PROCESS MAPPING - STORES

S.No PROCESSES Remarks

1 Truck arrives at the unit
2 The MM in charge goes down to the truck
3 Material is unloaded
4 Material checked against the packing list and the invoice
5 Send Invoice to security for sealing Sealing should be done at the arrival of RM

6 Material is loaded to a trolley

7 Material moved to the lift
8 Material moved to the inward area from the lift
9 Unloading from the trolley
10 Collect Invoice from security Sealing should be done at the arrival of RM

11 Random checking of the quantity by referring the BOM Reduce checking time by setting standards of checking

12 Material waiting for inspection in the inward area

13 Inspecting the material (Assortment according to the grades)
14 Counting/ physically checking the material Reduce time by standardising the counting qty according to lot size
15 The material is then moved to the testing area Rreduce movement by reducing distance
16 In-house Tests are performed and 10% of the material is sent to CLRI
17 Waiting till the test reports are prepared Authentic test reports should be requested from the supplier
18 Variations in the material to be reported to CIL
19 The Goods receipt note is prepared
20 Prepare DC for Leather Re-measurement
21 10 % Leather to sent for Re-measurement
22 Receipt of Re-measurement leather
20 Prepare DC for Leather Re-measurement
21 10 % Leather to sent for Re-measurement
22 Receipt of Re-measurement leather
23 DCM variations to be reported
24 Store Material as per the BOM qty in racks
25 Place sticker according to customers
26 Receipt of Production Plan
27 Check details in production plan
28 Prepare bundles of raw material according to the carton/ issuable lot size
29 Reserve materials according to planned lot size
30 Move Leather to the respective rack
31 Consumption trial run (leather cutting)
32 Waiting for coach inspector Coach inspector should be intimated 2 days prior to specified date

33 Verification of consumption, leather defects by coach inspector

34 Approval by inspector
35 Making approval and the acceptable standards chart
36 Prepare the job card and the kanban racks according to the production plan
37 Every hour requirement checked (The material is issued on receipt of the FG)
38 Material is issued and FG is collected cell wise based on job card
39 Material moves to FG area
39 Material handler walks to reservation area
40 Picks up the material and issues it using the job card every hour
41 Walks to the cell
42 Delivers the material
43 Come back to the store
44 Update the RM issue register and the FG Received register
45 Maintain Stock of FG
46 Request for the bar code stickers from MWC 5 day in advance
47 Receive the bar code stickers
48 Stick bar code stickers to the cartons
49 Provide atleast 80% of the shipment qty to buyer for AQL audit
50 Receive Packing List from MWC
51 Preparing the DC and Invoice
52 Security verification
53 Loading of the cartons on the trolley
54 Move the trolley to the ground floor
55 Loading FG Cartons in truck for shipment
56 Sealing the cartons

Value Added Process

Necessary Non Value Added
Inspection
Delay
Transportation
Storage