SOP

/SOP
SOP2018-03-30T18:02:20+00:00
SOP ON ORDER MANAGEMENT SYSTEM








This SOP starts from receipt of PO from Customer and  ends with stuffing the container
SOP Ref
Process
SOP  Control No.
SOP
Responsibility
Time line
Documents 
Remarks
OMS/1718/001
PO  Checking
0101
To check all the details in PO and ensure it matches the agreed terms; This covers i) Description of the item ii) Price per piece  & Price terms iii) Technical spec iv) Payment Terms v)Delivery condition vi) Order on correct Company and location (ZEN / Classic) (MEPZ / Sricity) vii) Destination location
Murali & Merchandiser concerned
On the day of Receipt
Buyer PO & our  Quote to Buyer

0102
If all okay, please put a seal which mentions all terms ok and sign
Murali & Merchandiser concerned
On the day of Receipt
Buyer PO

0103
If changes are required, Merchandiser can make a request to Buyer
Merchandiser Concerned
On the day of Receipt
Buyer PO

0104
If buyer agrees, get the revised PO or Mail confirmation from Buyer
Merchandiser Concerned
Within a week of first buyer PO receipt
Mail or Revised PO

0105
If some terms  still not matching or buyer did not agree to change, discuss with Director and take his approval in writing (in PO itself or through mail)
Murali & Merchandiser concerned
On the day of Receipt
Buyer PO

OMS/1718/002
Receipt of Buyer PO
0201
Maintain a manual register for Buyer PO / Loading Plan
Murali
Continuous
Sale Order Register

0202
Manual Register shall contain: i. Sl. No. , ii. Date; iii. Buyer Name iv. Oder reference v. Value of order vi. Buyer Ship date vii. SO created date viii. BOM created date ix. Invoice reference
Murali
Continuous
Sale Order Register

0203
Enter all Buyer PO / Loading Plan in the Manual Register
Murali
On the day of Receipt
Sale Order Register

0204
Maintain Buyer PO Register in Excel in sharable folder
Murali
Continuous
Buyer PO Register in Excel

0205
Buyer PO Register in Excel shall contain: i. Sl. No. , ii. Date; iii. Buyer Name iv. Oder reference v. Value of order vi. Buyer Ship date vii. SO created date viii. BOM created date ix. Invoice reference
Murali
Continuous
Buyer PO Register in Excel

0206
Enter all PO in Buyer PO Register in Excel
Murali
On the day of Receipt
Buyer PO Register in Excel

0207
CBM calcuation shall be done for both Exports and domestic and feasibility of container / Vehicle loading to be studied
Murali/ Merchandiser
On the day of Receipt
CBM Calculation sheet
Take some professionally trained Packaging Executive from Indian Institute of Packaging
0208
For Domestic orders, to ensure CBM per vehicle is at least up to 15 CBM per location; For any vehicle required below this level, get prior approval from AVP, with submission of additional cost impact.
Merchandiser
Within one day of receipt of PO / Loading Plan
CBM Calculation sheet & AVP approval (if required)
Working Format to be designed
OMS/1718/003
Creation of Bill of Material & Sale Order Entry
0301
Manual BOM to be created in Excel by Merchandiser and hand over to data entry operator
Merchandiser
1 days after receipt of PO / Loading Plan and for new products 4 days instead of 1 day
BOM in Excel

0302
Creation of FG Master code for new items
Merchandiser
1 day after receipt of PO / Loading Plan for new products 4 days instead of 1 day
ERP Master

0303
Create items codes for Input Materials; While creating codes to ensure different code for fabric & fiber purchased from different sources. But same fabric from same supplier, two different code should not be created.
Merchandiser
within 3 days after receipt of PO / Loading Plan & 5 days for the new products
ERP Master

0304
Creation of Bill of Material
Merchandiser
1 day after receipt of PO / Loading Plan for existing items and 5 days for New items
ERP

0305
Create the Sale Order and enter the details in the ERP System; In the case of Home Center Projection Sale Order created based on loading plan.
Merchandiser
Within 3 days after receipt of PO / Loading Plan for existing items and 5 days for New items
ERP

OMS/1718/004
Style Study for New Products
0401
Merchandiser, R &D/Sampling, Quality control, GGMO(For Sricity SKUs), Planning,VSM should conduct a thorough style study to establish efficient production process
Merchandiser
within 5 days after receipt of PO / Loading Plan
Product Information File (PIF)

0402
Make QC plan with milestone at what stages quality will be checked during entire manufacturing process.
Merchandiser & Quality
within 5 days after receipt of PO / Loading Plan
PIF

0403
Establish correct consumption and make a time study / SAM of production. Customer manual if any must be referred to.
Planning, IE & Costing
within 5 days after receipt of PO / Loading Plan
PIF

0404
Merchandiser shall collect information regarding container loading, palleting, carton box marking from the Buyer PO or Buer Porta and pass on hard copy of such instruction to VSM and get it signed by VSM
Merchandiser
within 5 days after receipt of PO / Loading Plan
Container Loading, Palleting and Carton Box marking instructions

0405
VSM shall educate Supervisors and monitor the processes are happening as per customer requirement
VSM
At the time of Production start
Container Loading, Palleting and Carton Box marking instructions

0406
A product information file (PIF) must be made where all the conclusion of style study, specs of finished product, Raw materials, buyer approved color lab dip, dying and printing styles etc. (Spec and Tech file) and it shall be signed off by the entire team and a copy given to Quality control, R & D / Sampling, GGMO (For Sricity SKUs), Planning, VSM.  This shall have a serial number and version controls.
Merchandiser & Quality
within 5 days after receipt of PO / Loading Plan
PIF

OMS/1718/005
PIF for existing Products
0501
A product information file (PIF) must be made one time for all existing products. This should contain the conclusion  of style study, specs of finished product, Raw materials, buyer approved color lab dip, dying and printing styles etc. (Spec and Tech file) must be entered and signed off by the entire team and a copy given to R & D/sampling, Quality control, GGMO(For Sricity SKUs),Planning, VSM.  This shall have a serial number and version controls
Merchandiser & Quality
within 2 days of receipt of first PO after 1st August 17
PIF

0502
PIF shall be verified and checked its perfection. If it requires any change, action shall be taken to change it.
Merchandiser & Quality
Half yearly by 1st March and 1st Sep
PIF

0503
For any change in PIF, the process needs to be repeated and new PIF shall be signed off by the entire team and a copy given to Quality control, GGMO (For Sricity SKUs), Planning, VSM. This will have the same serial number of original PIF, but Version number will change
Merchandiser & Quality
within 2nd day of receipt of first PO after 1st August 17
PIF

OMS/1718/006
Timeline and Anchor Dates for SO
0601
List down the activities required for the execution of orders; This shall cover material order placing, In-house of materials, Cutting schedule, Process, finishing, packing, stuffing etc. It should also contain Manpower required on each production day including cutting planned days. This list is not exhaustive and should include all the activities required in an extensive manner
Merchandiser with Planning
6th day of receipt of PO / Loading Plan
Signed off Plan

0602
The Plan shall cover activity, Anchor date, responsible person
Merchandiser with Planning
6th day of receipt of PO / Loading Plan
Signed off Plan

0603
If the planning indicates any terms of the order is not feasible and require a change, to take it up with the buyer and get his approval for altered terms in writing
Merchandiser
6th day of receipt of PO / Loading Plan
Mail to Buyer
If buyer approval get delayed, the process may get delayed accordingly
0604
The anchor dates shall ensure Trims & Accessories for cutting & sew is in-house 15 days before the date of cutting;
Merchandiser with Planning
6th day of receipt of PO / Loading Plan
Signed off Plan

