.

    Two important things for the checking of the material are BOM and DC.

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    A BOM is a bill of material which is provided by the merchandising department. BOM

    contains the type, quantity and consumption per garment of trims for a particular lot.

    It also contains the contents of trims like labels, tags etc which need to be verified.

    Thus, quality checking is done against BOM.

    DC is required for the preparation of quality report. Quality report contains the

    information about the total quantity, type of trims, number of pieces checked for

    quality, total number of pieces rejected, GRN number and DC number. It also

    contains the sample of the trim checked. If the total number of pieces rejected is

    more than the defected pieces allowed in 2.5 AQL, the whole quantity of the trims is

    rejected.

    In case of rejection of trims, 100% quality checking is done and the rejected trims are

    returned to the supplier for replacement.

    Firstly, the DC and BOM are taken and the trims are checked for contents. The trimsshould have the correct content according to the BOM.

    If the content is correct, the trims are checked for possible defects. After checking an

    inspection report is prepared with the sample of the trims. The report contains the

    information about the total quantity of the trims, quantity inspected, defects occurred

    and the quantity rejected.

    In case of rejection, 100% checking of the goods in done and the rejected goods are

    returned to the supplier for replacement.

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    2.5 AQL Inspection Chart

    Lot / Batch Size

    From To

    Sample Lotto be

    inspected

    Acceptance

    Lot/Nos

    Rejection

    Lot/Nos

    2 to 8 2 0 1

    9 to 15 3 0 1

    16 to 25 5 0 1

    26 to 50 8 0 1

    51 to 90 13 1 2

    91 to 150 20 1 2

    151 to 280 32 2 3

    281 to 500 50 3 4

    501 to 1200 80 5 6

    1201 to 3200 125 7 8

    3201 to 10000 200 10 11

    10001 to 35000 315 14 15

    35001 to 150000 500 21 22

    150001 to 500000 800 21 22

    500001 to Over 1250 21 22

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    Material stored in inspected goods area and rejected goods area

    After the quality inspection, the quality passed trims are stored in inspected goods

    area. Floor space is allocated to the trims which are inspected. The trims which are

    rejected are stored in a separate area which is known as the rejected goods storage

    area. Separate rack is allocated to keep rejected trims.

    Material returned to supplier for replacement

    The rejected trims are returned to the supplier and in the meantime they are stored

    in rejected goods area to differentiate them from other trims. When they are received

    back, again the process starts from quantity checking.

    Preparation of swatch cards

    After the checking of trims swatch cards are prepared. Swatch card contains the

    sample of the trims received. These cards are sent to various departments which

    include production, merchandising, quality, finishing and one is used for the store.

    The approval for the trims is taken and then only the process is carried on further.

    Approval of swatch cards

    The swatch cards are approved by the merchandiser. If it is approved, it indicates

    that the trims are good to use and the process goes to the next step i.e. the

    preparation of statement.

    If the merchandiser does not approve the swatch card, the trims are returned to thesupplier for replacement. When the replacement trims are received, the process

    again starts from quantity checking. When they are received back, again the process

    starts from quantity checking.

    Preparation of statement against BOM

    After the approval of swatch cards, the statement is prepared in excel. The

    statement is prepared referring to the BOM. BOM is a document which is received to

    the store from the merchandising department and contains information about the

    quantity of trims required for a single lot.

    The statement contains the quantity of the trims which are mentioned in the BOM.

    Cross checking with DC quantity

    The BOM quantity is mentioned in the statement. The BOM quantity is cross

    checked with the actual received quantity. Statement is a reference to know which

    material is not received for a particular lot.

    After the preparation of statement the supplier is contacted to inquire about the

    balance material and to send the material as soon as possible.

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    Preparation of Purchase Order (PO)

    Purchase order is a document issued by a buyer to the seller indicating types,

    quantities etc. for the products the seller will provide to the buyer. For the goods

    which are not received from SSAL, purchase order and invoice for the goods is

    provided by the seller.

    PO number acts as a reference for a particular lot. It is the identity of trims belonging

    in the same lot.

    For the goods which are received from SSAL, the PO is prepared in the trims store

    and a single PO number is given to the trims of a particular lot. PO number acts as a

    reference for all the trims of a particular lot.

    If balance material of a particular lot is received the quantity is modified in a

    particular PO. If the balance material is thread, a new PO is created becausequantity of threads cannot be modified.

    Purchase Order is prepared in STAGE.

    PO number stored in PO book

    The PO number generated while preparing PO is stored in PO book.

    GRN preparation

    Goods receipt note is a document which is used to record the inward entry of trims

    received in the store. The document contains the details of quantity of trims received.

    GRN is prepared after the PO in STAGE. One GRN is prepared for every DC. A

    copy of GRN is attached with DC.

    QC pass report made in STAGE

    After the GRN preparation, the quality status of the trims is updated in STAGE.

