Apparel Manufacturing Process Flow

Madura Clothing
Process Improvement Initiative
Process SOP Docket CCPL
Apr, 2011
Rashmi Rao, Projects, Madura Clothing
Table of Contents
Version Control Sheet
Glossary of Process Elements
Key Process Stakeholders and Roles
L0 Process Workflow
L1 Process Summary
L1 Process Detailing
Table of Contents
L0 Process Workflow
L1 Process Summary

Process Name
FCL & CCPL Process Mapping
Version
V1.0
Prepared By
Rashmi. Rao. M
Published On
REVIEWED BY
#
1
Name
Abhishek Kumar
Brand
Designation
Madura Clothing
Projects Manager
Date
2
3
4
5
AMENDMENT LOG
#
1
Version Number
Version 1
Amended By
Rashmi. Rao. M
Date
6-05-2011
2
3
4
Table of Contents
L0 Process Workflow
L1 Process Summary
Processes have been designed to cover Process Maps,

Policies, Templates, KPIs and RACI Charts
Process Documentation Scope
How is the process carried out and by which functions ?
Captures the basic operational flow and the steps to be followed
Process
ProcessMaps
Maps
Who plays what role in the execution of the process ?

Captures roles and responsibilities of the persons directly involved
RACI
RACICharts
Charts
Cross-functional
Cross-functional
Touch
TouchPoints
Points
Which other functions need to be involved in process execution?

Captures the areas where other functions are to take the process ahead
Policies
Policies
What guidelines are to be followed in running the process ?

Captures key decisions/rules guiding the functioning of the process
KPIs
KPIs
How can the success of the process be measured ?

Captures the metrics against which performance can be measured
Input
Input/ /Output
Output
Templates
Templates
What analyses and formats are used to support the process ?

Captures standardized formats of documents used in different process steps
Glossary of Shapes used in this Document

External
process
L2 processes
within L1 process
Notes (1) : R Responsible
Inter-linked L1
processes
A Accountable
Input
Interfaces
C Consulted
Output
Interfaces
I Informed
T - Template
Decision
Event
Stored Data
Table of Contents
L0 Process Workflow
L1 Process Summary
Key Stakeholders Roles / Designations

Designation
Head Manufacturing
Role Description
Reporting
Authority
Head of In-house Manufacturing (Madura Clothing)
President
General manager
Heads individual domains such as shirts, trousers and suits, IE
Head Manufacturing
Factory Manager
Heads the factory, responsible for general management
GM
Responsible for the technical part of the factory
GM
Technical manager
Manager-WCM
Manager-HR
Head WCM
Head HR
Manager-Finance
Head Finance
Asst manager- project
Head projects
Asst manager-WCM
Asst Manager- HR
Responsible for
Head OD
Head Manufacturing
Head Manufacturing And
HR-VP
Head Manufacturing
Head Manufacturing
Head Manufacturing
Head Manufacturing

Designation
Role Description
Reporting
Authority
Plans and allocates available manufacturing capacity for executing work orders is liaison
between manufacturing and brands
Head
Manufacturing
Responsible for managing production
Factory Manager
Responsible for management of fabric / trims warehouse - inwards, storage and issue- to own
and outsourced factories
Factory Manager
Responsible for sample production
Factory Manager
Responsible for pattern-making / CAD marking for in-house production
Factory Manager
Ensure production capacity availability for third Party Business and Product Costing of Styles ,
Ensure on-time delivery to customers .Retaining Customer and Vendor for sustained Business .
Head Manufacturing
Responsible for factory production planning
Factory Manager
CAD In-charge
Responsible for making markers style wise and fabric consumption planning
Factory Manager
Cutting Officer
Responsible for managing cutting and fusing
Factory Manager
Responsible for packing and finishing
Factory Manger
Responsible to set and maintain the quality systems in factory.
Factory Manager
Responsible for Dispatch
Factory Manager
Responsible for productivity and efficiency
Factory Manager
Responsible for recruitment, induction, canteen , security and legal compliance
Manager HR
Responsible for timely payment and benefits administration.
Manager HR
Responsible to maintain the IT Infrastructure in the factory
Factory Manager
Central Planners
Production officer
Store In-charge
Sampling In-charge
Pattern Master
Merchandising executive
Production planning
executive
Finishing In-charge
Quality Officer
Ware-House In-charge
Senior Industrial
Engineer
HR executive
Payroll and compensation
Officer
IT In-charge

