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
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VSM / Shift in Charge
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Continuous
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Sharp Tool Register
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3010
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Sharp Tools receipt, issues details to be maintained in the Register
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VSM
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Continuous
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Sharp Tool Register
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3011
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Every day end, VSM / Shift in charge shall check the physical availability of Sharp Tools and ensure its stock count
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VSM / Shift in charge
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Continuous
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Sharp Tool Register
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S S Manivannan
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Swadeep Patnaik
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Asst Vice President (F & A)
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Chief Executive Officer
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