0605
The anchor dates shall ensure Packing materials in-house 7 days before the date of filling date as per 6DWC plan;
Merchandiser with Planning
6th day of receipt of PO / Loading Plan
Signed off Plan

0606
To discuss the full plan with anchor date with all concerned - Purchase, Cutting & Sewing, VSMs, Stores, Quality, HR
Merchandiser with Planning
6th day of receipt of PO / Loading Plan
Signed off Plan

0607
Lead time for manufacturing, transportation etc. for each material shall be taken from Purchase and that shall be the basis of timeline and anchor dates
Merchandiser with Planning
6th day of receipt of PO / Loading Plan
Signed off Plan

0608
The full Plan shall be signed off by all persons physically and this signed copy shall be available with Merchandiser and a copy with all signed
Merchandiser
6th day of receipt of PO / Loading Plan
Signed off Plan

OMS/1718/007
Material Request from Merchandiser for Fiber, Fabric and Shell
0701
As soon as the Timeline & Anchor dates are signed off by all concerned, a material request shall be made by Merchandisers in the specified Material Requisition Form. They should forward the soft copy as well as physically signed copy to Purchase
Merchandiser
6th day of receipt of PO / Loading Plan
Material Requisition Form
Form to be Attached
0702
The Material Requisition form shall contain i) the Material ii) Quantity as per BOM with permitted tolerance iii) Spec Sheet iv) In-house date v) Delivery location and vi) Target Rate
Merchandiser
7th day of receipt of PO/ Loading Plan
Material Requisition Form

0703
Purchase Department shall get the best price and give it to Merchandisers
Purchase
10th day of receipt of PO /Loading Plan
Material Requisition Form

0704
The rate given by Purchase shall be compared with the Target rate and if the rate is within RFQ, Merchandiser shall fill the rate and return the final Material Request to Purchase
Merchandiser
10th day of receipt of PO /Loading Plan
Material Requisition Form

0705
If the rates are above RFQ rate, Merchandiser shall send back to purchase  to renegotiate
Merchandiser
10th day of receipt of PO /Loading Plan
Material Requisition Form

0706
If Purchase is unable to get rate below RFQ, Merchandiser shall prepare a cost impact based on last quoted rate available Vs RFQ and shall refer  to CEO and/or Director for renegotiation
Purchase
11th day of receipt of PO /Loading Plan
Material Requisition Form

0707
CEO and/or Director shall renegotiate to get the best price and will take final decision on the rate
Purchase
11th day of receipt of PO /Loading Plan
Material Requisition Form

0708
The rate approved by CEO / Director in the above case, will be filled by Merchandiser and give the Material request back to Purchase
Merchandiser
11th day of receipt of PO /Loading Plan
Material Requisition Form

OMS/1718/008
Purchase Planning & Ordering for Fiber, Fabric, Shells
0801
Medline and Home Center, Orders are based on ROL, which is based on Projection from Buyer; For rates, confirmation shall be taken from Merchandisers to ensure it is within RFQ / Budgeted rate
Purchase Imports / Domestic
Routine
Plan based on ROL

0802
Consumption for projected orders shall be worked out by Planning and given to Purchase
Head Planning
Routine
Plan based on ROL

0803
While placing PO for ROL items, Purchase shall consider i) Consumption based on Projections; ii) the stock available iii) Expected date up to which the stock will last iv) Inward date required for material v) Space availability at stores  vi) Lead time required for Production, Transport, clearance etc.;
Purchase Imports / Domestic
Routine
Plan based on ROL & PO

0804
Orders shall be placed considering all the factors in 0801 and 0802
Purchase Imports / Domestic
Routine
PO

0805
Purchase shall continuously discuss with Stores in charge to ensure space available at the time of ETA.
Purchase Imports / Domestic
Routine
????

0806
For NON ROL, Purchase shall act based on the Material Requisition from Merchandisers; This is applicable for both Import and Domestic purchase
Purchase Imports / Domestic
On the date of receipt of final Material Request from Merchandiser
Material Request

0807
For NON ROL, before placing the PO, Purchase shall check the free stock available at stores Vs the Purchase request from Merchandiser and place order only for the difference quantity.
Purchase Imports / Domestic
On the date of receipt of final Material Request from Merchandiser
Purchase Plan

0808
For ROL as well as NON ROL items: i. PO shall be sent to the Vendor; ii. Spec Sheet as given by the Merchandiser shall be attached to the PO; iii. All receipts shall mention the PO reference in the Bills / Delivery Advice raised by Vendor; iv. For Fabric, Fabric Color Lot Card shall be received along with the materials
Purchase Imports / Domestic
On the date of receipt of final Material Request from Merchandiser
PO with attachments
Information should be shared with corresponding merchandisers
0809
Purchase shall follow up with Vendors  / Logistic, until the materials are in warded as per time line committed and copy of mails shall also be marked to Merchandiser to ensure they are aware of material arrivals
Purchase Imports / Domestic
Continuous
Signed off Plan with GRN
Purchase team has to mark the copy of the mail to concerned Merchandiser, when they are writing to supplier
0810
There shall be parallel follow up by Merchandiser with Purchase as well as vendor to ensure inward of materials as per anchor dates
Merchandiser
Continuous
Signed off Plan with GRN

OMS/1718/009
Fabric cutting Request
0901
Fabric Cutting Requisition shall be made by Merchandiser to  PPC department
Merchandiser
7th day of receipt of PO / Loading Plan
Fabric Cutting Request
To discuss with MD
0902
The requisition shall contain: i) Fabric description; ii) Width; iii) Consumption iv) Number of pieces to be cut; v) Cutting start date (in line with time line anchor date) vi) Shell in house date (in line with time line anchor date);
Merchandiser
7th day of receipt of PO
Fabric Cutting Request
OMS/1718/010
Trims, Accessories & Packing material request
1001
A material request shall be made by Merchandisers and formally send it to Purchase department for Trims, Accessories & Packing materials; Merchandiser shall give soft as well as hard copy of the request to purchase
Merchandiser
7th day of receipt of PO
Material Request
In case of Printing involved, the day calculation will start only after 12th day
1002
The request shall contain i) the Material ii) Quantity as per BOM with permitted tolerance iii) Spec Sheet iv) In-house date (15 days before cutting date for Trims & Accessories), v) Delivery Location &  vi) Target rate
Merchandiser
7th day of receipt of PO
Material Request

1003
Purchase Department shall get the best price and give it to Merchandisers
Purchase
8th day of receipt of PO
Material Request

1004
The rate given by Purchase shall be compared with the RFQ and if the rate is within RFQ, Merchandiser shall fill the rate and return the final Material Request to Purchase
Merchandiser
8th day of receipt of PO
Material Request

1005
If the rates are above RFQ rate, Merchandiser shall send back to purchase  to renegotiate
Merchandiser
8th day of receipt of PO
Material Request

1006
If Purchase is unable to get rate below RFQ, Merchandiser shall prepare a cost impact based on last quoted rate available Vs RFQ. With respect to Carton Box, Polybag  shall refer  to CEO for renegotiation; For others Merchandiser shall renegotiate
Merchandiser
8th day of receipt of PO
Material Request

1007
CEO shall renegotiate to get the best price and will take final decision on the rate for Carton Box & Poly Bag;
Merchandiser
9th day of receipt of PO
Material Request

1008
For others Merchandiser shall negotiate themselves and get final approval from AVP (with revised analysis based on final rate)

9th day of receipt of PO
Material Request

1009
The rate approved by CEO/AVP in the above case, will be filled by Merchandiser and give the Material request back to Purchase
Merchandiser
9th day of receipt of PO
Material Request