    Inspection report carries the details of quantity of the material which passed quality

    check. If trims are rejected, it is mentioned in the inspection report. Inspection report

    can only be made of the DCs for which GRN is already made. . A copy of inspection

    report is attached to the DC.

    System location given to material

    In the next step location is allocated to the QC passed trims because they need to be

    stored before sewing starts. Before the physical allocation of trims to the rack,

    location planning needs to be done which is done in STAGE. Empty locations are

    checked and the location is shifted from floor to the respective rack number. A

    location report is generated which shows the quantity, type of and location of the

    trims. A print out of the location report is taken and a separate file is maintained to

    keep all the location reports for future reference.

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    Physical shifting of material against location report

    After giving system location to the material, it is physically shifted to the location. The

    shifting is done by the issue worker because it helps in the time of issue if the worker

    knows the location of the material. The material is shifted from the inspected goods

    area (floor) to the location allocated in stage. Usually trolleys are used to transfer the

    material. Shifting is also done by hand.

    Updating of bin card on the inward of material

    Bin card is used to keep track of the material which is stored in the racks. Every rack

    has a bin card which is updated as soon as the material is shifted to the rack. It

    contains the details of the quantity, type and lot number of the material which is

    present in a rack.

    Bin card is kept in the rack after the shifting of material. The total quantity of thematerial, its lot number and the date of inward of material is updated in the bin card

    Issue of trims to lines against cutting slip

    The trims are issued to the lines against cutting slip. Cutting slip gives the number of

    garments cut in a given time. According to the cut quantity and the consumption of

    trims per garment, the trims are issued.

    The sewing line has an operator which is known as the feeding helper. The feeding

    helper comes to the trims store with the cutting slip and requisition slip. The number

    of trims required are counted base on consumption per garment and cutting slip by

    the issue worker. The total quantity of trims issued is written on the material

    requisition slip. The feeding helper takes the trims to the sewing lines and issues

    them according to need.

    Issue in stage

    After the issue of the material, the issue is done in stage. The quantity of the issued

    material is subtracted from the available quantity (in stage) so that the system shows

    the actual remaining quantity.

    Updating of bin card on outward of material

    After the material is issued the bin card is updated. The issued quantity is subtracted

    from the previous quantity and the current quantity is written in the bin card.

    When the material is issued to sewing lines, the issued quantity is updated in the bin

    card and subtracted from the actual available quantity.

    Receiving of excess material from lines against requisition slip

    The excess material which is left in the sewing line after production is returned to thestore against return slip. Return slip is a document which states the quantity, lot and

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    type of material which is returned. The quantity is checked and the material is again

    stored in the store.

    The returned quantity is updated in STAGE.

    Storing of trims with respect to the location of issue

    The trims are then given location according to the location of issue.

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    TRIMS STORE MACHINERY DETAILS

    MACHINE TYPE NUMBER OF MACHINES MODEL NO

    LABEL CUTTING MACHINE 1 -

    W/B LINING SHRINKAGEMACHINE

    2 PRETEX PFC 320

    WEIGHING MACHINE 1 CONTECH CT35K2

    W/B LINING ROLLINGMACHINE

    1 GAST GR-II

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    SHORTCOMINGS

    PROBLEM 1

    Problem in identifying and misplacement of the goods in case of goods

    received without DC.

    The goods which are received without DC are easily misplaced and get lost as no

    track of such goods are kept because of the lack of proper documents.

    The entry can only be done in STAGE if a DC is present and there have been cases

    where the DCs are not received and material goes missing or issued to lines for

    urgent orders without the knowledge of the Store Manager.

    The missing material only gets noticed at the last hour when there is an urgent need.

    SOLUTION

    Maintaining a separate rack for goods which are received without DC.

    There is no permanent place for storing these goods and hence they go missing

    easily without coming into anyones notice.

    Maintaining a permanent place to store these goods will ensure that everyone from

    the store head to the workers know that the DC of these goods has not beenreceived. It helps in easy identification of material and when the DC arrives, it can

    easily be matched with the goods and the process can be carried on further.

    A bin card is to be maintained in the rack. This helps in keeping track of the goods

    which are in the rack. The goods can be issued and the issued quantity can be

    subtracted from the actual quantity of the material.

    A different process for balance material can be followed. STAGE accepts returns

    from sewing lines and return material quantity is added in the actual available

    quantity. The quantity of the balance material can be updated and location can be

    allocated as return material in STAGE. The balance material can be stored as

    returned material and issued to lines.

    IMPLEMENTATION

    A specific rack with yellow taping is allotted for the goods which are received without

    DC. A BIN CARD is maintained in the rack for goods which are received for new lot.

    For balance trims, the quantity is updated and location is allocated in STAGE as

    return materials.

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    PROBLEMS DURING AND AFTER IMLEMENTATION

    Goods were stored but no filling of bin card. The responsibility was given to the team

    leader but it was changed and given to the issues worker.