Designation
Lab In-charge
WCM Executive
Maintenance Officer
Safety Officer
Utility Officer
Vapour Phase
supervisor
Embroidery In-charge
MIS executive
Central MIS
Accounts officer
Reporting
Authority
Role Description
Ensure effective lab quality system and processes are adhered to the standard
Factory Manager
Assist in implementation of 8 dimensions of WCM
Manager WCM
Responsible for preventive maintenance and breakdowns
Factory Manager
Responsible for establishing and complying safety, health and environment rules / norms in
factories.
Manager HR
Ensure upkeep of all electrical installations ,UPS, generators, boilers,STP,vapour
Factory Manager
Coordinating with production and finishing department to meet timelines as per the plan for Vapor
phase production
Factory Manager
Develop embroidery designs as per brand requirement and coordinate with cutting and sewing
department to meet timelines for production.
Factory Manager
Collect and compile all Management information reports for factories and Highlight the deviations
for the necessary actions to all concerned
Ensure Accuracy of financial and operation al reports as per timelines , analysis of variances and
highlight deviations to FMs and HOM
To ensure correct and timely accounting and reporting of financial transactions, as per the
SOPs of the company and to ensure financial control and financial proprietary so as to
facilitate meeting legislative requirements and optimizing shareholders value.
Factory Manager
Head Manufacturing
Manger - Finance
10
Table of Contents
L0 Process Workflow
L1 Process Summary
11
Macro level process

Core and Supporting processes
Storage
1
Business
Strategy &
P&B
Value creation
2
Stores
Lab
4
Planning
Deliver
CAD
6
Cutting
Sewing &
finishing
Warehouse
8
Merchandising and IE
9
Quality
10
People
11
Finance and Accounts
12
Maintenance and IT
Core Processes
Enablers
12
L1 Processes(FCL)
L1 processes
1. Stores
2. Lab
3. Centralized Planning
4. Factory Planning
FCL
5. CAD
6. Cutting
7. Sewing
8. Finishing
9. Warehouse
10. IE
11. Maintenance
12. Vapour Phase
13
L1 Processes in Stores
L1 processes
1. Stores
1. Receipt of material in stores
Stores
2. Issue of materials
3. Material requisition, indent, purchase
order follow up
4. Receipt, verification & issue of
products purchased
5. Approval of new supplier
6. Supplier evaluation & re-evaluation
14
Process Map : Receipt Of Material In Stores

Manufacturing
(Store)
Start
1 Receipt of materials with
supplier invoice /DC
Fabric: P.O, supplier name,

material code, ordered qty.,
Received qty., Visual
parameters, laboratory test &
design approval from brand
Trims: P.O, supplier name,

material code, ordered qty.,
Received qty., Visual
parameters, lining, buttons &
labels, items overview
OK
Inspection
5 Preparation of goods
Quantity confirmation
receipt note
Entry in Goods Inward

Register
Updation of stock in
SAP system
Entry of material in
identified location in
stores
Not OK
Entry in Goods Inward

Register
7 Rejected material placed in
Updation of quantity in SAP
identified location
End
External
process
L2 processes
within L1 process
Quantity confirmation
Inter-linked L1
processes
Preparation of Rejected Goods

Return note
Input
Interfaces
Output
Interfaces
8 Rejected material sent back to
supplier with DC
Decision
Stored Data
Event
T -Rashmi
Template
Rao, Projects, Madura Clothing
15
Process Map : Issue Of Materials
3 Issue of 10 cm fabric
to cad for marker

consumption
Start
4 Receipt of cad
consumption
5 Amendment of production
order and BOM as per cad

consumption
6 Preparation of cutting
order
Manufacturing
(Store)
Download of production
order and BOM through sap
INFORM BRAND &

CORRECT BOM
3 Receipt of material requisition
Issue of material
from production for sewing and

packing accessories
No
Verification of
material requisition
with BOM
Yes
Issue of materials to
production as per PPC(cut
qty)
End
Updation of issued qty in

sap
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
16
Process Map : Material Requisition, Indent, Purchase

Order Follow Up
Revise
Start
1 Receipt of Material
Verification by
12 A/c officer as
per budget
11 Approval by Stores-in charge &
requisition slip
Department in charge
Manufacturing
(Store)
Stock
2 verification
of material
Not in stock
3 Enquiry sent to approved
supplier through mail
Follow up with supplier
Purchase as per budget

9 Approval of quotation
by Factory Manager
Yes
14Final approval by Factory
Manager
Material collected as per
requisition
Follow up with supplier
17 Purchase Order sent to

13 Approval by Accounts
Officer
4
18
No
Yes
10 Material indent raised by
In stock
Sufficient material in stock inform

process owner
End
Verification
8 of quotation
7 Receipt of quotation
from supplier
No
Inform supplier for

revised quotation
supplier and obtain

acknowledgement through
mail
16 Approval by Stores-in
charge and Final approval

by Factory Manager
Yes
15
Preparation of
Purchase Order in Tally
15
Verification of PO
by Stores in
charge as per
indent
No
Revise
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
17
Process Map : Receipt, Verification & Issue Of Products

Purchased
Manufacturing
(Store)
Start
Receipt of material from

supplier with invoice as per PO
8
2
Verification of
quantity by
Security &
purchase
Yes
No
Inform supplier & accept the

material
Incoming
inspection for
3
quality by
concerned dept.
4
Yes
Submission of GRN along

with PO to accounts department
& take acknowledgement
Preparation of
inspection report
Physical transfer of
material to the concerned
process owner through
material requisition and
take acknowledgement
No
Material sent back to supplier
5 Preparation of GRN by
Purchase in Tally
Store material in allocated

area, provide identification
and maintain traceability
records
10
Entry of issue in Tally
6 Approval of GRN by Accounts
End
and Final approval by Factory