OMS/1718/011
Trims, Accessories &Packing ordering
1101
Purchase shall check available free stock before placing any order
Purchase
On the date of receipt of final Material Request from Merchandiser
Material Request

1102
Orders shall be placed as per the approved material request
Purchase
On the date of receipt of final Material Request from Merchandiser
Material Request

1103
Purchase to ensure:  i. PO shall be sent to the Vendor; ii. Spec Sheet as given by the Merchandiser shall be attached to the PO; iii. All receipts shall mention the PO reference in the Bills / Delivery Advice raised by Vendor;
Purchase
On the date of receipt of final Material Request from Merchandiser
PO with attachments

1104
If the minimum order quantity is more than Material Request from merchandiser, there shall be approval of Inventory Controller before placing the order
Purchase
On the date of receipt of final Material Request from Merchandiser
Special approval in Material Request

1105
Purchase shall follow up with Vendors  / Logistic, until the materials are in warded as per time line committed
Purchase
Continuous
Signed off Plan with GRN

1106
There shall be parallel follow up by Merchandiser with Purchase as well as vendor to ensure inward of materials as per anchor dates
Merchandiser
Continuous
Signed off Plan with GRN

OMS/1718/012
Printing in Label / Hang tag /Stickers, inlay cards & printed poly bag & Carton Box (for outside printing)
1201
Merchandiser to collect all artwork and printing matters to be printed from customer PO or customer portal as the case maybe, and submit to Artwork Approval Officer on his Email Id: artworkapproval@zenclassicgroup.com
Merchandiser
7th day of receipt of PO / customer projection
Artwork proof
 
1202
To do proof reading along with the original details available either in PO or in customer portal and do necessary corrections, if required
Artwork Approval Officer
7th day of receipt of PO / customer projection
Artwork proof
1203
Will directly interact with printer and develop the art work and label and will take approvals from Merchandiser and QC
Artwork Approval Officer
7th day of receipt of PO / customer projection
Artwork proof
1204
The artwork approved by Merchandiser and QC shall be sent to Buyer for final approval
Merchandiser
8th day of receipt of PO / customer projection
Mail to Buyer
1205
After getting the approval from Buyer, it shall be signed off by Merchandiser, Quality and Artwork Approval Officer and will be part of Tech file
Merchandiser
9th day of receipt of PO / customer projection
Mail from Buyer
1206
The copy of signed off proof shall be sent to Purchase to be attached with the PO and a target price shall be given for printing
Merchandiser
10th day of receipt of PO / customer projection
Artwork proof
1207
Purchase shall get the quote, compare the price quote within target price ,  if outside printing done
Purchase
11th day of receipt of PO / customer projection
Quote
1208
On receipt of bulk printing matter, it has to be checked again by Merchandiser, Artwork Approval Officer and  QC
Merchandiser & Quality
2 days after sending for Printing
Quote Approval
1209
If there is change in buyer requirement, follow the steps from 1202
Merchandiser
On the day of receipt of buyer approval

1210
For running and existing products, Buyer approval is not necessary; Quality and Merchandiser approval is sufficient.
Merchandiser
7th day of receipt of PO / customer projection

OMS/1718/013
Receipt of Materials
1301
There shall be a weekly intimation report from Purchase (Import & Domestic) to each stores location specifying : i) Material (description and item code) expected to be delivered to Stores in the next week, ii) Supplier of Material, iii) PO reference iv) Quantity, v) Expected in-house date, vi) approximate space to be occupied
Purchase
Every Wednesday pertaining to deliveries in the subsequent week beginning Monday
Weekly intimation Report on Deliveries
 
1302
There shall be a confirmation one day before arrival of goods to the stores containing: i) Material (description and item code) expected to be delivered to Stores in the next day ii) Supplier of Material, iii) PO reference iv) Quantity, v) Expected in-house date, vi) approximate space to be occupied
Purchase
One day before receipt of Material
Material Arrival Note
 
1303
GRN through ERP to be prepared for all the materials received (refer 1303 before GRN preparation)
Head Stores
On the date of receipt
GRN
 
1304
Stores need to check i) PO for any material sent by Vendor ii) SCORDER & DA through which material sent to Sub-contract vendor. In all cases availability of a valid invoice is a must. Where the receipt does not match or not supported by the documents referred, report should be sent to Purchase & AVP for normal purchase and to  Sub-contract process owner with copy to Lakshmanan, Hariharan, Kumara raja and AVP for sub-contract transaction;
Head Stores
On the date of receipt
Mail
 
1305
For Fabrics, to check the receipt of Fabric color Lot/shade Card and if not received, to report to Purchase along with step 1304 above; it means if Fabric Color Lot / shade Card not received, no GRN shall be done;
Head Stores
on the date of receipt
Fabric Colour Lot Card
 
1306
Purchase shall close the gaps by amending PO or any other suitable action so that GRN process is completed
Head Purchase
Within 24 hours of report by Stores
GRN
 
1307
The Materials received shall be offered to Quality for checking
Head Stores
Within 24 hours of GRN
ERP
 
1308
Quality shall do the checking in line with the Spec Sheet, Tech sheet, Fabric color Lot / shade card (in case of fabrics) and ensure proper matching; The qualitative techniques like 4 points system or Accepted Quality Limit checking shall be carried out by Quality
Head Quality
Within 24 hours of GRN
???
 
1309
Quality shall check and pass the GRN as per ERP process
Head Quality
Within 24 hours of report by Stores
ERP
 
1310
Store should provide the swatches of all the rolls with identification and hand over to the QC.
Head Stores
Within 24 hours of report by Stores
Swatches of all rolls
 
1311
 Shade-wise segregation of Fabric rolls to be done;
Head Quality
Within 24 hours of report by Stores
Separate Report at Stores
 
1312
Shade Card to be maintained by both Quality and Stores
Head Stores & Quality
Within 24 hours of report by Stores
Separate Report at Stores
 
1313
Fabric rolls should be arranged Buyer wise, Shade wise and lot wise
Head Stores
Continuous

To be verified by Audit team and report
OMS/1718/013a
Issue of Materials
1314
Material Request as per ERP shall be sent by VSM /Cutting Head To Stores
VSM/ Cutting Head
1 day before the production start
MREQ
 
1315
Request for date-wise requirement at Production (in case of partial delivery requirements at Shop floor)
VSM/ Cutting Head
1 day before the production start
MREQ with Manual request in writing for split up date deliveries
 
1316
Keep the Material to be issued separately as a KIT and offer for inspection by Quality
Head Stores
1 day before the production start
MREQ
 
1317
Quality inspects the material with reference to Tech file and Spec file and if any change required, Stores to organize
Head Stores
1 day before the production start
MREQ with Manual request in writing for split up date deliveries
 
1318
Quality clears the material and physically sign the MREQ / Split details
Quality
1 day before the production start
MREQ with Manual request in writing for split up date deliveries
 
1319
Prepare the LTO for the entire KIT
Head Stores
On the day of transfer
LTO
 
1320
Transfer the material to Shop Floor as a KIT
Head Stores
On the day of transfer
LTO
 
OMS/1718/014
Capacity details for Planning Process
1401
A Capacity Report should be created which contains Unit-wise, Machine-wise, Product-wise, Style-wise capacity per hour and signed off by Head of the Plant  / VSM / Head-Maintenance / Head Planning
CEO
One time Activity
Capacity Report
To create a format and submit
1402
There shall be a control number and version number for the Capacity Report; Every change shall have version number change.
CEO
One time Activity
Capacity Report

1403
For every addition of Machinery, Capacity Report shall be revised and sign off by Head of the Plant / VSM / Head - Maintenance
CEO
One time Activity & within 15 days of installation of new machinery
Capacity Report