    GOODS WITHOUT DC RACK FOR TRIMS WHICH ARE RECEIVED

    WITHOUT DC

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    PROBLEM 2

    Quality pass report preparation before actual QC check.

    a) The GRN, PO and QC report are made together when the DC is received

    before the physical checking of the material. The QC pass is done in thesystem is not dependent on the actual quality check both being the same

    functions. The value of inspected and rejected goods is not updated in

    STAGE and the whole received quantity is taken as QC passed goods in

    STAGE. Even if the goods are rejected and returned to supplier for

    replacement, STAGE shows quantity of goods which are actually not in the

    store. This creates confusion.

    b) Moreover, the person making the GRN has to wait for the quantity and quality

    check after which she gets DCs so that she can make GRN.

    In the above pictures, physical QC pass report is made on 1/6/12 whereas STAGE

    inspection report is made on 23/5/12.

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    SOLUTION

    The solution is in changing the process flow of the store.

    Making of PO and GRN as soon as the DC is received and then passing it for

    quantity and quality inspection.

    The DC must go straight to the GRN worker for making PO and GRN. In the

    meantime the quantity and quality checking can be done. After making the PO and

    GRN the DC is passed to quantity checking worker to crosscheck DC quantity with

    actual received quantity. The DC is again passed to the quality worker for

    preparation of quality report.

    Accordingly a QC report is to be generated based on the actual checking of the

    material with details of QC passed quantity and actual received quantity.

    The DC is to be passed to the GRN worker to prepare inspection report and allocate

    location to the goods.

    IMPLEMENTATION

    The implementation of the new process flow is done.

    The opinion of the workers was taken and they were made to understand about the

    process.

    Accordingly the implementation was done and 6 day observation of the new processwas done.

    The GRN and PO are made before the quantity and quality checking and QC report

    in STAGE is prepared after the quantity checking.

    PROBLEMS DURING AND AFTER IMLEMENTATION

    The problem in implementation of the new process was lack of communication

    between the GRN worker and quantity/quality worker.

    The GRN area is away from the quantity and quality checking area, hence there waslack of communication as to GRN of which DCs are completed and which DCs are

    left for the quality checking.

    SOLUTION

    Maintaining a separate file for keeping DCs for which GRN and quality

    checking is already done.

    By maintaining a separate file, the quantity and GRN worker knows where to collect

    the DCs from without asking anybody.Separate files for keeping DCs for which

    GRN is made and quality check is done are maintained.

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    PROBLEM 3

    No identification of DCs for which quality checking has been done.

    SOLUTION

    A QC passed/rejected stamp to be put on the DC after physical checking of the

    material.

    A QC pass/reject stamp should be put on the DC after the physical checking of

    material which will be useful in knowing if the quality checking of the particular

    material has been done or not just by looking at it.

    IMPLEMENTATION

    The quality stamps have been ordered for the store. The stamps helps in easy

    identification of DCs for which quality checking has already been done.

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    PROBLEM 4

    a) DC and PO no stored in two separate books.

    DC number and PO/GRN number is required if one need to search for any

    material on STAGE. The PO and GRN number is written on each DC while

    preparing GRN and PO. DC number is stored in the DC inward register and

    PO/GRN number has to be checked from the DC file. He has to refer to two

    different books in order to get the required information. The same person

    (GRN worker) enters information for DC inward register and DC file.

    b) There is no way of knowing how many DCs are pending for GRN unless

    someone manually count the DCs themselves.

    c) Two times entry of the same DC number in DC inward register on different

    dates due to receiving multiple DCs with same DC number.

    SOLUTION

    Writing of DC, GRN and PO numbers in the same book.

    DC number is already written in the DC inward register. Instead of writing the PO

    and GRN number on top of every DC, it can be written in the DC inward book

    against every DC number. The GRN worker does not need to open separate files for

    writing each number and if anyone needs to know the PO and GRN number of a

    particular DC, they can refer to the DC inward register.

    IMPLEMENTATION

    The trims store now follows a single inward book for DC, GRN and PO number. It is

    now easy to find the PO and GRN for every DC. The DC inward register is useful in

    knowing how many DCs are pending for GRN.

    PROBLEMS DURING AND AFTER IMPLEMENTATION

    Two times entry of the same DC number due to receiving of multiple DCs with same

    DC number.

    This problem creates two POs and GRNs of the same DC. This shows excess

    inventory in STAGE of the material which does not exist.

    SOLUTION

    Writing of DC numbers in increasing order.

    The DC numbers are to be written in increasing order so that it can be identified if

    two DCs with the same DC number are received. If a number which is lesser than

    the last DC number is received, the number can be cross checked with the already

    received DCs and it can be found out if the DC is received two times.

    The DC numbers are written in increasing order.

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    DC INWARD BOOK

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    PROBLEM 5

    Unsystematic storage of quantity check information

    Information stored in quantity checking book is important for making statement for

    balance material. It is unsystematic stored and sorted only according to the receiveddate and lot number. The quantity of all the goods is written together one after the

    other.

    The quantity for the uncommon trims can be retrieved from this format of quantity

    checking register. But it is a different case for common trims.

