Garment_ERP/WORKFLOW_GUIDELINE.md

Tiruppur Garment Manufacturing ERP — Complete Step-by-Step Workflow Guide

Odoo 19 Community / Enterprise Edition
Industrial Apparel & Knitwear ERP Suite for Tiruppur Garment Manufacturers

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Table of Contents

1. End-to-End Workflow Architecture
2. Phase 1: Base Masters & Factory Foundation
3. Phase 2: Style Master, POM Grading & Tech Pack
4. Phase 3: Garment Pre-Costing & Target Margin
5. Phase 4: Sales Orders & 2D Color × Size Order Matrix
6. Phase 5: Garment Bill of Materials (BOM) & Routing
7. Phase 6: Master Production Planning (PP)
8. Phase 7: Material Requirement Planning (MRP) & Purchase RFQs
9. Phase 8: Fabric Roll Inventory & 4-Point Quality Inspection
10. Phase 9: Cutting Room Lay Planning & Marker Ratio
11. Phase 10: Barcode Bundle Generation & Traveler Tracking
12. Phase 11: Sewing Floor & Real-Time Hourly Efficiency Logging
13. Phase 12: Subcontracting & Job Work (Delivery Challans)
14. Phase 13: Multi-Stage Quality Control (QC) & Rework Routing
15. Phase 14: Master Carton Packing, Finished Goods (FG) & Dispatch
16. Control Room: Factory Dashboard & Traceability Explorer
17. Index of Standard Print Reports & Barcode Tickets

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1. End-to-End Workflow Architecture

flowchart TD
    M1[1. Base Masters: Colors, Sizes, Fabrics, Lines] --> S1[2. Garment Style & Tech Pack]
    S1 --> C1[3. Pre-Costing Sheet]
    S1 --> SO[4. Sales Order & 2D Matrix Grid]
    SO --> PP[5. Production Master Plan]
    PP --> BOM[6. Garment BOM & SAM Routing]
    PP --> MRP[7. MRP & Shortage Purchase RFQ]
    MRP --> FR[8. Fabric Roll Inward & 4-Point QC]
    FR --> CP[9. Cutting Plan & Lay Ratio]
    CP --> BND[10. Barcoded Bundle Tickets]
    BND --> SEW[11. Sewing Line & Hourly Efficiency]
    BND -.-> JW[12. Job Work Subcontracting: Dyeing/Print/Embroidery]
    SEW --> QC[13. Endline QC & Rework Routing]
    QC --> RW[13b. Rework Order & Repair]
    RW --> QC
    QC --> PCK[14. Export Carton Packing]
    PCK --> FG[15. Finished Goods Inventory]
    FG --> DSP[16. Dispatch & Shipping Logistics]

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Phase 1: Base Masters & Factory Foundation

Configure these fundamental building blocks before entering transactions:

• Menu Path: Garment ERP > Configuration

Master Name	Technical Model	Purpose & Required Settings
Garment Colors	garment.color	Name, unique color code, color family group, Pantone reference (TPX/TCX), and Hex swatch code (e.g., #000000 for Black, #1E3A8A for Navy).
Garment Sizes	garment.size	Size code (e.g., XS, S, M, L, XL, 2XL), size category (Adult, Youth, Infant), and display sequence (controls column ordering in the 2D matrix).
Fabric Knit Types	garment.fabric.type	Knit structures (Single Jersey, 1x1 Rib, 2x2 Rib, Interlock, Pique Polo, Fleece, French Terry, Waffle) with target GSM ranges.
Compositions	garment.composition	Yarn composition percentages (e.g., 100% Cotton, 60/40 CVC, 95/5 Cotton Lycra).
Brands & Seasons	garment.brand, garment.season	Brand identities, logos, and seasonal milestones (e.g., SS-2026, AW-2026).
Garment Types	garment.type	Top wear, Bottom wear, Outerwear, Activewear, Innerwear.
Defect Types	garment.defect.type	Under Quality & Rework > Defect Categories Master. Stitching, Fabric, Measurement, Print/Embroidery, and Finishing defects with severity levels (Minor, Major, Critical).
Sewing Lines	garment.sewing.line	Under Sewing Floor > Sewing Lines Configuration. Line code, supervisor, operator count, helper count, daily target capacity.