1404
Capacity Report to be reviewed every 6 months and revised based on analysis of actual production during this period; Maximum achieved per hour during this period shall be kept as the capacity
CEO
December 10th and June 10th
Capacity Report

OMS/1718/015
Basis for Planning
1501
Production Plan shall be prepared for 26th of a month to 25th of the subsequent month
Head Planning
Continuous
P1 and P2

1502
All the Sale orders ETD falling during the period mentioned in 1501 shall be considered; Plan should consider 2 - 3 days FG stock after production in Warehouse, before dispatch
Head Planning
Continuous
P1, P2 and Sale order Register

1503
Preventive Maintenance required during this period shall be considered in Machine hours availability
Head Planning
Continuous
P1 and P2

1504
Hours required for Physical verification of stock & training during this period shall be considered.
Head Planning
Continuous
P1 and P2

1505
For increase of Manpower Direct Labor Timeline Commitment Chart from HR to be considered
Head Planning
Continuous
P1 and P2

1506
If there is a substantial change in Manpower between P1 status and P2 status, prior discussion with Factory HR is a must to ensure increase / decrease can happen within the short span of time; Planning should be done considering this aspect
Head Planning
Continuous
Exchange of e-mail on confirmation of Manpower

1507
Overtime and third shift should not be considered in Planning
Head Planning
Continuous
P1 and P2

1508
When new manpower is provided and if he requires training in advance of 1 week or the time line mutually agreed with VSM, to meet specific skill set, Manpower Planning shall be done accordingly
Head Planning
Continuous
P1 and P2

1509
The time required for Buyer QA / Third Party QA inspection shall be considered
Head Planning

P1 and P2

1510
Two Plans shall be released -P1 on 11th and P2 on 22nd - both for the subsequent month
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1511
Discussion among GGMO (for Sricity), Merchandisers, Planning, VSM, HR, Purchase and Stores shall be done on 24/25th before the start of the P2 Plan and it shall be signed off by all member
Head Planning
24th of Every month
P2

1512
The Plan should be made for MEPZ, Sricity and Bhiwandi separately
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1513
Daily Production Plan shall be circulated covering Plan for the next day, next day +1 and Next day +2
Head Planning
Daily at 4 pm
Daily Production Plan (DPP)

1514
There should be a separate plan for cutting
Head Planning
1st & 16th
Cutting Plan

1515
Daily Cutting Plan shall be circulated covering Plan for the next day, next day +1 and Next day +2
Head Planning
Daily at 4 pm
Daily Cutting Plan (DCP)

1516
All internal and external movement should be suitably taken care of in the planning and adhering to customs compliance
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1517
The capacity available at all locations - MEPZ, Sricity, Bhiwandi shall be properly balanced in the Plan
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1518
The Plan shall cover the filled as well as non-filled products for all locations; For example Flat sheet, Fit sheet produced at Bhiwandi and Inspection offered and Shipped from Mepz.
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1519
Plan should consider capacity of available resources' time - Men and Machine hours (as per capacity report). This shall be for all locations and all products (filled and non-filled)
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

OMS/1718/016
Contents of Production Planning
1601
Sales Orders considered during the period
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1602
Start date and End date of Production
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1603
Stuffing date & Container booking date
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1604
Material Required (based on BOM)
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1605
Man power required
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1606
Machine Hours required
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1607
Idle Time of Production
Head Planning
P1 on 11th and P2 on 22nd
P1 and P2

1608
DPP will contain buyer name, sale order number, Product, Machine, Total order quantity, Balance quantity to produce, Target quantity for each given day
Head Planning
Daily at 4 pm
DPP

OMS/1718/017
Provision of Manpower
1701
Study the Manpower requirement and available Manpower and gaps based on P1 and P2
Head HR
On 12th and 23rd
P1 and P2

1702
Analyze the cost and sales details, adherence to Budget % etc.
Head HR
On 12th and 23rd
P1 and P2

1703
Re-discuss with Planning on gaps and how this can be managed
Head HR
On 13th as well as 24th


1704
Revised Manpower requirement details prepared based on discussion with Planning and get it approved by Planning, VSM, GGMO (for Sricity) and Head HR
Head HR
24th of Every month
Revised Manpower List

1705
Ensure provision of Manpower as per the Revised Manpower List
Head HR
Continuous
Manpower Strength Report

1706
HR shall have a timeline commitment chart for provision of Manpower; This will cover the days required for addition of Manpower for different categories of Labor
Head HR
16th August 2017
Direct Labor timeline commitment chart

1707
Special request for change of Manpower (beyond P2 plan) shall be given by VSM through Planning to HR in writing
VSM
4 days prior to change
Special Request

1708
Change of Manpower during the day shall be discussed with Planning and VSM and implemented
VSM / HR
Continuous


1709
All Compensatory off and leave of Labor shall be approved by HR to ensure effective Manpower availability
VSM / HR
Continuous


1710
For change of Shift of a person 'Shift Change Approval' shall be given to HR by  VSM
VSM
1 days prior to change required
Shift Change Approval

OMS/1718/018
Cutting & Stitching Plan
1801
Cutting & Stitching Plan to be released every fortnight
Head Planning
1st & 16th
Cutting & Stitching Plan

1802
The Plan will cover the Sale orders received during this period & BOM created;
Head Planning
1st & 16th
Cutting & Stitching Plan

1803
The shell shall be available 6 working days before fill date as per P1;  to do back work the start date based on Fabric in-house date, Trims & accessories in house date, cutting & stitching time required
Merchandiser
1st & 16th
Cutting & Stitching Plan

1804
Daily Cutting Plan shall be circulated covering Plan for the next day, next day +1 and Next day +2
Head Planning
Daily at 4 pm
Daily Cutting Plan (DCP)

1805
The Merchandiser request shall contain Fabric Width, Consumption, how many pieces to cut, date of cutting start and end
Merchandiser
1 day after Time line anchor dates finalized
Cutting Request

1806
Any shortage of Fabric shall be identified and managed by Merchandiser
Merchandiser
Continuous
Cutting Request

OMS/1718/019
Follow up and monitoring of Production Plan
1901
Daily reviewing of 6 DWC, Plan Vs Actual
Head Planning
Daily
Daily Report, Plan Vs Actual

1902
Discussion among Merchandisers, Planning, VSM, Purchase, HR and Stores before taking up a work order : This should cover i) BOM perfection ; ii) Right Material availability iii) Manpower availability iv) Machine availability and v) Alternate arrangements in case of any issues
Merchandiser
1 day before the Work Order
Minutes of the meeting
The meeting shall be followed by a minutes of meeting circulated to members concerned
1903
Measure Machine-wise and SKU-wise production efficiency
Head Costing
Every fortnight
DPR Vs Capacity Report

1904
Discuss with Planning & VSM on daily basis with respect to deviation from shipment date, identify the cause and action plan for the future
Merchandiser
Daily


OMS/1718/019a
Change of Plan after P2 Release
1905
Any change arising after the release of P2, shall be routed through a proper approval procedure; It may be a change of location of sale or manufacture or a process; The activity starts with a request raised by Head Planning; Material Transfers required can also be combined with this.
Head Planning
7 days before the date of change
Plan Change Request

1906
Plan Change request shall be physically signed by the following persons: (1) Merchandiser (2) VSM of MEPZ (3) VSM of Sricity (4) Cutting Head, in case of cutting & Stitching involved (5) Purchase (6) Quality (7) Stores person at MEPZ (8) Stores Person at Sricity (9) Planning (10) Factory HR (11) Logistics (16) Kamlesh Pathak (if Bhiwandi transaction involved) (17) Vijay Pooraja (If bhiwandi transaction is involved);  Head Planning can add / delete persons, based on the relevance of the transaction
Head Planning
6 days before the date of change
Plan Change Request

