1. Order Intake → TNA Generation
flowchart TD
A(["Omega Line sends Sub PO
tech pack PDF + PO email"]) --> B["Merchandiser creates
Style Master"]
B --> C["Merchandiser creates
Sub PO"]
C --> D{"Style already
has costing?"}
D -- No --> E["CM Costing form
created"]
D -- Yes --> F["TNA sheet
auto-generated
14 milestones"]
E --> G["MD reviews costing"]
G -- Approved --> F
G -- Rejected --> E
F --> H["TNA milestones
tracked per PO"]
H --> I{"PP Sample
approved?"}
I -- No --> J["Sample cycle
see Flow 4"]
I -- Yes --> K(["Bulk production
unlocked"])
style A fill:#E0F5FE,color:#0f172a,stroke:#0f172a,stroke-width:1px
style K fill:#D1FAE5,color:#0f172a,stroke:#0f172a,stroke-width:1px
2. Fabric GRN → MRN → Cutting
flowchart TD
A(["Fabric truck arrives"]) --> B["Store Keeper
creates GRN draft"]
B --> C["Enters roll-level data
roll no · weight · shade · width"]
C --> D["QC checks each roll
approve / reject"]
D --> E["GRN submitted
status: Submitted"]
E --> F["TNA milestone
Fabric Received auto-ticked"]
F --> G{"Cut Order
requested?"}
G -- Yes --> H["Cutting Master
creates Cut Order"]
H --> I["Fabric MRN issued
from GRN rolls"]
I --> J["MRN approved
fabric allocated"]
J --> K["Bundles generated
QR code per bundle"]
K --> L(["Cutting starts"])
style A fill:#E0F2FE,color:#0f172a,stroke:#0f172a,stroke-width:1px
style L fill:#D1FAE5,color:#0f172a,stroke:#0f172a,stroke-width:1px
3. CM Costing & MD Approval
flowchart TD
A(["Sub PO exists"]) --> B["Merchandiser fills
CM Costing form
SAM · CPM · Efficiency"]
B --> C["System calculates
CM/piece = SAM × CPM / Eff
Total CM = CM × Qty"]
C --> D["Costing submitted
status: Pending"]
D --> E["MD reviews
margin · buyer price · profit%"]
E -- Approved --> F["status: Approved
TNA milestone ticked"]
E -- Rejected --> G["Merchandiser revises"]
G --> D
F --> H{"Invoice
ready?"}
H -- After dispatch --> I["CM Invoice generated
per shipment"]
I --> J(["Invoice sent to Omega Line"])
style A fill:#E0F2FE,color:#0f172a,stroke:#0f172a,stroke-width:1px
style J fill:#D1FAE5,color:#0f172a,stroke:#0f172a,stroke-width:1px
4. Sample Cycle
flowchart TD
A(["Sub PO created"]) --> B["Sample Request raised
type: Fit / PP / Size Set / Sealer"]
B --> C["Sample made in
sample room"]
C --> D["Sample submitted
to buyer / Omega Line"]
D --> E{"Buyer decision"}
E -- Approved --> F["status: Approved
attempt logged"]
E -- Rejected --> G["Rejection remarks
recorded"]
G --> H{"Max attempts
reached?"}
H -- No --> C
H -- Yes --> I["Escalate to MD"]
F --> J{"Sample type
PP?"}
J -- Yes --> K(["Bulk cutting
unlocked"])
J -- No --> L(["Next sample type
triggered"])
style A fill:#E0F2FE,color:#0f172a,stroke:#0f172a,stroke-width:1px
style K fill:#D1FAE5,color:#0f172a,stroke:#0f172a,stroke-width:1px
5. Cut → Bundle → Sewing → Daily Production
flowchart TD
A(["Cut Order approved
fabric MRN issued"]) --> B["Cutting Master
lays fabric
records layers · marker eff"]
B --> C["Bundles generated
QR: PO-Color-Size-SeqNo"]
C --> D["Line Supervisor
scans bundle in"]
D --> E["Line Allocation
PO assigned to line
start/end dates · daily target"]
E --> F["Hourly production entry
by Line Supervisor"]
F --> G["System calculates
efficiency · DHU · trend"]
G --> H{"End of day"}
H -- Continue --> F
H -- Line done --> I["Sewing output
matches target?"]