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Phase 2: Style Master, POM Grading & Tech Pack

The Style Master represents the garment's design, Point of Measurement (POM) grading chart, and SKU generator.

• Menu Path: Garment ERP > Merchandising > Garment Styles

Step-by-Step Procedure:

1. Click New and enter:
   • Style Code: Internal style code (e.g., TSH-1001).
   • Style Description: Full commercial title (e.g., Men's Crew Neck Bio-Washed T-Shirt).
   • Classification: Select Brand, Season, Gender, Garment Type, and Buyer.
   • Tiruppur Fabric Specs:
     • Knit Structure: e.g., Single Jersey.
     • Fabric Composition: e.g., 100% Combed Cotton.
     • Fabric GSM: e.g., 180 g/m².
     • Fabric Width: e.g., 30.0 inches.
     • Width Type: Select Tubular / Dia (Circular Knit) or Open Width (Slit & Stentered).
     • Shrinkage %: Enter Length & Width expected shrinkage (default 4.0%).
     • Yarn Count: e.g., 30s Combed.
   • Industrial Engineering (IE):
     • Sewing SAM: Standard Allowed Minutes (e.g., 12.0 min).
     • Total SMV: Total Standard Minute Value including cutting and finishing (e.g., 18.0 min).
   • Colors & Sizes: Pick all active colors and sizes for this style.
   • Media & Tech Pack: Upload front/back sketch photos and attach the buyer's Tech Pack PDF.
   • Point of Measurement (POM) Specifications:
     • Add measurement lines: Chest Width, Body Length, Across Shoulder, Sleeve Length, Neck Drop, Bottom Hem, etc.
     • Define Tol (+) and Tol (-) tolerances.
     • Enter graded measurements across XS, S, M, L, XL, XXL, 3XL in cm or inches.
2. Click Generate Product Variants (Header button):
   • Automatically generates standard Odoo product.product records with the SKU structure [STYLE]-[COLOR]-[SIZE] (e.g., TSH-1001-BLK-M).
   • Product variants are immediately available for inventory tracking and BOM linking.

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Phase 3: Garment Pre-Costing & Target Margin

Calculate cost per piece, cost per dozen, overheads, and target profit margins.

• Menu Path: Garment ERP > Merchandising > Garment Pre & Post Costing

Step-by-Step Procedure:

1. Click New, select the Garment Style, Buyer, and enter Target Order Quantity (e.g., 10,000 Pcs).
2. Set Costing Stage: Select Pre-Costing (Quotation / Estimate).
3. If an approved BOM exists, click Load from BOM to pull fabric, trim, and labor costs automatically; otherwise enter:
   • Raw Materials: Fabric cost / pc + Dyeing & Finishing cost / pc.
   • Trims & Accessories: Labels, tags, polybags, cartons, threads.
   • Value Addition: Chest print / Rotary print / Embroidery / Bio-washing.
   • Manufacturing CM (Cut & Make): Cutting labor / pc + Sewing CM labor / pc.
   • Packaging & Freight: Polybags & Cartons / pc + Local freight & Port handling / pc.
   • Factory Overheads %: e.g., 8.0%.
4. Review the auto-computed metrics:
   • Total Garment Cost / Pc
   • Total Garment Cost / Dozen
   • Total Order Cost
5. Enter Target Selling Price / Pc (e.g., ₹180.00).
6. Inspect the auto-computed Gross Margin / Pc, Gross Margin %, and Total Expected Profit.

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Phase 4: Sales Orders & 2D Color × Size Order Matrix

Handle customer orders with multi-dimensional Color × Size distribution.