1907
Recommendation from GGM (Operation) for Sricity related transactions
Head Planning
6 days before the date of change
Plan Change Request

1908
Get the approval from AVP / CEO
Head Planning
5 days before the date of change
Plan Change Request

1909
Inform Logistics / Commercial to get suitable approval from Customs for any transfer of material
Head Planning
5 days before the date of change
Plan Change Request

1910
To get approval for transfer of Material from Customs
Head Logistics
2 day before the date of change
Custom Approval

1911
To arrange for transfer of Materials
Head Stores
1 days before the date of change
ERP Document

OMS/1718/020
Cutting & Stitching
2001
Review the Cutting plan and correctness of the Plan based on BOM, Material availability, time required for Cutting, Stitching, Man Power  & Machinery required; Communicate if any change required and ensure plan is suitably changed
Cutting Head
On receipt of Plan
Cutting Plan

2002
Create work order for SO
Cutting Head
3rd & 18th Work order to be created
Work Order

2003
Material Requisition to be made and given to Stores
Cutting Head
2 days before the cutting start date
MREQ

2004
Materials checked by quality including shade segregation to be issued for cutting
Head Stores
1 days before cutting start date
LTO with quality initial

2005
Cross check the quantity and quality of Fabrics
Cutting Head
On receipt of material
Special Document
Form to be Attached
2006
Before start of cutting Fabric rolls to be checked
Checkers
As per Cutting Plan
Special Document
Form to be Attached
2007
In line checking by QC for each new SKU and approval taken from the Merchandiser
Quality
During Production
First Piece  & Five Piece Approval Report & In line checking report

2008
Before laying process Fabric measurement to be checked as per spec
Checkers
As per Cutting Plan
Special Document
Form to be Attached
2009
During lay process, Fabric Measurement to be checked as per spec
Checkers
As per Cutting Plan
Special Document
Form to be Attached
2010
If any defect found in fabrics escalate to Cutting Head for removing or flagging and as per Cutting Head approval take appropriate action
Checkers / Cutting Head
As per Cutting Plan
Special Document
Form to be Attached
2011
After laying Markings to be checked
Checkers
As per Cutting Plan
Special Document
Form to be Attached
2012
Start the cutting process & continue
Cutting Head
As per Cutting Plan
Special Document
Form to be Attached
2013
During cutting process, Cut Panels to be measured and checked
Checkers
As per Cutting Plan
Special Document
Form to be Attached
2014
After cut process, all cut panels to be checked, based on requirement
Checkers
As per Cutting Plan
Special Document
Form to be Attached

Cut panels should be pasted with a sticker which shall carry the same code number as mentioned on the fabric rolls - to avoid the shade variations & Mix ups
Cutting Head
As per Cutting Plan
Cutting Report

2015
PR to be made for cut Panels
Cutting Head
As per Cutting Plan
Special Document
Form to be Attached
2016
Cut Panel issued to sewing process segregating shade-wise
Supervisor
As per Cutting Plan
Special Document
Form to be Attached
2017
Carry out the Sewing Process as per spec and Turning
Supervisor
As per Cutting Plan
Special Document
Form to be Attached
2018
To ensure all aspects in Shell as per the spec
Checkers
As per Cutting Plan
Special Document
Form to be Attached
2019
Rejected pieces are reviewed with QC, Merchandiser &  Cutting Head (both at the time rejection at Cut Panel Level and Shell)
Cutting Head
During Production
Rejection Report

2020
A rejection report to be prepared signed by QC, Merchandiser & Cutting Head
Quality
Daily
Rejection Report

2021
Rejection Report to be circulated to all concerned
Quality
Daily
Rejection Report

2022
Rejected pieces to be returned to Stores through DC signed by Cutting Head, QC & Merchandiser
VSM
Daily
DC for return to Stores

2023
Quality to raise MREQ amendment for the short quantity based on Rejection Report with reason for Rejection
Cutting Head
daily
MREQ Amendment

2024
Merchandiser to check the following before approval of MREQ Amendment:  a) availability of stock to complete the production b) Is it better to short ship quantity or ship full quantity based on stock c) analyze the reason for amendment and possibility of more such rejection and its impact on consumption pattern d) possibility of arranging additional raw material within stipulated time; If he is convinced, he can approve amendment
Merchandiser
daily
MREQ Amendment

2025
Taking additional material based on MREQ amendment and continue production
Cutting Head
daily
LTO /LTI

2026
To raise PR PS and send it stores through LTO
Cutting Head
daily
PR & PS ,  LTO

2027
LTO should be based on SO only;  Direct LTO option cannot be used; Separate LTO for each SO should be done
Cutting Head
daily
PR & PS ,  LTO

2028
To circulate Daily Production Report
Cutting Head
daily at 6pm
DPR

OMS/1718/021
Pillow Filling
2101
Review of P2 and signed Tech file and bring to the notice of planning, if there is any discrepancy in capacity mapping, Manpower gaps, Supply Chain gaps
VSM
1 day after P2 release
P2 Plan

2102
Confirmation Sign off P2 Plan
VSM
24th of Every month
P2 plan signed off

2103
Creation of work order as per Plan start date
VSM
2 days before production start date
Work order

2104
Raising Material request (MREQ) for the full WO quantity and hard copy given to stores for arranging the Material
VSM
1 day prior to Production start date
MREQ

2105
Issue of materials as per the requirement of VSM through LTO but within the MREQ quantity; The quantity shall not exceed the MREQ;
Head Stores
As per VSM requirement
LTO

2106
Check the physical receipt of material from Stores to Production and do LTI
VSM
On the date of receipt
LTI

2107
Based on the spec details, prepare Fiber weight of each SKU and share to operator
VSM
one day before P2 start date
Tech support sheet

2108
Setting the Machine to suit the required SKU
VSM
one day before P2 start date


2109
Start the Filling process on the start date as per P2
VSM
Start date as per P2
P2 plan signed off

2110
In line checking by QC for each new SKU and approval taken from the Merchandiser
Quality
During Production
First Piece& five piece Approval Report & In line checking report

2111
To check hourly production and update on Board
Supervisor
During Production
Board / Hourly Production Report

2112
Rejected pieces are reviewed with QC, Merchandiser & VSM
VSM
During Production
Rejection Report

2113
A rejection report to be prepared signed by QC, Merchandiser & VSM
Quality
Daily
Rejection Report

2114
Rejection Report to be circulated to all concerned
Quality
Daily
Rejection Report

2115
Rejected pieces to be returned to Stores through DC signed by VSM, QC & Merchandiser
VSM
Daily
DC for return to Stores

2116
Quality to raise MREQ amendment for the short quantity based on Rejection Report with reason for Rejection (after ensuring the rejected pieces received and accounted at Stores)
Quality
Within 1 day of Rejection Report
MREQ Amendment

2117
Merchandiser to check the following before approval of MREQ Amendment:  a) availability of stock to complete the production b) Is it better to short ship quantity or ship full quantity based on stock c) analyze the reason for amendment and possibility of more such rejection and its impact on consumption pattern d) possibility of arranging additional raw material within stipulated time; If he is convinced, he can approve amendment
Merchandiser
Within 1 day of Rejection Report
MREQ Amendment

2118
Taking additional material based on MREQ amendment and continue production
VSM
daily
LTO /LTI

2119
Daily update of PR & PS; In case of any MREQ Amendment, excess quantity shall be consumed in PR
VSM
Daily process
PR & PS

2120
After completion of sale order quantity, finished FG are offered for inspection to Buyer QA / Third party  QA
VSM
Production end date
Mail correspondence