    Common trims can be received for a number of lots together. The quantity is

    distributed for different lots and then the balance statement is made. These trims can

    be used for any lot as they are common for all the lots. The total number of common

    trims received can be found out by using the above described format of quantitychecking register, but it takes time.

    SOLUTION

    Maintaining a separate quantity inward book for common trims in which

    sorting is done according to the product type.

    Certain number of pages should be allotted to a specific type of trim. Sorting of

    information on the basis of product type helps to know the total quantity of the

    common trims which are received till date as quantity of one type of trim is written

    together. The information can easily be retrieved from this type of format of register

    without delay.

    IMPLEMENTATION

    A separate inward register is maintained for common trims in the store. It is highly

    useful in knowing the exact quantity of common trims which are received till date in

    the store.

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    COMMON TRIMS INWARD REGISTER

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    PROBLEM 6

    Returned material from lines is kept in the store which is of no use and

    occupies space.

    The excess material left in the sewing lines is returned to the trims store after thesewing is done. The return material is kept in the return rack and can be used for

    future orders. The return rack also store waste material which cannot be used for

    future orders because of meagre quantity or deterioration of the material.

    These materials are stored in the return rack occupies space which can be used for

    other productive purposes.

    SOLUTION

    Preparation of swatch cards for the materials which are received from lines before

    they are stored in the return rack. This helps in knowing what all material is available

    in the return rack.

    The swatches are to be provided to the merchandiser who in turn shows them to his

    higher authorities so that the material can be cleared after regular intervals of time.

    IMPLEMENTATION

    The swatches for all the current material in return rack have been prepared and

    provided to the store head so that further action can be taken and the material can

    be cleared.

    The swatch cards will be taken to the SSAL for approval to dispose the trims.

    The preparation of swatch cards for return material is included in the SOP so that

    they can be referred for clearing the dead stock.

    Some of the materials which were of no use have already been sent to the SSAL.

    REPORT FOR THE MATERIALS WHICH ARE PRESENTLY (17/08/2012) IN THE

    RETURN RACK AND WHICH ARE SENT TO SSAL IS ENCLOSED AT THE LAST OF

    THE DOCUMENT.

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    PROBLEM 7

    Randomly storing of goods in the returns rack with no labelling.

    Goods stored in the return rack are not segregated according to the product type and

    there is no labelling of the trims. They are randomly stored in the racks.

    SOLUTION

    Segregation of goods according to product type and labelling of all the racks.

    All the same type of material should be stored together for easy searching of

    material

    IMPLEMENTATION

    The material in the return rack is segregated according to product type and everyrack is labelled accordingly.

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    PROBLEM 8

    The threads in the trims store are stored according to the order. It takes a lot

    of time to search for the threads as same color threads are spread over

    different racks.

    SOLUTION

    Storing of threads in the increasing order of their color.

    The threads should be stored in increasing order of their color. This helps in easy

    searching of threads as all specific colors are stored together. If one is searching for

    a specific color it will only be available in a certain rack. Since the threads are stored

    in increasing order of their color, if one does not find a color till a certain rack, he

    knows that the color is not available in the store as none of the racks beyond can

    store a smaller number of color.

    IMPLEMENTATION

    All the threads are stored according to the increasing order of their color in the trims

    store.

    Firstly the location planning was done and accordingly the threads were physically

    shifted to that location.

    It took around one week to shift the threads to the new location.

    PROBLEMS DURING AND AFTER IMPLEMENTATION

    There was not enough space for all the threads color wise in separate location.

    While doing the location planning there was a lack of space.

    Location planning for almost all the threads was done except some of the threads.

    The threads were physically shifted and some of the locations were changed for

    convenience to adjust the remaining threads in the racks.

    The threads are now stored color wise which provides ease for searching.

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    PROBLEM 9

    Updating the quantity of used threads in STAGE as full cone/tube quantity.

    Used threads from lines are returned from the lines after the sewing is done. The

    quantity of the threads is updated in STAGE. As the precise quantity of the thread isunknown, the quantity of thread entered in STAGE is taken as full cone quantity. As

    a result, STAGE shows excess stock of threads which is not actually available in the

    store.

    The used thread is again kept with respect to the location of issue.

    The actual stock of threads is less than stock which is updated in the database.

    SOLUTION

    Used threads to be stored in separate cartons in return rack.

    Used threads should be stored in separate cartons return rack. The threads are to be

    separated according to color and stored in separate boxes. The quantity of such

    thread should not be updated in STAGE as it accepts only full cones and tubes. A

    separate report should be maintained in excel to keep track of the quantity of used

    threads received. As the precise quantity cannot be known, the report will contain the

    number of used tubes and cones.

    A format for storing the information of these threads is to be generated as an excel

    sheet.

    IMPLEMENTATION

    The implementation started by separating all the used threads from the rack. All the

    threads were collected into boxes. The quantity checking of the threads was done

    And that quantity subtracted from STAGE by showing issues of those threads.

