final document1
TRANSCRIPT
-
7/29/2019 Final Document1
1/86
AAA
SSSUUUMMMMMMEEERRRIIINNNTTTEEERRRNNNSSSHHHIIIPPP RRREEEPPPOOORRRTTT
AAAttt
RRRAAAYYYMMMOOONNNDDD AAAPPPPPPAAARRREEELLL LLLIIIMMMIIITTTEEEDDD,,, GGGAAAUUURRRIIIBBBIIIDDDNNNAAAUUURRR
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))
-
7/29/2019 Final Document1
2/86 2
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.
-
7/29/2019 Final Document1
3/86 3
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.
-
7/29/2019 Final Document1
4/86 4
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.
-
7/29/2019 Final Document1
5/86 5
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.
-
7/29/2019 Final Document1
6/86 6
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.
-
7/29/2019 Final Document1
7/86 7
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).
-
7/29/2019 Final Document1
8/86 8
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.
-
7/29/2019 Final Document1
9/86 9
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.
-
7/29/2019 Final Document1
10/86 10
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.
-
7/29/2019 Final Document1
11/86 11
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
-
7/29/2019 Final Document1
12/86 12
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.
-
7/29/2019 Final Document1
13/86 13
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.
-
7/29/2019 Final Document1
14/86 14
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.
-
7/29/2019 Final Document1
15/86 15
Gum tape: It is used to secure the cartons after packing of garments inside
the cartons.
-
7/29/2019 Final Document1
16/86 16
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.
-
7/29/2019 Final Document1
17/86 17
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.
-
7/29/2019 Final Document1
18/86 18
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.
-
7/29/2019 Final Document1
19/86 19
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.
-
7/29/2019 Final Document1
20/86 20
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.
-
7/29/2019 Final Document1
21/86 21
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.
-
7/29/2019 Final Document1
22/86 22
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.
-
7/29/2019 Final Document1
23/86 23
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.
-
7/29/2019 Final Document1
24/86 24
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.
-
7/29/2019 Final Document1
25/86 25
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.
-
7/29/2019 Final Document1
26/86 26
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.
-
7/29/2019 Final Document1
27/86 27
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.
-
7/29/2019 Final Document1
28/86 28
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.
-
7/29/2019 Final Document1
29/86 29
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.
-
7/29/2019 Final Document1
30/86 30
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.
-
7/29/2019 Final Document1
31/86 31
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.
-
7/29/2019 Final Document1
32/86 32
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.
-
7/29/2019 Final Document1
33/86 33
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.
-
7/29/2019 Final Document1
34/86 34
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
-
7/29/2019 Final Document1
35/86 35
RETURN OF MATERIAL FROM SEWING DEPARTMENT
STORED IN RETURN MATERIAL RACKS
RETURNED TO SUPPLIER OR KEPT FOR FUTURE USE
-
7/29/2019 Final Document1
36/86 36
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.
-
7/29/2019 Final Document1
37/86 37
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
-
7/29/2019 Final Document1
38/86 38
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
-
7/29/2019 Final Document1
39/86 39
Receiving of excess material from lines
against requisition slip
Storing of trims with respect to the location
of issue
B
-
7/29/2019 Final Document1
40/86 40
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.
-
7/29/2019 Final Document1
41/86 41
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.
-
7/29/2019 Final Document1
42/86 42
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.
-
7/29/2019 Final Document1
43/86 43
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
-
7/29/2019 Final Document1
44/86 44
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.
-
7/29/2019 Final Document1
45/86 45
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.
-
7/29/2019 Final Document1
46/86 46
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
-
7/29/2019 Final Document1
47/86 47
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.
-
7/29/2019 Final Document1
48/86 48
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
-
7/29/2019 Final Document1
49/86 49
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.
-
7/29/2019 Final Document1
50/86 50
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
-
7/29/2019 Final Document1
51/86 51
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.
-
7/29/2019 Final Document1
52/86 52
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.
-
7/29/2019 Final Document1
53/86 53
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.
-
7/29/2019 Final Document1
54/86 54
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.
-
7/29/2019 Final Document1
55/86 55
DC INWARD BOOK
-
7/29/2019 Final Document1
56/86 56
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.
-
7/29/2019 Final Document1
57/86 57
COMMON TRIMS INWARD REGISTER
-
7/29/2019 Final Document1
58/86 58
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.
-
7/29/2019 Final Document1
59/86 59
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.
-
7/29/2019 Final Document1
60/86 60
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.
-
7/29/2019 Final Document1
61/86 61
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.
-
7/29/2019 Final Document1
62/86 62
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
-
7/29/2019 Final Document1
63/86 63
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
-
7/29/2019 Final Document1
64/86 64
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.
-
7/29/2019 Final Document1
65/86 65
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
-
7/29/2019 Final Document1
66/86 66
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
-
7/29/2019 Final Document1
67/86 67
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
-
7/29/2019 Final Document1
68/86 68
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
-
7/29/2019 Final Document1
69/86 69
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
-
7/29/2019 Final Document1
70/86 70
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
-
7/29/2019 Final Document1
71/86 71
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
-
7/29/2019 Final Document1
72/86 72
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.
-
7/29/2019 Final Document1
73/86 73
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.
-
7/29/2019 Final Document1
74/86 74
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.
-
7/29/2019 Final Document1
75/86 75
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.
-
7/29/2019 Final Document1
76/86 76
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
-
7/29/2019 Final Document1
77/86 77
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