2121
Request to Buyer QA / Third party QA for Inspection
Merchandiser
Production end date
Mail correspondence

2122
Buyer QA / Third Party QA to do the inspection and clear the FG for Shipment
Quality
Inspection date
Buyer / Third Party QA report

2123
In case of Inspection failure, FGs rechecked / reproduced and offer for re-inspection and go through the entire process
VSM / Quality
As per Buyer timeline
Buyer / Third Party QA report (revised)

2124
Circulation of Daily Production Report (DPR): i. Machine name; ii. SKU run; iii. Target in pieces & boxes; iv. Actual in pieces & boxes; v. Minutes of break down, if any; vi. Reasons for break-down; vii. Machine-wise Manpower utilized; viii. Shift Target; ix Shift Actual.
VSM
At 10.30 am daily for cumulative previous day as per DPP
DPR

2125
Based on DPR, Plan Vs actual report is updated by Planning department and discussion happens among Planning, VSM, Purchase, Stores, Quality, Logistics &  Merchandiser
Planning
11 am daily
Minutes of the meeting with Action Plan
Minutes to be prepared
OMS/1718/022
Wadding for Single Quilting
2201
Review of P2 and signed Tech file and bring to the notice of planning, if there is any discrepancy in capacity mapping, Manpower gaps, Supply Chain gaps
Wadding VSM
1 day after P2 release
P2 Plam

2202
Confirmation Sign off P2 Plan
Wadding VSM
24th of Every month
P2 plan signed off

2203
Creation of work order as per Plan start date
Wadding VSM
2 days before production start date
Work order

2204
Raising Material request (MREQ) for the full WO quantity and hard copy given to stores for arranging the Material
Wadding VSM
1 day prior to Production start date
MREQ

2205
Issue of materials as per the requirement of Wadding VSM through LTO but within the MREQ quantity; The quantity shall not exceed the MREQ;
Head Stores
As per VSM requirement
LTO

2206
Check the physical receipt of material from Stores to Production and do LTI
Wadding VSM
On the date of receipt
LTI

2207
Based on the spec details, prepare wadding size and weight of each SKU and share to wadding operator
Wadding VSM
As per P2
Wadding Tech support Sheet

2208
Setting the Machine to suit the Wadding Tech Sheet with GSM
Wadding VSM
As per P2


2209
Start the Filling process one day before the production start date of quilting
Wadding VSM
As per P2


2210
In line checking by QC for each new SKU and approval taken from the Merchandiser
Quality
During Production
First Piece & five piece Approval Report & In line checking report

2211
To check hourly production and update on Board
Supervisor
During Production
Board / Hourly Production Report

2212
Wadding piece mouth closed and transferred to Quilting Area for single needle process
Wadding VSM
Continuous


2213
Circulation of Daily Production Report (DPR): i.SKU run; ii. Target in pieces; iii. Actual in pieces; iv. Minutes of break down, if any; v. Reasons for break-down; vi. Machine-wise Manpower utilized; vii. Shift Target; ix Shift Actual.
Wadding VSM
At 10.30 am daily for cumulative previous day as per DPP
DPR

2214
Based on DPR, Plan Vs actual report is updated by Planning department and discussion happens among Planning, Wadding VSM, Purchase, Stores, Quality, Logistics &  Merchandiser
Planning
11 am daily
Minutes of the meeting with Action Plan
Minutes to be prepared
OMS/1718/023
Wadding for Multi Needle Quilting
2301
Review of P2 and signed Tech file and bring to the notice of planning, if there is any discrepancy in capacity mapping, Manpower gaps, Supply Chain gaps
Wadding VSM
1 day after P2 release
P2 Plan

2302
Confirmation Sign off P2 Plan
Wadding VSM
24th of Every month
P2 plan signed off

2303
Creation of work order as per Plan start date
Wadding VSM
2 days before production start date
Work order

2304
Raising Material request (MREQ) for the full WO quantity and hard copy given to stores for arranging the Material
Wadding VSM
1 day prior to Production start date
MREQ

2305
Issue of materials as per the requirement of VSM through LTO but within the MREQ quantity; The quantity shall not exceed the MREQ;
Head Stores
As per VSM requirement
LTO

2306
Check the physical receipt of material from Stores to Production and do LTI
Wadding VSM
On the date of receipt
LTI

2307
Based on the spec details, prepare wadding size and weight of each SKU and share to wadding operator
Wadding VSM
As per P2
Wadding Tech support Sheet

2308
Setting the Machine to suit the Wadding Tech Sheet with GSM
Wadding VSM
As per P2


2309
Start the wadding process one day before the production start date of quilting
Wadding VSM
As per P2


2310
In line checking by QC for each new SKU and approval taken from the Merchandiser
Quality
During Production
First Piece & five piece Approval Report & In line checking report

2311
To check hourly production and update on Board
Supervisor
During Production
Board / Hourly Production Report

2312
To transfer the wadding to Multi Needle Quilting process through PR PS
Wadding VSM
As per P2
PR & PS

2313
Circulation of Daily Production Report (DPR): i.SKU run; ii. Target in pieces; iii. Actual in pieces; iv. Minutes of break down, if any; v. Reasons for break-down; vi. Machine-wise Manpower utilized; vii. Shift Target; ix Shift Actual.
Wadding VSM
At 10.30 am daily for cumulative previous day as per DPP
DPR

2314
Based on DPR, Plan Vs actual report is updated by Planning department and discussion happens among Planning, Wadding VSM, Purchase, Stores, Quality, Logistics &  Merchandiser
Planning
11 am daily
Minutes of the meeting with Action Plan
Minutes to be prepared
OMS/1718/024
Single Needle Quilting
2401
Setting the Machine to suit the Quilting Tech Sheet with design
Operator
During Production


2402
Wadded shells are clamped, framed and inserted in to the machine for quilting
Operator
During Production


2403
Completed Quilts are checked in-house for trimming and loose stiches, jump stitch
Checkers
During Production


2404
In line checking by QC for each new SKU and approval taken from the Merchandiser
Quality
During Production
First Piece & five piece Approval Report & In line checking report

2405
Inspection cleared pieces are moved to the packing area;
Checkers
During Production


2406
Rejected pieces are reviewed with QC, Merchandiser & VSM
VSM
During Production
Rejection Report

2407
A rejection report to be prepared signed by QC, Merchandiser & VSM
Quality
Daily
Rejection Report

2408
Rejection Report to be circulated to all concerned
Quality
Daily
Rejection Report

2409
Rejected pieces to be returned to Stores through DC signed by VSM, QC & Merchandiser
VSM
Daily
DC for return to Stores

2410
Quality to raise MREQ amendment for the short quantity based on Rejection Report with reason for Rejection
Quality
Within 1 day of Rejection Report
MREQ Amendment

2411
Merchandiser to check the following before approval of MREQ Amendment:  a) availability of stock to complete the production b) Is it better to short ship quantity or ship full quantity based on stock c) analyze the reason for amendment and possibility of more such rejection and its impact on consumption pattern d) possibility of arranging additional raw material within stipulated time; If he is convinced, he can approve amendment
Merchandiser
Within 1 day of Rejection Report
MREQ Amendment

2412
Taking additional material based on MREQ amendment and continue production
VSM
daily
LTO /LTI

2413
Completed Quilts are checked in-house for trimming and loose stiches, jump stitch, labels, measurements and other defects
Checkers
During Production


2414
Inspection cleared pieces are moved to the packing area;
Quality
During Production


2415
Rejected pieces are reviewed with QC, Merchandiser & VSM
VSM
During Production


OMS/1718/024 (contd...)
Single Needle (contd...)
2416
A rejection report to be prepared and signed by QC, Merchandiser & VSM
Quality
Daily
Rejection Report

