TEXTILE AND APPAREL PLANT PRODUCTION PROCESS AND IMPORTANCE OF SUPPLY CHAIN MANAGEMENT

Prepared by,NAZMUS SAMA SUNIAEXECUTIVE-Supply Chain Management

Presentation outline:

• Textile plant cycle.• Textile production process.• Apparel plant flow chart.• Apparel plant production process.• Warehouse system.• Supply Chain Management work flow.• Importance of Supply Chain Management.

Textile Plant Basic Work plan serial:Contents :1.Lab dip (Coloration)2.Store/Warehouse3.Knitting4.Grey Inspection5.Batch Preparation 6.Wet Process •Dyeing •Finishing7.Final Inspection8.Lab Test •Physical test •Chemical test9.Ready For Delivery(RFD)

Textile Plant Cycle:

Taking order

Analyzing Order

KnittingDyeing

Finishing

Working procedure:

Taking orders

Analyzing the orders

Planning for knitting

Planning for dyeing

Planning for finishing

Merchandiser/Marketing Dpt.

Technical department

Planning Department

Lab dip/coloration flow chart:Swatch from

buyer

Color selection

( from Buyer)Receiving standard

swatch from buyer

Determination of sample’s

possible color combination

Sent to buyer for approval

Lab

Dip

Bulk production by considering the buyer’s

approved sample as standard

Warehouse System:Planning

Organizing

Staffing

Directing

Controlling

Objectives of strategic warehouse:- Outline existing operation.- Determine warehouse storage and inventory needs. - Find weaknesses and areas for change in current warehouse effort. - Identify alternative solutions.

- Evaluate new plans. Tax Time value of moneyTotal operation cost

Possibility of inventory damageHow you adjust the changes

- Update plan based on assessments.

Perfect warehouse system:

Key factors:1.Location

2.Efficient loading and unloading.3.Temperature(23˚C – 27˚C)4.Planning and predicting the amount of stock.5.Seasonality and high selling product by using previous data.6.Enough storage facility.

1.Location

Apparel warehouse:Fabric warehouse

Accessories warehouse

Chemical warehouse

Spare parts warehouse

Information

Information

Inventory

Inventory

Inventory

Inventory

Warehouse Process Flow Chart:

Order Projection

Requisition from buyer

Booking list from merchandiser

Order by LC or loan

Capacity analysis and adjustment

Receive products

Quality check

Kept details of the products

Store products

Bill

and

invo

ice/C

halla

n

Com

mer

cial

Depa

rtmen

tYarn, Dice & Chemical,

Grey Fabric, Finished fabric

13579

111315171921232527293133353739414345474951535557596163656769717375

0 2,000,000 4,000,000 6,000,000 8,000,000 10,000,000

Stock BDT including interest Interest Stock Value (BDT)

Inventory Turnover:

Inventory turn over =

SalesInventory

Example: Let a Company’s annual sales is 476.3 billion and year end inventory is 44.9 billion . Annual cost of sales 351.1 billion.

Inventory turn over for the year = (351.1/44.9)=8 Its days inventory = (1/8)×365=46 days Which shows the company has a good inventory system.

Knitting Process Flow Chart:

Withdraw knitting

Weighting

Grey inspection

Any faults in the fabric, stop mark ,

oil stain

Knitting

Batch preparation for

dyeing

Set the machine as

per design & GSM

Yarn requisition

Order Sheet

Planning

Graph on knitting production:

Single jersey Single jersey Single jersey Single jersey Single jersey Single jersey Single jersey Single jersey Single jersey Single jersey Single jersey Single jersey Single jersey

Fleece Fleece

Rib Rib Interlock Rib Interlock

Rib Interlock

Eight Lock S Jersey

Rib

0 50 100 150 200 250 300 350 400

Capacity and Production Chart

Series2 Series1

Wet processing/Dyeing Flow Chart:

Batch receiveBatch

preparation

After treatment Risk factor removal

Lab preparation

Lab & Process engineering

Process selection

Fabric Loading

Pre TreatmentScouring

Bleaching

Dyeing

Fabric Unloading

Slitting

Drying

Compacting

QC check

Garments or Store

Finish

ing

Squeezing

Planning department

Lab test Flow Chart:Final inspection

Lab Test

Physical test Chemical test

Pressure Test

GSM test

Shrinkage Test

Color fastness test

Rubbing

Phenolic Yellowing

Fabric composition Test

Ready Fabric for Delivery

Garment production flow chart:Finished Fabric

Cutting

SewingFinishing

Final Inspectio

n

Apparel plant garment manufacture flow chart:

Finished fabric

Design & product

developmentSample making

Approved sample

Sorting

CuttingFabric Spreading

Production pattern

Costing Sewing

Finishing

Final inspection

Packing

Send to Buyer

Buye

r re

quisi

tion

Planning dpt.

Information

Sample Section Working Process:

Make Photo

SampleQuotation Sample

Develop Sample

Send to Buyer

Correction made

Size set Sample

PP Sample

Buyer’s Approval

Starting Bulk

production

Process Flowchart of Merchandising:

Make buyer required sample

for approvalMake requisition for

bulk production

Make requisition for accessories

Raw material availability and

listing

Make PP sample with all actual

Start bulk production

Order received from buyer with

detailsSample

development

Price negotiation with the buyer

Confirmation of order and receive

order sheet

Info

rmat

ion

Info

rmat

ion

& fo

llow

up

Cutting Flow Chart:Work order

sheet

Fabric cutting

Send sewing/Printing section for bulk

productionMarker

making by CAD

Panel check

Fabric spreading

Receiving fabric from

store

Placing marker paper on the

lay

Sorting & Bundling

Sewing flow chart:Fabric from cutting dpt.

Parts distribution to the worker

Marking(individual)

Inline quality inspection

Parts joining

Output counting and checked

with the planning

End line quality inspection

Finishing

Information

Garments finishing flow chart:

Line wise garments input Ironing QC check

Folding Metal detection Packing

ShipmentFinal inspection

Structure of SCM system:Supply Chain Management

Inventory Management Procure to pay

Requisition

Purchase

Warehouse

Inventory planning

Material receive & Quality Control

Material transfers & issue

Material sent on returnable & non returnable basis

Physical Verificatio

nInventory

Classification

Stores Managemen

t

Information & Follow up

Efficient supply chain helps:

1.Ensure the availability of product.2.Efficient channel management.3.Procuring the cheapest source available.4.Maintaining best possible relationship with the suppliers.5.Maximizing the profit margins by reducing the cost.6.Minimize the level of inventories.

Thank you all