Manager
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
18
Process Map : Approval Of New Supplier
Rejected
Start
No
Manufacturing
(Store)
Identification of new supplier

5 Procure samples from
suppliers
2 Compile Data about
Yes
Approve, establish and

maintain records of
approved supplier by AO
ability of supplier
3 Select the supplier For
Assess quality
and cost of the
product
Evaluation
Visit the supplier
Creation of supplier
ledger in Tally
End
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
19
Process Map : Supplier Evaluation & Re-evaluation

Manufacturing
(Store)
Start
If graded C, inform supplier in
writing for improvement for the next
three consecutive POs
1
If graded D, remove from approved

supplier list.
Prepare supplier list

Communicate rating to supplier
as per grade
A -90-100, B -80-90, C- 60-80, DBELOW 60.
Define the Criteria for

Evaluation/re-evaluation Such
as Quality, delivery & service
Rate performance once in 6

months. Statistically analyze
performance of suppliers for continual
improvement
5
3 Fix weight age for each of
the Criterion as mentioned

above for each supplier
4 Monitor Performance
7 Obtain Acknowledgement from
supplier
End
8
Monitor the corrective action by

the supplier (Whenever Necessary)
based on evaluation
Evaluate
Effectiveness
11Continue appraisal & re-
appraisal
10
Yes
Retain the supplier In

Approved supplier List
No
Withdraw supplier approval

and amend approved supplier
list
Communicate to supplier
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
20
L1 Processes in Lab
L1 processes
1. FCL Lab Process
Lab
21
Process Map : Lab

Fabric , trims, garments
Sourcing /
PDQA
8 Approved?
No
Yes
Fabric ,trims, garments
Manufacturing
(Store)
Start
Receipt of sample
9
Send back test report signed copy to
Lab, photocopy forwarded to store
4
Carry out Test as per standard test
method (AATCC, ASTM, ISO)
Lab
2
5
Enter detail in register
7
Prepare hand written draft report/
Enter test details in register
3
Decide type of Test Package, cut &
distribute to concerned technician
6 Result
Approved?
Send test report along with tested

specimen to QA Manager-RM for final
approval
10
Keep all test reports in Box File in
sequence/ Keep record in register
No
11
Discard tested & untested sample as
per Lab sample retention policy
Yes
Bulk - Enter result in SAP & accept.

Other cases: Send PDF report to
concerned Person
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
End
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
22
L1 Processes in Centralized Planning

L1 processes
1. Centralized Planning
Centralized Planning
23
Process Map : Centralized Planning

Brand
2
Month-wise plan
at Style code level
3
WO Creation
5 BCDS Process
implementation with Cut-of
date
Correcting BOM
End
Start
Yes
1
Risk Analysis for Quality
feasibility with A4
size swatches
21 Variance analysis
& TECO
Status
4 Visibility
No
10 Costing rectification by
brand SC
PPC(Factory)
Fortnight Plan for cutting, sewing

11 & dispatch based on line
capacity, Garment styling
6
WO Download and Review with
Factory Capacity blocked
Yes
WO Cancellation/ change in order

qty in case of partial fabric or
trims avblty within 1 wrkng day by
brand SC
7
No
Trims & Fabric

Avblty after
Testing
8
Yes
Gold Seal
Avblty
No
WO Cancellation by
brand SC
Milestone confirmation
against Plan for Cutting,
19 Sewing, Finishing and
dispatch
12
Marker Preparation
Correct
9 Costing &
Routing
20 Brand commitment
date follow-up
18
Cross verification of Fab consm
BOM v/s Marker & trims BOM
13
(In case +-5%)
No
14
Correct
BOM
Yes
17
WO release
Fabric ready
16
Trims checking
15
BOM & WO print
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
24
L1 Processes in Factory Planning

L1 processes
1. FCL Factory Planning Process
Factory Planning
25
Process Map : Factory Planning

Highlight to brand & correct
BCDS
Brand
Reschedule with higher

authorities approval
No
Check fabric,
trims &
5
consumables
available as per
BOM
PPC(Factory)
1
Receipt of BCDS
13 Schedule for
Yes
6 BOM correction as
per actual
No
Start
7
4
Check gold
2 seal & fabric
availability
Yes
12
Is OPBD
available
Is Garment
treatment
12 Follow up
No
Yes
Yes
13
WO & BOM
Yes
Yes
Swatch
3 collection &
risk analysis
No
Highlight to brand & get

gold seal
No
Highlight to brand &

correct
Plan based on delivery

requirement
11 Milestone confirmation
9 Block line based on expected
10 Schedule for cutting &
efficiency & allotted capacity
loading
New style
Stores
No
garment treatment
(CO11N)
Schedule for pilot run
14
15
Dispatch on
scheduled date
OCR
TECO
End
Check for fabric & trims

availability
Check with IE dept
IE
Pilot run & follow up
Production
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
26
L1 Processes in CAD
L1 processes
1. FCL CAD Process
1. Sample development
CAD
2. For regular production

