The document outlines critical information and processes for various departments including merchants, production, costing, and scenarios around in-house and outsourced production, rework, and extra material issues. Key steps include maintaining bills of materials (BOM), routings, conversion charges, purchase orders, cost estimates, and communications between departments for new materials, vendors, production orders, and changes.

1. Business Process & Hand
shake points

2. Critical information for respective departments.
Merchants -
 FG to exist and extended to relevant locations -
Core , fashion, basic, sample, bespoke….
 BOM to exist in both plants and ‘zero qty’ & ‘deviation
qty’ to be maintained for required materials.
 Conversion charges to be included for outsourced
BOM’s.

3. Critical information for respective departments.
Merchants -
 For conversion charges, after sampling presentation
for the season from merchant with outsourcing
team. The outsourcing team would give the
conversion charges for each style within a week to
merchant.
 Planned orders only on ALC plant.
 Phantom wash material to be used as per the
wash details and to be included in the BOM –
Critical.

4. Critical information for respective departments.
Production -
 Routing to be maintained at relevant plants.
 Control keys to be used as required in Routing-
Critical.
 Operation numbers to be used as finalised.
 For external operations, info record number to be
added.
 Release of order – Batch determination, planned W/C
to Actual W/C, CAD release.
 Actual consumption qty to be entered during cutting
confirmation – Inhouse / Outsourced.
 At closure of order, all confirmations to be ‘final
confirmation’ status with ‘open clear reservation’ ticked.

5. Critical information for respective departments.
Production -
 All operation in the routing to be confirmed and actual
qty to be posted in goods movement.
 Purchase orders to be created as soon as production
orders is release for all external orders. In case of
external operations is added later in the routing,
purchase orders would be created accordingly.
 All purchase orders to be closed before ‘TECO’ status.

6. Critical information for respective departments.
Costing -
 Cost estimate to be run for each new FG code
created . Information of materials created would
be checked by costing on regular basis.
(Twice in a week)
 For PPC team, in case before release of order , there is an costing
error, inform costing dept – clear the error and then release the
order.-
Correction : In case of costing error during release of
order, costing dept will check for all orders which have
error and rectify it.
 For ABL brands, if the production is done Inhouse,
costing dept. needs to be informed by mail and cost
estimate needs to be run again @ manufacturing
plants.

7. Scenarios
• Inhouse Production
• Outsourced Production
• Refinishing of FG after receiving at ALC.—
Sent to AFL.
• Refinishing of FG after receiving at ALC.—
Sent to vendor.
• Change of item 1 to item2 – Sent from
ALC to AFL
• Change of item 1 to item2 – Sent from
ALC to vendor

8. Scenarios
• Change of item1 to item 2 during production
at AFL.
• Change of item1 to item2 during production
at Vendor.
• Sampling.
• Third party washing.
• Bespoke orders.

9. In house /Outsourced Production
• FG code creation – upload – merchant
• BOM - upload – Merchant.
• Routing – upload – IED. (New Routing) Information of
creation of new Routing would be given during the
monthly meeting (cut plan meeting) to PPC head
who in turn would give the message to IED dept .
The information of F.G’s for which Routings have
been created would be sent back to the merchant
from IED dept by mail.
• Washing BOM – Upload - Washing dept ( New BOM’s)
– Information of creation of new BOM’S to merchant
sent by mail.

10. In house /Outsourced Production
• In case of new materials – Acc/ trims , information to
be sent from merchant by entering in the template for
creation of new materials and sent to the sourcing
dept.
• On MRP run, generation of P.R for raw materials from
system.
• For new vendors – Production team would fill up the
vendor information form and send to finance. Finance
would forward the same to vendor master creation cell
and creation of vendor would be done within a day.
• In case of new vendors (job workers), Storage locations
would be created by the help desk based on the
requirement sent from finance dept with proper
authorisation.

11. In house /Outsourced Production
• Create Info record and approve the rate from proper
authorities and then use in Routing.
• After release of production order, copy of order to be
given to stores for issue of goods.
• Goods moved against order can be seen in md51 by
PPC team.
• Check on planned cost v/s actual cost . In case of
significant variation, costing dept will inform prod team.
And if required order would have to be revoked.
• For CAD dept, copy of QM report would be
forwarded to CAD to make markers.
• Prioritisation for fabric Quality reports would be given
from PPC to Quality dept based on the monthly
meeting b/n PPC and Sourcing.

12. In house /Outsourced Production
• CAD would subsequently make the markers & specify
the roll numbers to be used in the consumption sheet.
• The consumption sheet would be approved by
finance and then issued to Production team.
• The roll #’s would be put in the production order.
• For debiting vendors, details would be provided by
Production team for each order to finance dept before
closing the production order. For production related
issues – Debit would be done within a month. For
customer compliant related issues – within 3 months.

13. Rework Scenarios
• When FG is sent from ALC to AFL or Vendor, ALC
would send a mail of FG code and qty’s despatched,
based on which production team would make an
‘Rework’ production order.
• For change of item1 to item2 during production ,
merchant would send a mail to production team
mentioning the new FG material code.
• If wash is changed after release of order, the new
wash information would be sent from merchant by mail,
after which the change in production BOM would be
done by PPC team.

14. Extra Issue of materials.
• If extra materials needs to be issued during
production, prod team would send a mail to stores.
And stores would subsequently send the materials to
the order mentioned.
• If new material is required to be added without release
of the order. Merchant will have to add in the BOM and
do MRP run again. PPC will have to read the PP
master data in CO02 to refresh the revised BOM. If
the material is not in stock, the order would be on hold
till the materials comes in stores.

15. Extra Issue of materials.
• If materials needs to be added after the order is
released and a operation is confirmed, the material
would be added in production BOM. If the material is
not in stores, the material would have to be procured
and then issued to the order. Until then the order would
be on hold. Subsequently the merchant would add the
material in the merchant BOM.
• Extra requirement of fashion/special trims would be
included in the merchant BOM ( Fashion code or
staple code) based on the percentage given from
Production team to merchant for specific items.