• Menu Path: Garment ERP > Merchandising > Garment Sales Orders

Step-by-Step Procedure:

1. Click New, pick the Buyer / Customer, and ensure Garment Manufacturing Order is checked.
2. Select the Garment Style (this auto-fills Season, Customer Style Ref, and Buyer).
3. Set Buyer PO Reference, Target Shipment Date, Ex-Factory Date, and Shipment Mode (Sea, Air, Road).
4. Navigate to the Size-Color Order Matrix tab:
   • Add lines selecting Color, Size, Quantity, and Unit Price.
   • The live HTML Order Matrix Summary renders the full 2D Color vs Size table with color swatches, row subtotals, column subtotals, and total piece count.
5. Click Sync Matrix to Order Lines (Header button):
   • Creates or updates native Odoo sale.order.line records linked to the specific variant SKUs (product.product).
6. Click Confirm to lock the Sales Order.

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Phase 5: Garment Bill of Materials (BOM) & Routing

Define raw material consumption and process routing per garment unit.

• Menu Path: Garment ERP > Planning & MRP > Garment BOMs

Step-by-Step Procedure:

1. Click New, choose the Garment Style, and keep Base Quantity as 1.0 Pc.
2. Fabric Components Tab:
   • Add components: Body Panels (Front & Back), Neck Rib, Flat Collar, Pocket Panels, Sleeve Cuffs, Plackets, Hoods.
   • Specify Fabric Product, Net Consumption (Kg/Pc) (e.g., 0.1800 Kg), Cutting Wastage % (e.g., 5.0%), and Fabric Cost / Kg.
   • The system computes Gross Consumption (Kg/Pc) and Fabric Cost / Pc.
3. Trims & Accessories Tab:
   • Add trims: Main Label, Size Label, Wash Care Label, Hang Tag, Price Tag, Polybag, Master Carton Box, Sewing Thread, Buttons, Zippers.
   • Specify Net Qty / Pc, Allowance % (e.g., 3%), and Unit Cost.
4. Operations & Routing Tab:
   • Add manufacturing operations in sequential order across Cutting, Sewing, Job Work, Washing, Finishing, and Packing.
   • Assign machine types (SNLS, 4T Overlock, 5T Overlock, Flatlock, Button Stitch, Steam Iron) with operation SAM and labor minute rate.
5. Save the BOM. The system calculates estimated garment production cost per piece.

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Phase 6: Master Production Planning (PP)

Master Production Planning links customer demand, floor scheduling, and shop floor execution.

• Menu Path: Garment ERP > Planning & MRP > Production Plans
  (Or click "Create Production Plan" inside the confirmed Sales Order)

Step-by-Step Procedure:

1. In the Production Plan, verify:
   • Sales Order Ref, Garment Style, and Garment BOM.
   • Planned Quantity, Production Start Date, Target Delivery Date, and Priority.
   • The Color/Size Production Targets table auto-populates all matrix lines from the sales order.
2. Click Confirm Plan \rightarrow Status changes to Planned / Scheduled.
3. Click Start Production \rightarrow Status changes to In Production.
4. Smart buttons track progress in real time:
   • Cutting Orders
   • Bundles
   • Job Work Orders
   • QC Inspections
   • Packing Plans
5. Progress bar and stage quantities (Cut Qty, Sewn Qty, Packed Qty, Dispatched Qty) update automatically from shop floor execution.

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Phase 7: Material Requirement Planning (MRP) & Purchase RFQs

Calculate gross material requirements, compare against on-hand stock, and generate purchase orders for shortages.

• Menu Path: Inside the Production Plan, click Calculate Material Requirements (MRP)
  (Or go to Garment ERP > Planning & MRP > Material Requirements (MRP))

Step-by-Step Procedure:

1. Open the MRP record and click Compute Material Requirements:
   • Multiplies planned garment pieces by BOM gross fabric consumption (Kg) and trim quantities.
   • Compares required quantities against warehouse stock on hand (qty_available).
   • Determines net Shortage Quantity and total procurement cost.
2. Click Generate Purchase RFQs:
   • Automatically creates draft Purchase Orders (purchase.order) for all shortage materials grouped by vendor.
   • Links generated RFQs directly to the MRP record for traceability.

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Phase 8: Fabric Roll Inventory & 4-Point Quality Inspection

Track knitted fabric roll inventory and enforce the international 4-point defect grading system before cutting.