3. Sample Pattern development
27
Process Map : CAD (Sample Development)

Merchandising
Dept
Sample indent
CAD
(Sampling
Section)
Start
Sending fabric requisition

3
to stores
Manual hard pattern
Pattern available / Make

2. c the new pattern
Receipt of sample
indent
2Updation of indent details

in system
Yes
Check the W/O

2. a creation for the
Indent in SAP
2. b
Yes
Sample cutting
7 Trimming/Spot wash
End
No
Inform the brand

merchandiser
L2 processes
within L1 process
Correction
Inter-linked L1
processes
Grading & Final
13 Gold Seal Sample

ready for production
Final
8
inspection
No
No
External
process
Dispatch
Rework / Inform to
brand
No
Brand
(Merchandiser
& designer)
12
Pressing
Buttoning & button hole
Yes
Check the
availability of
Fabric, Trims &
Accessories in
stores
11
10 Folding & packing as

per indent details
Stitching
Input
Interfaces
Output
Interfaces
Yes
14 Approval
Decision
Stored Data
Event
T -Rashmi
Template
28
Process Map : CAD (For Regular Production)

Stores
WO with swatches
CAD
Issue consumption to stores
Receipt of WO
4 Measure fabric repeat & width
before preparation of marker
5
Prepare the ratio as per WO qty
Yes
Start
2
Check for
availability of gold
seal no & brand
name in WO
3
Yes
Check for
availability of
pattern & gold seal
sample
No
6
Marker preparation as per ratio
No
Calculate the consumption
Print marker from plotter
Make changes
No
Marker
verification
Yes
Brand
Check with brand
Sampling
Dept
Check with sampling

dept
11
Stripe & checks markers sent

to manual cutting
End
Cutting
10
Issue to cutting
11 Solid & pin stripe markers sent

to Gerber cutting
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
29
Process Map : CAD (Sample Pattern Development)
Start
1
Receipt of specification sheet from brand
to make proto (development) sample
CAD
Development of pattern in PDS as per

specification
Print pattern using plotter
Make hard Pattern
End
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
30
L1 Processes in Cutting
L1 processes
1. FCL Cutting Process
1. Cutting(Plain fabric)
Cutting
2. Cutting(Stripes & checks fabric)
31
Process Map : Cutting (Plain Fabrics)

CAD marker
CAD
Lay Plan
Start
Manufacturing
(Cutting)
5
1 Receipt of CAD marker
& lay plan
Receipt of fabric &

2
trims
Spreading
Lay
4
inspectio
n
Cutting(Auto cuttingGerber cutting)
9 Ready cutting
8 Relay of front
panel
6
Confirmation of cut qty in
SAP
Panel
10
Inspectio
n
11
Bundling
12Issue to
sewing
No
Numbering
8
No
Recut
Fusing
End
Relay
Inspectio
n
Yes
No
Recut
Manufacturing
(Fabric/Trims
Stores)
External
process
Cutting order
Fabric & accessories
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
32
Process Map : Cutting (Stripes & Checks Fabrics)

CAD marker
CAD
Lay Plan
Relay
Start
1 Receipt of CAD marker
& lay plan
Manufacturing
(Cutting)
Lay
7
inspectio
n
2 Receipt of fabric &

accessories
No
Straight Knife Cutting
13 Ready cutting
Yes
9
Band Knife Cutting(For
small parts)
12 Relay of front
panel
Panel
14
Inspectio
n
Spreading
Verification of
centre line in marker
4 Pin setting based
Yes
5
Verificatio
n
on repeat size
10
Confirmation of cut qty in
SAP
11
15
Bundling
16Issue to
sewing
No
12
13
Recut
Fusing
Numbering
No
Yes
Inspectio
n
Yes
End
No
Recut
Manufacturing
(Fabric/Trims
Stores)
External
process
Cutting order
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
33
L1 Processes in Sewing
L1 processes
1. FCL Sewing Process
Sewing
34
Process Map : Sewing(Shirts)

Production plan &
line plan
PPC
IE
Line plan
Manufacturing
(Fabric/Trims
Stores)
Trims
Manufacturing
(Cutting)
Cut panels
Manufacturing
(Sewing)
4
1 Receive
production plan
5
Load small parts
Trims receipt
8 Trimming
Start
Collar ready
2
Receive line plan
Sleeve ready
Cuff make
Back
9
Receive cut parts

7
Assembly
EOL
inspection
Yes
No
Alteration /
Rework
10
Issue to finishing
Manufacturing
(Finishing)
External
process
Front ready
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
End
Decision
Stored Data
Event
T -Rashmi
Template
35
L1 Processes in Finishing
L1 processes
1. FCL Finishing Process
Finishing
36
Process Map : Finishing
10 Shirt folding with tissue paper, and
Extra thread trimming
Start
back support (card board), metal &

plastic clip
2 Loose thread removed in
Manufacturing
(Finishing)
thread sucking machine
Packing inside poly

bag
Insertion of collar traveller
Pressing the inner side bottom,

front placket, side & pocket
tag, bar code sticker on swing tag &

product box
12
Pre iron
Buttoning the shirt
11
Placement of price sticker, collar size
Attach price tag, collection tag,

collar support and butter fly
13
Issue to warehouse
End
Yes
Final
6 Inspection
Outside full pressing
No
Rework
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
37
L1 Processes in Warehouse
L1 processes
1. FCL Warehouse Process
Warehouse
38
Process Map : Warehouse