    The color wise sorting of these threads was done and they were separated into

    different cartons.

    A format in excel is prepared to store information of all the used threads.

    PROBLEMS DURING AND AFTER IMPLEMENTATION

    It took a lot of time to get the workers to remove the half cones from the rack and to

    separate them into different cartons based on their color.

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    USED THREADS REPORT

    USED THREADS

    ITEM CODE CONTENTS

    MATERIAL

    NAME

    STYLE

    NUMBER COLOR

    TOTAL

    QUANTITY

    HO/156160 Gutterman Thread TKT-160 1 40000

    HO/156161 Gutterman Thread TKT-160 5 10000

    HO/156176 Gutterman Thread TKT-160 38 50000

    HO/156179 Gutterman Thread TKT-160 40 210000

    HO/156232 Gutterman Thread TKT-160 132 30000

    HO/156239 Gutterman Thread TKT-160 186 30000

    HO/156268 Gutterman Thread TKT-160 339 10000

    HO/156618 Gutterman Thread TKT-120 493 3000

    HO/156622 Gutterman Thread TKT-240 496 5000

    HO/156624 Gutterman Thread TKT-160 497 150000

    HO/156643 Gutterman Thread TKT-150 634 1000

    HO/156668 Gutterman Thread TKT-160 676 20000

    HO/156669 Gutterman Thread TKT-240 676 25000

    HO/156700 Gutterman Thread TKT-160 702 280000

    HO/156713 Gutterman Thread TKT-160 727 10000

    HO/156722 Gutterman Thread TKT-160 780 40000

    HO/156745 Gutterman Thread TKT-120 972 10000

    HO/156780 Gutterman Thread TKT-150 3454 3000

    HO/156833 Gutterman Thread TKT-150 7905 1000

    HO/156838 Gutterman Thread TKT-30 9299 1200

    HO/156844 Gutterman Thread TKT-30 9333 300

    HO/156845 Gutterman Thread TKT-150 9333 2000

    HO/156846 Gutterman Thread TKT-70 9444 1400

    HO/156848 Gutterman Thread TKT-150 9444 2000

    HO/156923 Amann ThreadSABA-120-Tex-

    180268 170000

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    HO/156927 Amann Thread SABA-30 307 300

    HO/156936 Amann ThreadSABA-120-Tex-

    180348 20000

    HO/156938 Amann Thread SABA-120 372 3000

    HO/156940 Amann Thread SABA-30 0381 300

    HO/156941 Amann Thread SABA-80 0381 1000

    HO/156942 Amann Thread SABA-120 0381 3000

    HO/156947 Amann Thread Serafil-200/2 0413 5000

    HO/156949 Amann Thread SABA-120 0414 3000

    HO/156952 Amann ThreadSABA-120-Tex-

    180415 10000

    HO/156965 Amann Thread SABA-120 0821 1000

    HO/156968 Amann Thread SABA-120 0822 2000

    HO/156982 Amann Thread Serafil-200/2 1043 5000

    HO/156984 Amann ThreadSABA-120-Tex-

    181050 130000

    HO/156989 Amann Thread SABA-120 1180 1000

    HO/156995 Amann Thread SABA-80 1239 3000

    HO/157012 Amann Thread SABA-80 1424 2000

    HO/157424 Gutterman Thread TKT-160 35 10000

    HO/157433 Gutterman Thread TKT-160 64 30000

    HO/157512 Gutterman Thread TKT-160 469 40000

    HO/157516 Gutterman Thread TKT-160 496 80000

    HO/157653 Gutterman Thread TKT-160 540 120000

    HO/157685 Gutterman Thread TKT-160 722 70000

    HO/157700Gutterman Thread TKT-160 815 80000

    HO/157715Gutterman Thread TKT-70 1643 2800

    HO/158340Vardhman Thread TKT-70/tex-40 D 20852 4000

    HO/165320Gutterman Thread TKT-160 367 30000

    HO/170970Gutterman Thread TKT-160 399 10000

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    PROBLEM 10

    Lack of communication to other departments about the balance trims for anorder.

    The balance trims status is important for other departments in order to makedecisions for loading in sewing lines and also in finishing and packing departments.

    There is a need to communicate the balance trims quantity to the other departments.This information is only with the store in charge and the employees have topersonally go and consult him in order to know if there is any balance trims whichare yet to come for any running order. The store is supposed to provide informationto the employees about the balance trims status but it is a lengthy process.

    SOLUTION

    Balance trims status board for communicating the exact quantity of balancetrims to other departments.

    Placing of a balance trims status board in the trims store where it is easily visible sothe employees can get formation about the balance trims without having to ask thestore head about it.

    IMPLEMENTATION

    A balance trims status board is kept in the store which is regularly updated forbalance trims quantity. The team leader has been assigned the job of updating theboard regularly.