• Menu Path: Garment ERP > Fabric & Stores > Fabric Rolls

Step-by-Step Procedure:

1. Inward Fabric Rolls:
   • Click New and record Roll Number, Fabric Product, Shade/Dyeing Lot #, Actual GSM, Width, Width Type (Tubular/Open Width), Gross Weight (Kg), Tare Weight (Kg), and Fabric Mill Supplier.
   • Initial status is Received / Uninspected.
2. Conduct 4-Point Inspection:
   • Click Create 4-Point Inspection (or go to Fabric 4-Point Inspections).
   • Inspector verifies measured GSM, measured Width, and evaluates Shade Grade (Grade A to Grade D).
   • Enter defect counts found across the inspected length based on standard 4-point defect rules:
     • 1 Point: Defect \le 3 inches.
     • 2 Points: Defect > 3 up to 6 inches.
     • 3 Points: Defect > 6 up to 9 inches.
     • 4 Points: Defect > 9 inches or any hole.
   • The system computes the defect score: \text{Score per 100 } \text{m}^2 = \frac{\text{Total Defect Points} \times 100}{\text{Inspected Length (Meters)} \times \text{Fabric Width (Meters)}}
   • Pass/Fail Decision:
     • If \text{Score} \le \text{Threshold (default 28 points)}: Click Quality Passed \rightarrow Roll status becomes Quality Approved (Ready to Cut).
     • If score exceeds threshold: Click Quality Failed \rightarrow Roll status becomes Quality Rejected (Quarantine).
     • Only Quality Approved rolls can be issued to cutting orders.

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Phase 9: Cutting Room Lay Planning & Marker Ratio

Plan marker dimensions, fabric roll allocation, and cutting ratios.

• Menu Path: Inside the Production Plan, click Create Cutting Order
  (Or go to Garment ERP > Cutting & Bundling > Cutting Orders)

Step-by-Step Procedure:

1. On the Cutting Plan form:
   • Select Body Fabric Color.
   • Enter Marker Length (Meters), Marker Width (Inches), Number of Plies / Layers (e.g., 100), and Bundle Size (default 25 pieces/bundle).
   • Review the Size Cut Ratio lines (auto-populated from the production targets, e.g., S:1, M:2, L:2, XL:1).
   • Planned Cut Pieces is computed: \text{Plies Count} \times \sum(\text{Ratios}).
2. Fabric Roll Allocation Tab:
   • Select approved fabric rolls (garment.fabric.roll).
   • Enter Weight Issued (Kg), Weight Consumed (Kg), and End-Bit Scrap (Kg).
   • The system computes Fabric Wastage % and deducts consumed weight from the fabric rolls.
3. Click Start Cutting \rightarrow Status changes to In Cutting.

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Phase 10: Barcode Bundle Generation & Traveler Tracking

Split cut plies into serialized bundle travelers with barcode tickets.

• Menu Path: Inside the Cutting Plan, click Generate Production Bundles

Step-by-Step Procedure:

1. Clicking Generate Production Bundles:
   • Divides cut pieces into bundles conforming to the configured Bundle Size (e.g., 25 pcs).
   • Creates serialized bundle records (BND-XXXXX) with ply ranges (e.g., Ply 1–25, Ply 26–50) and unique barcodes.
   • Sets Cutting Plan status to Cut & Bundled.
2. Print Bundle Barcode Tickets:
   • Open the Generated Bundles smart button, select all bundles, and click Print > Production Bundle Barcode Tickets.
   • Attach printed tickets to the cut bundles as physical travelers.
3. Shop Floor Traveler Workflow:
   • As bundles move through manufacturing cells, operators scan or click:
     • Send to Sewing \rightarrow Stage: Sewing Assembly
     • Send to Job Work \rightarrow Stage: External Processing
     • Move to Quality \rightarrow Stage: Quality Inspection
     • Move to Packing \rightarrow Stage: Packing Section
     • Complete Packing \rightarrow Stage: Finished Goods / Packed
   • Every movement creates an immutable entry in the bundle's Operation Tracking History table.

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Phase 11: Sewing Floor & Real-Time Hourly Efficiency Logging

Track hourly line outputs, defect counts, and operator efficiency.

