General idea about building Supply Chain system in RMG sector.

1. TEXTILE AND APPAREL PLANT
PRODUCTION PROCESS AND
IMPORTANCE OF SUPPLY CHAIN
MANAGEMENT
Prepared by,
NAZMUS SAMA SUNIA
EXECUTIVE-Supply Chain Management

2. 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.

3. Textile Plant Basic Work plan serial:
Contents :
1.Lab dip (Coloration)
2.Store/Warehouse
3.Knitting
4.Grey Inspection
5.Batch Preparation
6.Wet Process
•Dyeing
•Finishing
7.Final Inspection
8.Lab Test
•Physical test
•Chemical test
9.Ready For Delivery(RFD)

4. Textile Plant Cycle:
Taking order
Analyzing
Order
Knitting
Dyeing
Finishing

5. Working procedure:
Taking orders
Analyzing the orders
Planning for knitting
Planning for dyeing
Planning for finishing
Merchandiser/Marketing
Dpt.
Technical department
Planning
Department

6. 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
LabDip
Bulk production by
considering the buyer’s
approved sample as
standard

7. Warehouse System:
Planning
Organizing
Staffing
Directing
Controlling

8. 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 money
Total operation cost
Possibility of inventory damage
How you adjust the changes
- Update plan based on assessments.

9. 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

10. Apparel warehouse:
Fabric warehouse
Accessories
warehouse
Chemical warehouse
Spare parts
warehouse
Information
Information
Inventory
Inventory
Inventory
Inventory

11. 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
Billand
invoice/Challan
Commercial
Department
Yarn, Dice &
Chemical, Grey
Fabric, Finished
fabric

12. 0 2,000,000 4,000,000 6,000,000 8,000,000 10,000,000
1
4
7
10
13
16
19
22
25
28
31
34
37
40
43
46
49
52
55
58
61
64
67
70
73
Stock BDT including interest
Interest
Stock Value (BDT)

13. Inventory Turnover:
Inventory turn over =
Sales
Inventory
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.

14. 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

15. Graph on knitting production:
0 50 100 150 200 250 300 350 400
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
Capacity and Production Chart
Series2 Series1

16. Wet processing/Dyeing Flow Chart:
Batch receive
Batch preparation
After treatment Risk factor removal
Lab preparation
Lab & Process
engineering
Process selection
Fabric Loading
Pre Treatment
Scouring
Bleaching
Dyeing
Fabric Unloading
Slitting
Drying
Compacting
QC check
Garments or Store
Finishing
Squeezing
Planning
department

17. 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

18. Garment production flow chart:
Finished
Fabric
Cutting
SewingFinishing
Final
Inspection

19. Apparel plant garment manufacture flow
chart:
Finished fabric
Design & product
development
Sample making
Approved
sample
Sorting
CuttingFabric Spreading
Production pattern
Costing Sewing
Finishing
Final inspection
Packing
Send to Buyer
Buyer
requisition
Planning
dpt.
Information

20. Sample Section Working Process:
Make Photo
Sample
Quotation
Sample
Develop
Sample
Send to
Buyer
Correction
made
Size set
Sample
PP
Sample
Buyer’s
Approval
Starting
Bulk
production

21. Process Flowchart of Merchandising:
Make buyer required
sample for approval
Make requisition for
bulk production
Make requisition for
accessories
Raw material
availability and listing
Make PP sample with
all actual
Start bulk productionOrder received from
buyer with details
Sample development
Price negotiation
with the buyer
Confirmation of order
and receive order
sheet
Information
Information&followup

22. Cutting Flow Chart:
Work order
sheet
Fabric cutting
Send sewing/Printing
section for bulk
production
Marker making
by CAD
Panel check
Fabric
spreading
Receiving
fabric from
store
Placing marker
paper on the lay
Sorting &
Bundling

23. 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

24. Garments finishing flow chart:
Line wise garments
input
Ironing QC check
Folding Metal detection Packing
ShipmentFinal inspection

25. 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
Verification
Inventory
Classification
Stores
Management
Information & Follow up

26. 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.

27. Thank you all