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    CURRENT STANDARD OPERATING PROCEDURE

    START

    Incoming goods

    Without DC With DC DC without goods

    Stored in material without DC

    rack and entry in bin card

    DC received Entry in DC inward book

    Entry in DC inward book

    Kept in pending file

    Goods receivedGoods stored in incoming

    goods area

    Preparation of statement

    against BOM

    A

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    Sending of statement with item code, sizeratio and thread sheet to the IT department

    Preparation of work order by IT department

    Receiving of reference number

    Purchase order preparation

    A

    GRN preparation against given reference

    number

    GRN preparation against given reference

    number

    Entry in DC inward

    book

    Entry in DC inward

    book

    B

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    100 % quantity checking

    B

    Entry in quantity

    checking book

    2.5 AQL quality checking

    Quality Check

    passed

    QC report

    preparation

    No

    100 % quality checking

    Rejected trims stored in

    rejected goods area

    Returned to supplier for

    replacement

    Trims received

    1

    Trims stored in inspected goods area

    Preparation of swatch cards

    Approval of swatch cards

    C

    1

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    C

    Swatch cardapproved No

    Preparation of statement

    Cross checking with DC quantity

    Inspection report preparation in

    stage

    System location of material

    Physical shifting of material to the

    location

    Updating bin card on the inward of

    material

    D

    Return to supplier for

    replacement

    Replacement trims

    received

    1

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    Issue of trims to the lines against

    cutting slip

    D

    Updating bin card on outward of

    material

    Receiving excess material from lines

    against requisition slip

    Updating of extra quantity in stage

    Return material

    consist of incomplete

    thread cones and

    tubes

    Yes

    Kept in returnthread rack

    2D

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    Updated in

    excel

    Material returnedis complete thread

    cones and tubes

    2D

    Yes

    Stored in return rack for future use

    Threads are stored with

    respect to the location of issue

    Preparation of swatch cards

    STOP

    Issue to sewing lines or return to the

    supplier

    3

    33

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    CURRENT SOP IN DETAIL

    RECEIVING OF MATERIAL

    The process starts with arriving of the trims to the trims store. The material is usually

    received from Silver Sparks Apparel limited in trucks. The material is also received

    from other suppliers which mostly include stationary material and sometimes trims.

    RECEIVING DC WITH SECURITY SEAL

    The material received is accompanied by a Delivery Chalan which is made in SSAL.

    It is the receipt of receiving of trims which is received along with the trims when they

    are delivered. It contains information about the quantity and types of material

    received. It also gives information about the buyer, order number and referencenumber of the material. When the material is received, it is taken for unloading and

    DCs are submitted at the security where the entry of DC number is done in the DC

    register and security seal is put on the DC. The security seal gives information about

    the in time of the material and the date of material received.

    After the seal is been put to the DC, it is collected by the trims store worker for

    documentation purpose.

    It is possible sometimes that the material is received without DC or only DC is

    received without material. In such cases theres a problem for trims store as everydocument related to the material is generated based on DC. Also if the DC is

    received without material, there is no basis for preparing the documents. If the DC is

    not received it can cause misplacing of materials as no record for the material is

    maintained in the system.

    For this purpose the store has a separate rack for the trims which are received

    without DC. A bin card is maintained for all the trims which are kept in the rack.

    When the DC is received then the standard process for documentation and storing is

    carried out.

    If there is an urgent requirement of the trims which happens when balance trims for

    previous order are received, the trims are checked and issued and the quantity is

    subtracted in the bin card.

    If the material is not received and only DC is received, then the DC is kept in the

    pending DC file in which all the DCs waiting for documentation are kept. When the

    material is received the documentation is done.

    While the DCs are checked at the security, the material is unloaded from the truck

    and taken to the store with the help of trolleys and lift which helps in easy transfer of

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    material. As soon as the material reaches the store it is kept in incoming goods

    storage area.

    ENTRY IN DC INWARD BOOK

    When the DC is received the entry of DC number and lot number is done in the DC

    inward register date wise to know what all DCs are received on a particular date.

    TEMPORARY STORAGE IN INCOMING GOODS STORAGE AREA

    As soon as the material reaches the trims store, it is temporarily stored in the

    incoming goods storage area for quantity and quality checking. Only after the

    checking the documentation can be done and a more permanent location can be

    allocated to the trims.

    Received material cannot directly go for quantity and quality as there is a large

    quantity and everything cannot be checked at the same time. So the material is

    stored temporarily in the incoming goods storage area and is taken one by one for

    checking. Material which is urgently required is given preference over other

    materials.

    PREPARATION OF STATEMENT AGAINST BOM AND SENDING OF

    STATEMENT, THREAD SHEET AND SIZE BREKUP TO IT DEPARTMENT

    BOM is received from the merchandising department.

    A BOM is a list of all the trims which are required for a particular lot. It gives details

    about the quantity, types of trims, content of trims (in case of labels), consumption

    per garment and order quantity.

    When the material is received the Statement is prepared by referring to the BOM.

    The statement consist of all the trims mentioned in the BOM, its item code,

    consumption quantity per garment, total quantity required for a particular lot and total

    quantity including the 3% extra quantity. 3 % extra quantity is included because it is

    useful in case of losing or missing of trims.