I -- Yes --> J(["Bundle moves to
Finishing / QC"])
I -- No --> K["Production Manager
reviews shortfall"]
K --> F
style A fill:#E0F2FE,color:#0f172a,stroke:#0f172a,stroke-width:1px
style J fill:#D1FAE5,color:#0f172a,stroke:#0f172a,stroke-width:1px
6. QC Inspection → Rework
flowchart TD
A(["Garments reach
QC checkpoint"]) --> B["QC Inspector creates
Inspection Record
type: Inline / Endline / Final / AQL"]
B --> C["Records defects
defect type · severity · qty"]
C --> D["System calculates
DHU · AQL result"]
D --> E{"Inspection result"}
E -- Pass --> F(["Garments proceed
to next stage"])
E -- Conditional Pass --> G["Minor remarks
logged"]
G --> F
E -- Fail --> H["Rework Order
created from inspection"]
H --> I["Assigned to operator
defect type · pieces"]
I --> J["Operator starts rework
timestamp recorded"]
J --> K["Re-inspection
by QC"]
K -- Fixed --> L["status: Fixed
pieces back to line"]
K -- Rejected --> M["status: Rejected
downgraded / scrapped"]
L --> F
style A fill:#E0F2FE,color:#0f172a,stroke:#0f172a,stroke-width:1px
style F fill:#D1FAE5,color:#0f172a,stroke:#0f172a,stroke-width:1px
7. Packing → Dispatch → Invoice → PO Close
flowchart TD
A(["Finished goods QC
passed"]) --> B["Packing List created
per Sub PO"]
B --> C["Cartons entered
color · size · pcs · weight · dims"]
C --> D["Fulfillment checked
ordered vs packed vs balance"]
D --> E{"All ordered
qty packed?"}
E -- No --> C
E -- Yes --> F["Packing List
status: Completed"]
F --> G["Dispatch Record
created
carrier · AWB · date"]
G --> H["Sub PO status
Shipped"]
H --> I["CM Invoice
auto-generated
Total CM = CM/piece × shipped qty"]
I --> J["Invoice sent
to Omega Line"]
J --> K{"Payment
received?"}
K -- Yes --> L["Sub PO
status: Closed"]
K -- Pending --> M["Follow-up"]
M --> K
style A fill:#E0F2FE,color:#0f172a,stroke:#0f172a,stroke-width:1px
style L fill:#D1FAE5,color:#0f172a,stroke:#0f172a,stroke-width:1px
8. Fabric Reconciliation
flowchart TD
A(["GRN submitted
fabric received"]) --> B["Roll-level
stock tracked"]
B --> C["MRN issued
for cutting"]
C --> D["Consumed qty
recorded from
cut order"]
D --> E["Reconciliation report
Received · Issued · Consumed · Wastage"]
E --> F{"Wastage %
vs allowed?"}
F -- Within limit --> G["status: Within
Signed off"]
F -- Exceeds limit --> H["status: Exceeds
flagged for MD"]
H --> I["Investigation
shrinkage / theft / error"]
I --> J["Remarks recorded"]
J --> G
style A fill:#E0F2FE,color:#0f172a,stroke:#0f172a,stroke-width:1px
style G fill:#D1FAE5,color:#0f172a,stroke:#0f172a,stroke-width:1px
9. Consumables BOM & Usage
flowchart TD
A(["Style Master
created"]) --> B["Store Keeper sets up
Consumable BOM
item · category · qty/piece · waste%"]
B --> C["BOM items defined
Thread · Labels · Packaging
Trims · Accessories"]
C --> D{"Production
starts?"}
D -- Yes --> E["Daily usage
recorded against BOM
qty issued · date"]
E --> F["Actual vs BOM
comparison tracked"]
F --> G{"Usage within
BOM estimate?"}
G -- Yes --> H(["Continue production"])
G -- Exceeds --> I["Flag to
Production Manager"]
I --> H
style A fill:#E0F2FE,color:#0f172a,stroke:#0f172a,stroke-width:1px
style H fill:#D1FAE5,color:#0f172a,stroke:#0f172a,stroke-width:1px
10. HR — Attendance → Payroll → Bank Files
flowchart TD
A(["End of month"]) --> B["ZKTeco attendance
file imported
CSV / Excel"]
B --> C["System processes
check-in / check-out per employee"]
C --> D["OT auto-calculated
1.5x normal · 2x weekend · 2x holiday"]
D --> E["Leave deductions
applied from leave balances"]
E --> F["Salary Advance
recovery deducted"]
F --> G["Payroll generated
Basic · OT · Incentive · Gross
EPF 8% · Net"]
G --> H["MD reviews
payroll summary"]
H -- Approved --> I["Payslips generated
PDF per employee"]
I --> J["Bank files generated
per bank: BOC · Commercial
Sampath · HNB · NSB"]
J --> K["EPF / ETF return
report generated"]
K --> L(["Files submitted
to bank / Labour Dept"])
style A fill:#E0F2FE,color:#0f172a,stroke:#0f172a,stroke-width:1px
style L fill:#D1FAE5,color:#0f172a,stroke:#0f172a,stroke-width:1px
11. Full Order Lifecycle (Summary)
flowchart LR
PO(["Sub PO
Received"]) --> S["Style
Master"]
S --> TNA["TNA
Auto-gen"]
S --> CST["CM
Costing"]
TNA --> GRN["Fabric
GRN"]
TNA --> SMP["Sample
Cycle"]
GRN --> CUT["Cut
Order"]
SMP --> CUT
CST --> CUT
CUT --> BND["Bundles
QR"]
BND --> SEW["Sewing
Lines"]
SEW --> QC["QC
Inspection"]
QC -- Fail --> RWK["Rework"]
RWK --> QC
QC -- Pass --> PKG["Packing
List"]
PKG --> DIS["Dispatch"]
DIS --> INV["CM
Invoice"]
INV --> CLO(["PO
Closed"])
style PO fill:#E0F2FE,color:#0f172a,stroke:#0f172a,stroke-width:1px
style CLO fill:#D1FAE5,color:#0f172a,stroke:#0f172a,stroke-width:1px