Stores
Packing trims
Finishing
Section
Garments
1 Receipt of finished
products
Start
Factory
Warehouse
Verification of
2 barcode &
size sticker
Yes
Size wise packing in outer

carton box as per location
Location wise
scanning
No
Repack
15
Yes
3 Size wise packing in inner

carton box
No
Replace barcode & size

sticker
6
Sealing of carton box
11 Create carton
stickers in YPDMR34
12
Do PGI in VL02N
7 GRN to be done in
SAP
10 Picking & packing

in VL02N
13 Print delivery
Chelan in YSOLR41
9 Delivery created in
VL04
14
8 STO to be created
in ME27
Central
warehouse
External
process
15
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Loading
Check
WO
status
Yes
16 TECO Final
confirmation & analyse
variance
End
Dispatch
Decision
Stored Data
Event
T -Rashmi
Template
39
L1 Processes in IE
L1 processes
1. FCL IE Process
IE
40
Process Map : IE SHIRTS

Merchandising
Gold seal
Industrial
Engineering(IE)
(Factory)
1
Start
Receipt of gold seal
Conduct method
study
5
Man/M/c allocation
Prepare OBD
Fixing CM, creating activity type /rate

3
and SAP updation
4 Plan for resources

based on targets and
styling
Design workplace
layout
8 Prepare final OBD &

freeze SMV
9 Analyze daily
production report
Coordinate with
supervisors & create
awareness of their
operators performance
12
11
Time study for bottle

necks
10
Calculate factory
efficiency on daily basis
13 Coordinate with operators &

encourage to practice effective
methods
14 Initiate continual
improvement activities
15
Prepare factory efficiency
& other MIS
End
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
41
L1 Processes in Maintenance
L1 processes
1. FCL Maintenance Process
1. Preventive maintenance
Maintenance
2. Breakdown maintenance
3. Critical spares
42
Process Map : Preventive maintenance

Start
Identify each equipment and machine

used for production/ service provision with
an inventory number
Prepare a master list
Maintenance
Dept
Prepare yearly plan for

preventive maintenance
Prepare a maintenance
checklist
5Carry out maintenance as per

plan
6 Maintain records of preventive

maintenance
End
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
43
Process Map : Breakdown maintenance

Start
1
Receipt of information regarding breakdown
of equipment/machinery from concerned
department
Rectify the breakdown
3 Register all break downs, malfunctioning,

trouble shooting for each equipment in
History card
Maintenance
Dept
Identify reasons for breakdown of

equipment and initiate corrective action
5 Carry out maintenance as per plan at

periodic intervals
6
Statistically analyze the causes for
break down of critical machines and use the
data for continual improvement
End
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
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44
Process Map : Critical Spares
Start
Identify and list out critical spares for

critical equipments
Entry of material into stock ledger
End
2 Fix minimum quantity for each of the

critical spares based on consumption and
lead time of supply
Receipt of material
Maintenance
Dept
Yes
External
process
Store Material in the Allocated Area,

Provide Identification And Maintain
Traceability Records.
Requirement is sent to purchase through

materials requisition
Purchase arranges for material
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Incoming
inspection
Receipt of material
Output
Interfaces
Decision
Stored Data
Event
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45
L1 Processes in Vapourphase
L1 processes
1. FCL Vapourphase Process
Vapourphase
46
Process Map : Vapour Phase
5 Load the trolleys in the chamber &

run the programme
Check the
processed
shirts
No
Second quality
Receipt of pressed
shirts from finishing
Set the programme number

7
Start
Check for
stains, damage
2
& unwanted
creases
Damage
Second quality
3 Place the shirts on VP production

trolleys (80 to 100 Pcs each with 2
2.5 gap. If the qty is less use dummy
shirts)
Yes
Stains
No
Yes
Yes
Spot
wash
Send to finishing
End
Creases
Spot wash
To pressing
Yes
Yes
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
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47
L1 Processes(CCPL)
L1 processes
1. Stores
2. IE
3. Lab
4. Factory Planning
CCPL
5. CAD
6. Cutting
7. Sewing
8. Finishing
9. Warehouse
10. Maintenance
11. Vapour Phase
48
L1 Processes in Stores
L1 processes
1. CCPL Stores Process
1. Fabric Store
Stores
2. Trims Store
3. Regular Purchase
4. Indent Purchase
49
Process Map : Fabric Stores

Fabric
Suppliers
Fabric Production and Supply

Bulk Fabric
Start
6 Visual & Shade
Lab testing
Fabric
Return
batching
Receipt of fabric
9 Fabric Return
Manufacturing
(Fabric Store)
2
Document
verification
No
Inform/Mail to
brand
Dispatch
Visual, Lab & Shade

batching Report
Yes
7 Quality
Approved?
Fabric
shortage
GIR
Fabric Discrepancy
Report (FDR)
11
Material issue to
CAD & Cutting
End
No
Yes
Fabric Rejection Advice