• Menu Path: Garment ERP > Sewing Floor > Hourly Production Logs

Step-by-Step Procedure:

1. Click New at the start of each production shift:
   • Select Sewing Line, Date, Shift, Garment Style Running, and Production Order.
   • Operators present and Style SAM auto-populate from the line and style masters.
2. Record output and defects at the end of each hour:
   • Enter Target, Actual Output, and Defect / Alteration Count for hours H1 through H8 (+ OT).
3. Review Live Line Performance:
   • The system computes day totals and line efficiency: \text{Line Efficiency \%} = \frac{\text{Total Day Actual Output} \times \text{SAM}}{\text{Operators Present} \times \text{Hours Worked} \times 60} \times 100
   • Awards an automated visual badge:
     • Excellent: \ge 90\%
     • Good: 75\% - 89\%
     • Below Target: < 75\%

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Phase 12: Subcontracting & Job Work (Delivery Challans)

Manage external operations for knitting, dyeing, chest print, embroidery, or bio-washing.

• Menu Path: Garment ERP > Subcontracting / Job Work > Job Work Challans (DC)

Step-by-Step Procedure:

1. Click New and enter:
   • Job Worker / Subcontractor partner.
   • Processing Operation: Knitting, Dyeing, All-Over Print, Chest Print, Embroidery, Washing, Finishing.
   • Rate Basis (Per Kg / Per Piece) and Job Work Rate (INR).
   • Standard Process Loss %: Allowed shrinkage/wastage during process (e.g., 4.0%).
   • Transport details: Vehicle Registration No, GST E-Way Bill Number, Expected Inward Date.
2. Materials Sent Outward Tab:
   • Add fabric rolls or garment bundles with dispatched quantities.
   • Click Dispatch Material (Outward DC) \rightarrow Status changes to Material Sent.
   • Print the official GST Job Work Delivery Challan (DC) report.
3. Materials Inward Received Tab:
   • As processed goods return, record Date, Vendor DC No, Received Qty, and Rejected Qty.
   • The system calculates Accepted Good Qty, Pending Balance Qty, Actual Process Loss %, and Total Job Work Cost.
4. Click Complete Job Work once all materials are returned.

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Phase 13: Multi-Stage Quality Control (QC) & Rework Routing

Inspect garments at key control gates and route defects for alteration.

• Menu Path: Garment ERP > Quality & Rework > Quality Inspections (QC)

Step-by-Step Procedure:

1. Click New and choose the Inspection Stage:
   • Fabric Inspection
   • Cutting Section QC
   • Sewing Inline Roaming QC
   • Sewing Endline 100% Checking
   • Job Work Inward QC
   • Final AQL 2.5 Pre-Shipment Audit
2. Select Production Plan, Garment Style, Color, Size, Bundle Ref, and Sewing Line.
3. Enter Lot Quantity, Sample Quantity Checked, Passed Quantity, and Failed Quantity.
4. Under Defect Details, log identified flaws from the Defect Master (e.g., Broken Stitch, Skipped Stitch, Oil Spot, Needle Hole, Measurement Variance).
5. Inspection Verdict:
   • Pass: Click Pass Inspection \rightarrow Status updates to Quality Approved.
   • Rework: Click Trigger Rework Order:
     • Creates a linked garment.rework.order record.
     • Verdict sets to Rework Required.
6. Rework Order Execution (Quality & Rework > Rework Orders):
   • Responsible section assigned: Sewing alteration, Cutting panel replacement, Spot cleaning, or Job worker re-processing.
   • Workflow stages: Assigned \rightarrow In Rework \rightarrow Ready for QA Re-check \rightarrow Passed QA Re-check (restores pieces to production) or Irreparable / Scrapped.

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Phase 14: Master Carton Packing, Finished Goods (FG) & Dispatch

Pack garments into shipping cartons, update finished goods inventory, and dispatch.