    These three documents are sent to the IT department for preparation of work order.

    Work order is prepared in IT department for every lot which is received. The system

    quantity of the trims is fixed according to the BOM i.e. the store cannot issue more

    trims than specified quantity in the work order and can only issue trims according to

    the lot. One reference number is for lot is sent to the trims store. This reference

    number is used to prepare PO in the trims store.

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    PREPARATION OF PURCHASE ORDER

    The PO is prepared according to the work order. It is prepared under RPO (Regular

    Purchase Order).

    Purchase order is a document issued by a buyer to the seller indicating types,quantities etc. for the products the seller will provide to the buyer. For the goods

    which are not received from SSAL purchase order and invoice for the goods is

    provided by the seller.

    For the goods which are received from SSAL, the PO is prepared in the trims store

    and a single PO number is given to the trims of a particular lot. PO number acts as a

    reference for all the trims of a particular lot.

    If balance material of a particular lot is received the quantity is modified in a

    particular PO. If the balance material is thread, a new PO is created becausequantity of threads cannot be modified.

    Purchase Order is prepared in STAGE.

    After the IT department prepares the work order a reference number is sent to the

    store for the preparation of work order. This reference number is used to prepare the

    purchase order. The quantity details are retrieved from the system and a PO number

    is given to a particular lot. The PO is saved for future reference.

    PREPARATION OF GRN IN STAGE

    Goods receipt note is a document which is used to record the inward entry of trims

    received in the store. The document contains the details of quantity of trims received.

    GRN is prepared after the PO in STAGE. One GRN is prepared for every DC.

    In the previous step the quantity according to BOM is already entered in the work

    order. While preparing the PO the quantity is retrieved through reference number.

    GRN is prepared for every DC i.e. GRN is prepared to enter and store DC wise

    quantity in the system. Here trims and their quantity are retrieved according to the

    DC. This is done to know which DC number has what quantity and type of material.

    After the preparation of GRN, the GRN number is entered in DC inward book against

    every DC. It makes it easy for the searching of GRN and PO numbers for every DC.

    The DC is passed to the quantity checking worker for checking of actual received

    quantity with the DC quantity.

    100% QUANTITY CHECKING OF GOODS

    After the GRN is prepared, 100% quantity checking of the goods is done to match

    the actual quantity of the received goods to the quantity mentioned in the DC.

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    The trims store does 100% quantity inspection of trims is done based on the unit of

    measurement of a particular trim. The physical quantity and invoice of the goods

    received is tallied.

    Buttons are measured in gross. (1GRASS = 144 BUTTONS)

    They are received in packets.

    Tapes and waistband lining in meters and number of rolls.

    Tapes and waistband lining is received in the form of rolls.

    Labels, tags, cartons, polybags, pins etc in pieces.

    These are received in packets.

    Threads in tubes and cones.

    Threads are received in boxes.

    Shoulder pads are measured in pairs.

    These are received in cartons.

    Sealed packets have the exact quantity as mentioned, therefore only the number of

    packets are counted. 100% quantity checking for loose packets is done.

    For quantity checking of tapes and waistband lining, numbers of rolls are counted.

    For quantity checking of threads number of boxes and tubes/cones are counted.

    After the checking of trims the quantity received in quantity inward register.

    Quantity register is different for common trims and uncommon trims. Common trims

    are those which are same for all the lots of a particular order. Entry of these is donetogether to know the exact number of trims received for all the lots. Common trims

    include shoulder pads, fusible tapes, bridle tape, belt loop fusible etc.

    Uncommon trims are those which are different for different lots of same order. The

    quantity of these trims is entered lot wise in a separate quantity book. Uncommon

    trims include labels, buttons, RFID sticker, barcode sticker etc.

    After quantity checking, the DC is passed to the quality checking worker for quality

    checking.

    2.5 AQL QUALITY CHECKING

    Quality inspection is done after the quantity inspection. A worker specially trained for

    quality checking is assigned for checking of trims. Quality is checked on predefined

    aspects of trims which vary according to the trims type. For quality checking the trims

    store follows Acceptance Quality Level 2.5.

    AQL specifies the maximum number of defective goods considered acceptable in a

    particular sample size. If the acceptable quality level (AQL) is not reached for a

    particular sample of goods, 100% checking of the material is done and the rejected

    goods are returned to the supplier.

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    The sample size for different quantity of goods can be known by the 2.5 AQL chart

    mentioned later in the manual

    Two important things for the checking of the material are BOM and DC.

    A BOM is a bill of material which is provided by the merchandising department. BOMcontains the type, quantity and consumption per garment of trims for a particular lot.

    It also contains the contents of trims like labels, tags etc which need to be verified.

    Thus, quality checking is done against BOM.