2417
Rejection Report to be circulated to all concerned
Quality
Daily
Rejection Report

2418
Rejected pieces to be returned to Stores through DC signed by VSM, QC & Merchandiser immediately
VSM
Immediately after DC signed
DC for return to Stores

2419
Quality to raise MREQ amendment for the short quantity based on Rejection Report with reason for Rejection (after ensuring the rejected pieces received and accounted at Stores)
Quality
Within 1 day of Rejection Report
MREQ Amendment

2420
Merchandiser to check the following before approval of MREQ Amendment:  a) availability of stock to complete the production b) Is it better to short ship quantity or ship full quantity based on stock c) analyze the reason for amendment and possibility of more such rejection and its impact on consumption pattern d) possibility of arranging additional raw material within stipulated time; If he is convinced, he can approve amendment
Merchandiser
Within 1 day of Rejection Report
MREQ Amendment

2421
Taking additional material based on MREQ amendment and continue production
VSM
daily
LTO /LTI

2422
Before closing the box, QC shall ensure the correctness of size, color, pieces per box etc.
Quality
daily


2423
Based on packing tech sheet, packing is done
Packers
During Production


2424
Finished cartons are stacked SKU-wise
Packers
During Production


2425
Daily update of PR & PS; In case of any MREQ Amendment, excess quantity shall be consumed in PR
VSM
Daily process
PR & PS

2426
After completion of sale order quantity, finished FG are offered for inspection to Buyer QA / Third party  QA
VSM
Production end date
Mail correspondence

2427
Request to Buyer QA / Third party QA for Inspection
Merchandiser
Production end date
Mail correspondence

2428
Buyer QA / Third Party QA to do the inspection and clear the FG for Shipment
Quality
Inspection date
Buyer / Third Party QA report

2429
In case of Inspection failure, FGs rechecked / reproduced and offer for re-inspection and go through the entire process
VSM / Quality
As per Buyer timeline
Buyer / Third Party QA report (revised)

2430
Circulation of Daily Production Report (DPR): i.SKU run; ii. Target in pieces; iii. Actual in pieces; iv. Minutes of break down, if any; v. Reasons for break-down; vi. Machine-wise Manpower utilized; vii. Shift Target; ix Shift Actual.
VSM
At 10.30 am daily for cumulative previous day as per DPP
DPR

2431
Based on DPR, Plan Vs actual report is updated by Planning department and discussion happens among Planning, VSM, Purchase, Stores, Quality, Logistics &  Merchandiser
Planning
11 am daily
Minutes of the meeting with Action Plan
Minutes to be prepared
OMS/1718/025
Multi Quilting
2501
Review of P2 and signed Tech file and bring to the notice of planning, if there is any discrepancy in capacity mapping, Manpower gaps, Supply Chain gaps
VSM
1 day after P2 release


2502
Confirmation Sign off P2 Plan
VSM
24th of Every month
P2 plan signed off

2503
Creation of work order as per Plan start date
VSM
2 days before production start date
Work order

2504
Raising Material request (MREQ) for the full WO quantity and hard copy given to stores for arranging the Material
VSM
1 day prior to Production start date
MREQ

2505
Issue of materials as per the requirement of VSM through LTO but within the MREQ quantity; The quantity shall not exceed the MREQ;
Head Stores
As per VSM requirement
LTO

2506
Check the physical receipt of material from Stores to Production and do LTI
VSM
On the date of receipt
LTI

2507
Based on the spec details, set the MNQ machine and load the fabric and wadding together for multi quilting
VSM
As per P2
Multi Quilting Tech support Sheet

2508
Each multi quilted cut panel are weighed and checked for correct weight; If found okay moved to next process
Checkers
Daily
Weightage record

2509
If weightage is not okay, to check wadding GSM;  If the wadding GSM is not okay i) to use the quilt for other suitable size; ii) to do wadding roll change iii) To cross check at wadding point, if it is running for same product
Quality
Daily
Weightage record

2510
In line checking by QC for each new SKU and approval taken from the Merchandiser
Quality
During Production
First Piece Approval Report & In line checking report

2511
Move the Multi Quilted piece for other processes like binding attachment, overlock, piping etc.
VSM
As per P2


2512
Completed Quilts are checked for Binding/piping defects, trimming and loose stiches, jump stitch, labels, measurements and other defects
Checkers
During Production


2513
Inspection cleared pieces are moved to the packing area;
Quality
During Production


2514
Rejected pieces are reviewed with QC, Merchandiser & VSM
VSM
During Production


2515
A rejection report to be prepared and signed by QC, Merchandiser & VSM
Quality
Daily
Rejection Report

OMS/1718/025 (contd...)
Multi Quilting (contd...)
2516
Rejection Report to be circulated to all concerned
Quality
Daily
Rejection Report

2517
Rejected pieces to be returned to Stores through DC signed by VSM, QC & Merchandiser immediately
VSM
Immediately after DC signed
DC for return to Stores

2518
Quality to raise MREQ amendment for the short quantity based on Rejection Report with reason for Rejection (after ensuring the rejected pieces received and accounted at Stores)
Quality
Within 1 day of Rejection Report
MREQ Amendment

2519
Merchandiser to check the following before approval of MREQ Amendment:  a) availability of stock to complete the production b) Is it better to short ship quantity or ship full quantity based on stock c) analyze the reason for amendment and possibility of more such rejection and its impact on consumption pattern d) possibility of arranging additional raw material within stipulated time; If he is convinced, he can approve amendment
Merchandiser
Within 1 day of Rejection Report
MREQ Amendment

2520
Taking additional material based on MREQ amendment and continue production
VSM
daily
LTO /LTI

2521
Before closing the box, QC shall ensure the correctness of size, color, pieces per box etc.
Quality
daily


2522
Based on packing tech sheet, packing is done
Packers
During Production


2523
Finished cartons are stacked SKU-wise
Packers
During Production


2524
Daily update of PR & PS; In case of any MREQ Amendment, excess quantity shall be consumed in PR
VSM
Daily process
PR & PS

2525
After completion of sale order quantity, finished FG are offered for inspection to Buyer QA / Third party  QA
VSM
Production end date
Mail correspondence

2526
Request to Buyer QA / Third party QA for Inspection
Merchandiser
Production end date
Mail correspondence

2527
Buyer QA / Third Party QA to do the inspection and clear the FG for Shipment
Quality
Inspection date
Buyer / Third Party QA report

2528
In case of Inspection failure, FGs rechecked / reproduced and offer for re-inspection and go through the entire process
VSM / Quality
As per Buyer timeline
Buyer / Third Party QA report (revised)

2529
Circulation of Daily Production Report (DPR): i.SKU run; ii. Target in pieces; iii. Actual in pieces; iv. Minutes of break down, if any; v. Reasons for break-down; vi. Machine-wise Manpower utilized; vii. Shift Target; ix Shift Actual.
VSM
At 10.30 am daily for cumulative previous day as per DPP
DPR

2530
Based on DPR, Plan Vs actual report is updated by Planning department and discussion happens among Planning, VSM, Purchase, Stores, Quality, Logistics &  Merchandiser
Planning
11 am daily
Minutes of the meeting with Action Plan
Minutes to be prepared
OMS/1718/026
Container booking for Export
2601
Request with internal packing list (based on P2)
Merchandiser
22 days before the container stuffing date
Request for Container

2602
Booking for container to be placed with the liner portal
Head - Logistics
21 days before the container stuffing date
Mail sent to Liner & Container booking Register
Merchandiser, Planning & VSM shall be copied in the mail loop
2603
Re-confirmation from Merchandiser on container booked (based on confirmation from VSM & Production Packing list)
Merchandiser
4 days before the container stuffing date
Mail Confirmation