Part A: Carton Packing Plan

• Menu Path: Garment ERP > Packing & Dispatch > Packing Plans

1. Click New, select Production Plan, Garment Style, and Carton Packing Method:
   • Solid Color / Solid Size (Single SKU per carton).
   • Solid Color / Assorted Size (Ratio pack, e.g., 1S:2M:2L:1XL).
   • Assorted Color / Assorted Size (Pre-pack mix).
2. Under Master Cartons, add cartons:
   • Enter box dimensions: Length (cm), Width (cm), Height (cm). The system computes CBM (m^3): \text{CBM} = \frac{\text{Length} \times \text{Width} \times \text{Height}}{1,000,000}
   • Enter Net Weight & Gross Weight.
   • Under Carton Breakdown, enter the color and size pieces packed in each box.
3. Click Transfer to Finished Goods:
   • Updates Finished Goods Inventory (garment.finished.goods) by variant SKU with on-hand quantities. Status updates to Packed & Transferred to FG.

Part B: Dispatch & Shipping Logistics

• Menu Path: Garment ERP > Packing & Dispatch > Dispatch & Shipments

1. Click New, select Buyer / Consignee, Sales Order, and Production Plan.
2. Enter logistics info: Carrier / Shipping Line, B/L or Air Waybill No, Container No, Customs Seal No, Truck No, Port of Loading, and Port of Discharge.
3. In Dispatched Cartons, select all cartons loaded into the container or truck.
   • Total cartons, total garments, total gross weight, and total shipment CBM are computed automatically.
4. Click Dispatch Shipment:
   • Deducts shipped quantities from Finished Goods inventory and marks the shipment as In Transit.
5. Click Mark Delivered upon destination arrival.

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Control Room: Factory Dashboard & Traceability Explorer

Factory Live Dashboard

• Menu Path: Garment ERP > Dashboards > Factory Live Dashboard

Monitors real-time shop floor performance across 4 operational domains:

• Executive KPIs: Active Garment Orders, Total Booked Pieces, Active Production Plans, Average Production Progress %.
• Sewing Floor Efficiency: Active Sewing Lines, Today's Output Target vs Actual, Average Line Efficiency %, Today's Alteration Count.
• Inventory & Materials: Fabric Stock (Kg), QC Approved Rolls, Finished Goods Stock (Pcs).
• Operations & Subcontracting: Pending Job Work Challans, Open Rework Orders, Cartons Ready for Dispatch.

End-to-End Traceability Explorer

• Menu Path: Garment ERP > Dashboards > Traceability Explorer

Enter any tracking number (Buyer PO, Production Plan #, Roll Barcode, Bundle QR, or Carton #) to view complete forward and backward traceability:

\text{Buyer PO} \longrightarrow \text{Production Plan} \longrightarrow \text{Fabric Rolls} \longrightarrow \text{Cutting Orders} \longrightarrow \text{Bundles} \longrightarrow \text{Sewing Logs} \longrightarrow \text{QC Inspections} \longrightarrow \text{Cartons} \longrightarrow \text{Dispatch}

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Index of Standard Print Reports & Barcode Tickets

All reports are available via the standard Print menu on their respective documents:

Document / Report	Technical Report ID	Primary Model	Contents
Sales Order Matrix Report	report_garment_sales_matrix	sale.order	Buyer PO, Style specs, 2D Color × Size grid, delivery terms.
Production Master Plan	report_garment_production_plan	garment.production.plan	Target quantities, style BOM reference, scheduled dates.
Bundle Barcode Tickets	report_garment_bundle_barcode	garment.bundle	Printable QR/Barcoded ply bundle stickers for floor tracking.
4-Point Fabric Inspection	report_garment_fabric_inspection	garment.fabric.inspection	Defect point scoring sheet and roll approval certificate.
Cutting Lay Plan & Marker	report_garment_cutting_plan	garment.cutting.plan	Marker length, ply count, size cut ratio, and roll allocation.
Job Work Delivery Challan	report_garment_jobwork_challan	garment.jobwork.order	GST-compliant outward delivery challan (DC) for subcontractors.
Quality Inspection Report	report_garment_quality_inspection	garment.quality.inspection	Stage defect breakdown, sample size, and rework instructions.
Export Packing List	report_garment_packing_list	garment.packing.plan	Box-by-box breakdown, CBM, weights, and shipping marks.
Garment Costing Sheet	report_garment_costing	garment.costing	Pre/Post costing analysis with component-wise margins.

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