(FRA) + sample
Swatch for
design approval
GRN in
system
No
Bale opening
10
Yes
Design
approval
Accept?
Garments Production
In-house Factories (4b.3)
Approvals/
Advice
PO and Order Management - Fabric (4a.4)

Sourcing
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
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50
Process Map : Trims Stores

Fabric
Suppliers
Trims Production and Supply

Trims
Start
Trims
Return
Visual & lab testing

1
Receipt of trims
Manufacturing
(Trims Store)
7 Trims Return
Dispatch
2
Document
verification
No
Visual & Lab Report

Yes
5 Quality
Approved?
GIR
Yes
GRN in
system
Material issue to
cutting, sewing &
finishing dept
No
End
Inform/Mail to
brand
No
Yes
Trims Rejection Advice

(TRA) + sample
Master sample
approval for first time
material receipt
Sample
approval
Accept?
Garments Production
Approvals/
Advice
PO and Order Management - Fabric (4a.4)

Sourcing
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
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Template
51
Process Map : Regular Purchase

Suppliers
Supply
Material
Material
return
Material Return
Dispatch
Start
5
1 Receipt of material
indent
PO Raise
Visual checking
6
Manufacturing
(Store)
RN(Receipt
Note) in system
Report
Quality
Approved
Yes
End
Material issue
Garments Production
No
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
52
Process Map : Indent Purchase

Suppliers
Supply
Material
Material
return
Visual Checking
Start
PO Raise
1 Receipt of material
Report
Material Return
Dispatch
indent
Manufacturing
(Store)
Supplier
2
approved?
Collect quotations
-
Yes
Quality
4
Approved?
Yes
RN(Receipt
Note) in system
End
Material issue
No
No
Meeting with
suppliers
Comparative
analysis
Garments Production
Approval
from FM
Management
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
53
L1 Processes in IE
L1 processes
1. CCPL IE Process
1. IE(Trousers)
IE
2. IE(Jackets)
54
Process Map : IE (Trousers)
Gold seal
Merchandising
Start
1
Industrial
Engineering(IE)
22
Factory
No
External
process
7
Man/M/c allocation
Prepare OBD
6
Costing mail to be
send for brand
Costing
FM
approval
8
Conduct method
study
Yes
L2 processes
within L1 process
Design workplace
layout
Prepare final OBD &

freeze SMV
10
11 Analyze daily
production report
5
Updation activity code in
SAP
Inter-linked L1
processes
Coordinate with
awareness of their
14
13

necks
12
Calculate factory
Coordinate with operators

& encourage to practice
effective methods
15
17
& other MIS
End
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
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55
Process Map : IE (Jacket)
Gold seal
Merchandising
Start
1
Industrial
Engineering(IE)
2
2
Factory
No
External
process
7
Man/M/c allocation
Prepare OBD
6
Costing mail to be
send for brand
Costing
FM
approval
8
Conduct method
study
Yes
L2 processes
within L1 process
9
Design workplace
layout
14
Prepare final OBD

10 & freeze SMV
13
11 Analyze daily
production report
5
Updation activity
code in SAP
Inter-linked L1
processes
Coordinate with
awareness of their

necks
12
Calculate factory
Coordinate with operators

& encourage to practice
effective methods
15
17
& other MIS
End
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
56
L1 Processes in Lab
L1 processes
1. CCPL Lab Process
Lab
57
Process Map : Lab

Fabric , trims, garments
Sourcing /
PDQA
No
8 Approved?
Yes
Fabric ,trims, garments
Manufacturing
(Store)
Start
Receipt of sample
9
Send back test report signed copy to
Lab, photocopy forwarded to store
4
Carry out Test as per standard test
method (AATCC, ASTM, ISO)
Lab
2
Enter detail in register
Prepare hand written draft report/

Enter test details in register
3
Decide type of Test Package, cut &
distribute to concerned technician
6 Result
Approved?
Send test report along with tested

specimen to QA Manager-RM for final
approval
10
Keep all test reports in Box File in
sequence/ Keep record in register
No
11
Discard tested & untested sample as
per Lab sample retention policy
Yes
Bulk - Enter result in SAP & accept.

Other cases: Send PDF report to
concerned Person
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
End
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
58
L1 Processes in Factory Planning

L1 processes
1. CCPL Factory Planning Process
Factory Planning
59
Process Map : Factory Planning

BCDS
Brand
PPC(Factory)
1
Receipt of BCDS
Start
2 Daily update WOs

created
Release plan
Give Brand Commitment

fortnightly
4
Weekly Dispatch plan
WO release
7 Follow up WOs in
different sections
WO dispatch
OTIF, Through Put &

other reports
End
CAD
Consumption
Check for trims availability
Stores
Communicate for work place
design
IE
Production
External
process
Gold seal review
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
60
L1 Processes in CAD
L1 processes
1. CCPL CAD Process
1. Sample development
CAD
2. Production Marker development
61
Process Map : CAD (Sample Development)