2604
If the Merchandiser give a different date, rebooking to be done with the liner
Head - Logistics
Immediate based on stuffing / vessel availability
Mail sent to Liner
Merchandiser, Planning & VSM shall be copied in the mail loop
OMS/1718/027
Stuffing the container
2701
Confirmed internal packing list to be provided by VSM to Merchandiser and Logistics
GGMO(for Sricity) / VSM for MEPZ
Two days prior to Stuffing date for all except Medline; For Medline one day prior to stuffing date
Confirmed Internal Packing list with date

2702
The confirmed internal packing list shall match the quantity committed to buyer
GGMO(for Sricity) / VSM for MEPZ
Continuous


2703
If there is a deviation, VSM shall submit a deviation report to Merchandiser and follow up till buyer approves the deviation
GGMO(for Sricity) / VSM for MEPZ
One day prior to Stuffing date
Buyer approval for deviation

2704
Confirmation of booking from the Liner to be received on vessel status
Head - Logistics
One day prior to Stuffing date
Booking details

2705
Logistics will prepare a final packing list (other than Home Center) and will forward a copy to Merchandiser for re-confirmation; Merchandiser shall check and handover to QC. QC shall check and hand it over to Loading Supervisor to proceed with stuffing
Merchandiser
Two days prior to Stuffing date for all except Medline; For Medline one day prior to stuffing date
Final Packing list

2706
Logistics will prepare the final packing list for Home Center; It should go to Merchandiser for confirmation; It should go to VSM for ASN number allocation; ASN allotted packing list and ASN separated stickers shall be handed over to QC by VSM. QC shall check and hand it over to Loading Supervisor to proceed with stuffing
Merchandiser
Two days prior to Stuffing date
Final Packing list

2707
Invoice with packing list to be prepared from ERP; Other documents required for dispatch shall also be prepared
Head - Logistics
On the day of stuffing
Invoice & export documents

2708
Container will be provided as per the timeline (original or Revised, if any)
Head - Logistics
On stuffing date
Container arrival data with security compared with the confirmation

2709
Count and Accuracy check will be done by Quality
Quality
On stuffing date


2710
Photos will be taken by QC for each row
Quality
On stuffing date


2711
For any deviation in stuffing quantity or holding of container, make  a formal request to CEO and get his approval
GGMO(for Sricity) / VSM for MEPZ
On stuffing date
Approval by CEO

2712
To get approval from Buyer for short shipment/Excess Shipment based on CEO approval
Merchandiser
On stuffing date
Buyer approval for deviation

OMS/1718/028
DTA vehicle stuffing
2801
Confirmed internal packing list with locations to be provided by VSM to Merchandiser and Logistics
GGMO(for Sricity) / VSM for MEPZ
Five day prior to Stuffing date
Confirmed Internal Packing list with date

2802
The confirmed internal packing list shall match the quantity committed to buyer
GGMO(for Sricity) / VSM for MEPZ
Continuous


2803
Duty Payment request shall be given 10 days before the stuffing date
Merchandiser
Continuous
Duty Payment Request
Format to be designed
2804
To arrange for customs duty payment 2 days before vehicle stuffing
Head - Logistics
Two days prior to Stuffing date
Duty payment receipt

2805
Vehicle to be arranged as per the location given by VSM
Head - Logistics
One day prior to Stuffing date
Booking details

2806
Vehicle to be available on the day of dispatch
Head - Logistics
On stuffing date
Vehicle arrival data with security compared with the confirmation

2807
Logistics will prepare a final packing list and will forward a copy to Merchandiser for re-confirmation; Merchandiser shall check and handover to QC. QC shall check and hand it over to Loading Supervisor to proceed with stuffing
Merchandiser
Two days prior to Stuffing date for all except Medline; For Medline one day prior to stuffing date
Packing List

2808
Invoice with packing list to be prepared from ERP; Other documents required for dispatch shall also be prepared
Head - Logistics
On the day of stuffing
Invoice

2809
Count and Accuracy check will be done by Quality before loading
Quality
On stuffing date


2810
For any deviation in stuffing quantity or holding of vehicle, make  a formal request to CEO and get his approval
GGMO(for Sricity) / VSM for MEPZ
On stuffing date
Approval by CEO

2811
To get approval from Buyer for short shipment/Excess Shipment based on CEO approval
Merchandiser
On stuffing date
Buyer approval for deviation

OMS/1718/029
Import Container Planning
2901
Import Container Plan shall be prepared for both ROL and Non-ROL items, discussed with Stores and finally approved by AVP; To ensure the monthly requirement is met with equal distribution week-wise
Purchase Imports
By 28th of every month for next month
Import Container Plan

2902
Monthly information to Logistics to arrange container based on approved import plan. This shall contain: i. Purchase Order No; ii. Vendor Name iii. Number of Containers; iv. ETD of Vendor
Purchase Imports
By 30th of every month for next month
Logistic Plan for Imports

2903
To get competitive quotation from various forwarders, prepare a comparison chart and get it approved by AVP and CEO for the best rate
Head Logistics
3 days from the date receipt of Logistic Plan for Imports
Approval Chart

2904
To book the containers within 5 days from the date of receipt of Logistic Plan for Imports
Head Logistics
Within 6 days from the date of receipt of Logistic Plan for Imports
Mail Communication
Copy of mail to be shared with Purchase and Merchandiser
2905
If any booking to be cancelled, 3 working days prior intimation to be given to Logistics
Purchase Imports
3 Working days before the date of placement of container
Mail Communication
Copy of mail to be shared with Stores and Merchandiser
2906
To submit full set of import documents to Logistics within 5 working days from the date of sailing at the port;
Purchase Imports
within 5 working days from the date of sailing at the port
Mail Communication
Copy of mail to be shared by Logistics with Planning, Stores and Merchandiser
2907
To ensure ETA and inward date at factory as per timeline
Head Logistics
Continuous
Mail Communication
Copy of mail to be shared with Planning, Stores and Merchandiser
OMS/1718/030
Needle and sharp tools handling
3001
The limit of needle to be kept in Shop floor will be fixed
VSM
Continuous
Needle Stock Register

3002
At any point of time good needle in hand, in Machine and defective shall match the limit fixed
VSM
Continuous
Needle Stock Register

3003
Needle receipt, issues, broken /defective details to be maintained in the Register with the name of Supervisor
VSM
Continuous
Needle Stock Register

3004
Any broken, defective needle to be pasted (the full needle part) in the Broken Needle Register Folder.
VSM
Continuous
Needle Register Folder

3005
Every week the needle to be replenished to the extent of broken and defective needle count
VSM
Every Monday
Needle Register Folder

3006
Every day end, VSM shall check the physical availability of needles (in hand, in machines & broken needle) and ensure its stock count
VSM
Continuous
Needle Stock Register & Folder

3007
To fix the limit of Sharp Tools maintained in Shop floor
VSM
Continuous
Sharp Tool Register

3008
The sharp Tools shall be fixed with the checking tables, wherever feasible
VSM
Continuous


3009
All loose sharp tools shall be issued at the start of the shift and returned back with proper counting and signature by the end of the shift
VSM / Shift in Charge
Continuous
Sharp Tool Register

3010
Sharp Tools receipt, issues details to be maintained in the Register
VSM
Continuous
Sharp Tool Register

3011
Every day end, VSM / Shift in charge shall check the physical availability of Sharp Tools and ensure its stock count
VSM / Shift in charge
Continuous
Sharp Tool Register




























S S Manivannan

Swadeep Patnaik





Asst Vice President (F & A)

Chief Executive Officer