    DC is required for the preparation of quality report. Quality report contains the

    information about the total quantity, type of trims, number of pieces checked for

    quality, total number of pieces rejected, GRN number and DC number. It also

    contains the sample of the trim checked. If the total number of pieces rejected is

    more than the defected pieces allowed in 2.5 AQL, the whole quantity of the trims is

    rejected.

    In case of rejection of trims, 100% quality checking is done and the rejected trims are

    returned to the supplier for replacement.

    Firstly, the DC and BOM are taken and the trims are checked of contents. The trims

    should have the correct content according to the BOM. If the content is correct, the

    trims are checked for possible defects. After checking an inspection report is

    prepared with the sample of the trims. The report contains the information about the

    total quantity of the trims, quantity inspected, defects occurred and the quantity

    rejected.

    In case of rejection, 100% checking of the goods in done and the rejected goods are

    returned to the supplier for replacement.

    After checking 5 swatch cards are prepared one each for the store, production office,

    merchandising department, quality department and finishing department.

    The approval for the trims is taken and then only the process is carried out further.

    STORING OF TRIMS IN INSPECTED GOODS AREA AND REJECTED GOODS

    AREA

    After the quality inspection, the quality passed trims are stored in inspected goods

    area. Floor space is allocated to the trims which are inspected. The trims which are

    rejected are stored in a separate area which is known as the rejected goods storage

    area. Separate rack is allocated to keep rejected trims.

    The rejected trims are returned to the supplier and in the meantime they are stored

    in rejected goods area to differentiate them from other trims.

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    RETURNING OF REJECTED TRIMS TO THE SUPPLIER

    The rejected trims are returned to the supplier for replacement. When the trims are

    received again 100% quantity checking is done and 2.5 AQL quality checking is

    done.

    PREPARATION AND APPROVAL OF SWATCH CARDS

    After the checking of trims swatch cards are prepared. Swatch card contains the

    sample of the trims received. These cards are sent to various departments which

    include production, merchandising, quality, finishing and one is used for the store.

    If the swatch card is approved by the merchandiser, it indicates that the trims are

    good to use and the process goes to the next step i.e. the preparation of statement.

    If the merchandiser does not approve the swatch card, the trims are returned to the

    supplier for replacement. When the replacement trims are received, the process

    again starts from quantity checking.

    PREPARATION OF STATEMENT AND FOLLOW UP FOR BALANCE MATERIAL

    After the approval of swatch cards, the statement is prepared in excel. The

    statement is prepared referring to the BOM. BOM is a document which is received to

    the store from the merchandising department and contains information about the

    quantity of trims required for a single lot.

    The BOM quantity is mentioned in the statement. The actual received quantity iscross checked with the BOM quantity and any difference in the quantity is mentioned

    in the statement.

    Statement is a reference to know which material is not received for a particular lot.

    After the preparation of statement the supplier is contacted to inquire about the

    balance material and to send the material as soon as possible.

    PREPARATION OF QC PASS REPORT IN STAGE

    After the physical checking and making of manual quality report, the quality status ofthe trims is updated in STAGE. Inspection report carries the details of quantity of the

    material which passed quality check. If trims are rejected, it is mentioned in the

    inspection report. Inspection report can only be made of the DCs for which GRN is

    already made

    GIVING SYSTEM LOCATION TO THE MATERIAL

    In the next step location is allocated to the QC passed trims because they need to be

    stored before sewing starts. Before the physical allocation of trims to the rack,

    location planning needs to be done which is done in STAGE. Empty locations arechecked and the location is shifted from floor to the respective rack number. Once

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    this is done, a location report is generated which shows the quantity, on type of trim

    and the rack number to which the trims are allocated.

    A print out of the location report is taken and a separate file is maintained to keep all

    the location reports for future reference.

    PHYSICAL SHIFTING OF THE MATERIAL TO THE LOCATION

    After giving system location to the material, it is physically shifted to the location. The

    shifting is done by the issue worker because it helps in the time of issue if the worker

    knows the location of the material. The material is shifted from the inspected goods

    area (floor) to the location allocated in stage. Usually trolleys are used to transfer the

    material. Shifting is also done by hand.

    UPDATING OF BIN CARD ON THE INWARD OF MATERIAL

    Bin card is used to keep track of the material which is stored in the racks. Every rack

    has a bin card which is updated as soon as the material is shifted to the rack. It

    contains the details of the quantity, type and lot number of the material which are

    stored in the rack. It also gives details about the exact quantity of the material which

    is issued to the lines and also the remaining material which is currently present in the

    rack.

    After the material is shifted to the rack, a bin card is kept in the rack along with the

    material. The total quantity of the material, its lot number and the date of inward of

    material is updated in the bin card. When the material is issued to sewing lines, theissued quantity is updated in the bin card and subtracted from the actual available

    quantity.

    ISSUE OF TRIMS TO THE LINE AGAINST CUTTING SLIP

    The trims are issued to the lines against cutting slip. Cutting slip gives the number of

    garments cut in a given time. According to the cut quantity and the consumption of

    trims per garment, the trims are issued.

    The sewing line has an operator which is known as the