Sample indent &
control sheet
Merchandising
Dept
1
Receipt of sample indent &
control sheet
CAD
Start
Pattern making
Digitizing / Manual marker

7
Develop size set sample
Sample development
9 Sample ready for

production
End
6 Grading / Final model

development
No
No
Brand sourcing
8 Approval
Approved
5 sample
Yes
Yes
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
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62
Process Map : CAD (Production Marker Development)

6
Marker preparation
Avg consumption
CAD
Yes
No
5
Receipt of control sheet
Approved gold
2 seal, measurement
chart & pattern
availability
Stores
WO detail with lay

1 1
plan
WO detail received with

consumption
4
Start
Yes
7 Marker
verification
Prepare control sheet
Cutting
8 Issue to cutting
End
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
63
L1 Processes in Cutting
L1 processes
1. CCPL Cutting Process
Cutting
64
Process Map : Cutting

Marker making
CAD
Start
1 Prepare lay plan &

accessory sheet
Check fusing
bond
strength /
thermal
shrinkage
Manufacturing
(Cutting)
Receipt of fabric & trims
Control
sheet
review?
No
Table planning &

spreading
External
process
L2 processes
within L1 process
BUNDLE
15 INSPECTI
ON
Yes
13
Check for
fab code &
width
before
spreading
Yes
Inter-linked L1
processes
Lay
7
inspectio
n?
No
Relay
No
Recut
No
16 Issue to
Yes
sewing
Yes
10 Sorting
11
Numbering
Panel
12
Inspectio
n
End
No
Recut
Issue fab
requisition slip
Return to stores
Input
Interfaces
Yes
Fusing
Recut
Yes
No
Control sheet
Cutting
Cut
9 panel
Inspecti
on
Yes
No
Manufacturing
(Fabric/Trims
Stores)
Change fusing
parameters
14
Bundling
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
65
L1 processes
1. CCPL Sewing Process
Sewing
66
Process Map : Sewing(Trousers)

Production plan
PPC
IE
Line plan
Manufacturing
(Fabric/Trims
Stores)
Trims
Manufacturing
(Cutting)
Cut parts
Manufacturing
(Sewing)
1 Receive
production plan
Trims receipt
5
Load small parts
8
Sewing assembly
Start
10
2
Receive line plan
3
Receive cut parts
Parts sewing
7 Panels & parts

sewing
Trimming
EOL
inspection
Yes
No
Alteration / Rework
11
Issue to finishing
End
Manufacturing
(Finishing)
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
67
L1 processes
1. CCPL Finishing Process
Finishing
68
Process Map : Finishing(Trousers)
Garments
Manufacturing
(Sewing)
Start
Receive material
2
Loose thread sucking
Manufacturing
(Finishing)
Side seam iron

4
Legger pressing
5
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Topper pressing
Issue to FQC
End
Decision
Stored Data
Event
T -Rashmi
Template
69
L1 processes
1. CCPL Warehouse Process
Warehouse
70
Process Map : Dispatch (TROUSERS)

Stores
Packing trims
Garments
Finishing
Section
Start
Re audit
1
Receipt of garments
Factory
Warehouse
2
Final quality
audit if qty >
80%
Yes
Tagging of price tag

3 with barcode
9 Receive details of
confirmed orders which
are dispatched
Packing
Appearance
audit
Yes
Generate DC
10
Check for cost variance
in SAP & TECO
No
Rescreen
No
Audit by
6 buyer QC
Yes
End
No
Rescreen
Rescreen
8
Dispatch to WH
Central
warehouse
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
71
L1 Processes in Quality
L1 processes
1. CCPL Quality Process
Quality
72
Process Map : Quality(Trousers)

CAD
Check
marker
Cutting
Check
laying
Yes
Check
cutting
No
Re - laying
Yes
No
Re - cutting
Sewing
Check
operators
for quality
Yes
Issue green flag Yes
No
Yes
Check
fusing
Check
panels
No
Check
bundling
No
Change fusing
parameters
Check
critical
operations
Yes
Re - cut
End of sections
check for
quality output
Yes
No
Yes
Issue red flag
Alterations
No
Check
operators
for quality
No
100%
inspection
Yes
Check as per
traffic light
system
Issue white flag
Choose single
Yes
sampling plan as
per order size
Final
Audit
Yes
Final Audit for

presentation
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
No
FQA
Alterations
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
73
L1 processes
1. CCPL Sewing Process
Sewing
74
Process Map : Sewing(Jackets)

Section wise
planning
PPC
Receive style details

and loading plan
IE
Manufacturing
(Fabric/Trims
Stores)
Control sheet
Trim kit
Manufacturing
(Cutting)
Manufacturing
(Sewing)
Cut parts
1
Receive plan
2
Receive material
Alteration /
Rework
Processing
(Sleeve,)
No
Start
Bundle wise
loading
4
Processing (Lining)
Body
assembly
Sleeve
assembly
7 Inspection
Yes
4
Processing (Body)
Manufacturing
(Finishing)
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
End
Issue to
Finishing
Decision
Stored Data
Event
T -Rashmi
Template
75
L1 processes
1. CCPL Finishing Process
Finishing
76
Process Map : Finishing(Jackets)
Manufacturing
(Sewing)
Garments
Start
Spot remover
3 Shoulder & sleeve

press
Manufacturing
(Finishing)
4
External
process
Receive material
Left & right front press
L2 processes
within L1 process
7 Button sewing
(Front button)
8 Button sewing
(Lining button)
13 Lapel pressing &

touch up
Label attaching on
sleeve
14
Collar press
12 Lining ironing &

fabric touch up
15
10
Armhole touch up
11
Sleeve touch up
16
Button marking
5
Side & back press
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Wrapping
Issue to FQC
End
Decision
Stored Data
Event
T -Rashmi
Template
77
L1 processes
1. CCPL Warehouse Process
Warehouse
78
Process Map : Dispatch (JACKETS)

Stores
Packing trims
Garments
Finishing
Section
11 Receive details of
Start
Re audit
1
Receipt of garments
Factory
Warehouse
2
Final quality
audit if qty >
80%
Yes
No
3 Put size ring for

jacket/trouser with
hanger
confirmed orders which

are dispatched
Packing
Appearance
audit
Yes
No
4 Paring of jacket &

trouser
Audit by
8 buyer QC
Rescreen
12
Check for cost variance
in SAP & TECO
Yes
End
No
Rescreen
Tagging of price tag
5 with barcode
Rescreen
10
Dispatch to WH
Central
warehouse
External
process
9 Generate DC
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
79
L1 Processes in Quality
L1 processes
1. CCPL Quality Process
Quality
80
Process Map : Quality(Jackets)

CAD
Check
marker
Cutting
Check
laying
Yes
Check
cutting
No
Re - laying
Yes
No
Re - cutting
Sewing
Check
operators
for quality
Yes
Issue green flag Yes
No
Yes
Check
fusing
Check
panels
No
Check
bundling
No
Change fusing
parameters
Check
critical
operations
Yes
Re - cut
End of sections
check for
quality output
Yes
No
Issue red flag
Alterations
No
Check
operators
for quality
No
100%
inspection
Yes
Issue white flag
Choose single
Yes
sampling plan as
per order size
Final
Audit
Yes
Final Audit for

presentation
Output
Interfaces
Decision
Stored Data
Event
T -Rashmi
Template
No
FQA
Alterations
External
process
L2 processes
within L1 process
Inter-linked L1
processes
Input
Interfaces
81
END OF DOCUMENT
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Apparel Manufacturing Process Flow

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Madura Clothing

Process Improvement Initiative

Process SOP Docket CCPL

Rashmi Rao, Projects, Madura Clothing

Version Control Sheet

Glossary of Process Elements

Key Process Stakeholders and Roles

Rashmi Rao, Projects, Madura Clothing

Version Control Sheet

Glossary of Process Elements

Key Process Stakeholders and Roles

Rashmi Rao, Projects, Madura Clothing

Version Control Sheet

FCL & CCPL Process Mapping

Version Control Sheet

Glossary of Process Elements

Key Process Stakeholders and Roles

Rashmi Rao, Projects, Madura Clothing

Processes have been designed to cover Process Maps,

Who plays what role in the execution of the process ?

Which other functions need to be involved in process execution?

What guidelines are to be followed in running the process ?

How can the success of the process be measured ?

What analyses and formats are used to support the process ?

Glossary of Shapes used in this Document

Notes (1) : R Responsible

Rashmi Rao, Projects, Madura Clothing

Version Control Sheet

Glossary of Process Elements

Key Process Stakeholders and Roles

Rashmi Rao, Projects, Madura Clothing

Key Stakeholders Roles / Designations

Head of In-house Manufacturing (Madura Clothing)

Heads individual domains such as shirts, trousers and suits, IE

Heads the factory, responsible for general management

Responsible for the technical part of the factory

Asst manager- project

Rashmi Rao, Projects, Madura Clothing

Key Stakeholders Roles / Designations

Responsible for managing production

Responsible for sample production

Responsible for pattern-making / CAD marking for in-house production

Responsible for factory production planning

Responsible for managing cutting and fusing

Responsible for packing and finishing

Responsible to set and maintain the quality systems in factory.

Responsible for Dispatch

Responsible for productivity and efficiency

Responsible for recruitment, induction, canteen , security and legal compliance

Responsible for timely payment and benefits administration.

Responsible to maintain the IT Infrastructure in the factory

Rashmi Rao, Projects, Madura Clothing

Key Stakeholders Roles / Designations

Assist in implementation of 8 dimensions of WCM

Responsible for preventive maintenance and breakdowns

Ensure upkeep of all electrical installations ,UPS, generators, boilers,STP,vapour

Rashmi Rao, Projects, Madura Clothing

Version Control Sheet

Glossary of Process Elements

Key Process Stakeholders and Roles

Rashmi Rao, Projects, Madura Clothing

Macro level process

Rashmi Rao, Projects, Madura Clothing

Process Map : Receipt Of Material In Stores