KANBAN PROCESS – Cut to Pack

TEXPORT syndicate (I) LTD.

Limiting the amount of Inventory using Pull

Kanban Definition

• Kanban is a Japanese word which means “Visual Card”

• Card system which controls production wip & Inventory.

• It is a “PULL” system.
Benefits of Kanban

a. Highly Visible system

b. Simple & effective
c. Improves lead times
d. Accountability - No last minute surprises
e. On-line Shipment Status – Actual status of packed and to be packed garments
f. On-Time-In-Full (OTIF) shipments – Online rejection/defect monitoring and daily status tracking
g. Better Quality – Only good pieces get filtered via end-line audits
h. Reduces Garment Dead Stock & leftover of good garments
i. Lower Cost for factory – Better utilization of manpower, less OT cost
j. Planning made easy – Better trim availability status and clarity of plan for Fabric stores, Bit
Cutting, Cutting, Sewing and Finishing
Cutting Kanban flow
Tangible Benefits – Cutting Section
Ratio wise
Cutting /
Order Chart
wise cutting

Quality RFT
End bits
(First Pass
management
Quality)
Cutting
Kanban

Fabric
Quantity
Reconciliation
Reconciliation
with
(pieces)
consumptions
Step 1: To Make Micro cut
Plan

1. Plan is made based on

a. Shipment priority
b. Minimarker

2. All Markers to be used in a such way to have equal

ratio of cutting in all sizes.
Step 2: To Issue Micro cut plan to Fabric section and
Supermarket.
1. Fabric Section to issue fabric based on Micro cut plan.
2. In below case, Fabric requirement is of 473 meters but to complete the roll 18 meters extra
issued and mentioned in book. Same to be deducted from next Kanban.
3. Fabric section will issue only 4 Kanban / Style as WIP to cutting section.
Step 3: To Issue Lay Record Based on Micro Cut plan
Step 4: To Cut End Bits Online.
1. For Woven Style, end bits to cut after every 5 Kanban.
2. For Knits Style, end bits to cut after every 4 Kanban.
3. End bits should not be given separate cut number and to be part of previous cut number mentioning as 5A (as per below
example)
4. End bits to store with lot number identification in separate pigeon type racks.
Step 5: Cutting Kanban Audit.
1. Kanban Audit to be done after Complete process of Numbering / Fusing or any other process.
2. To Audit all Kanban by Cutting Quality Audit team and any failed kanban to be rescreened by cutting team.
3. Pass Kanban will move to Supermarket.
Step 6: Kanban Closure
1. Quality team to seal the Kanban card with green (for pass) or red (for fail) smileys.  /
2. Supermarket team to seal the kanban card with “Cut Bundle received seal”
3. Sealing should be according to KANBAN mentioned qnty. No cutting / Parts shortage.
KANBAN Dash Board
1. To Display all KANBAN pending in cutting on Dashboard for clear understanding
and review.
 Finishing
Sewing &

Kanban Flow
FINISHING SEWING
SECTION SECTION
Tangible Benefits – Sewing & Finishing

Ratio wise
loading

Quality RFT
Online rework (First Pass
Quality)
Sewing &
Finishing
Kanban

Quantity Online re-

Reconciliation cutting within
(pieces) 2hrs.
 Step 1: Micro Load Plan

1. Micro Load Plan to be given to supermarket /

Sewing Lines / Dispatch Team.

2. Loading should be done in the sequence of

Micro load plan and to be highlighted with
Highlighter to Keep tracking .

3. Supermarket to keep Minimum 1 day ready to

load WIP.
Step 2: Supermarket Ready to load Stock
Step 3: Kanban Ledger Entries
1. After Issue of each Kanban entries will be done in Kanban Input Ledger
2. Ledger to maintained Line Wise.
Kanban WIP Tracker
Line WIP = 2 Kanban + (No. of Workstations X 5 Units) + 2 Kanban

Eg. Style ABC – 55 workstations & 50pc Kanban size, hence WIP = 100 + (55*5) + 100 = 475 pcs
Kanban Dashboard
• All the pending Kanban cards to be displayed @End line Dash Board.
Serial Card in Sewing for Tracking
• Serial Card to be used of every Parts setting work stations for easy
closure of Kanban.
Step 4: Kanban Audit by Counter Auditor
1. Kanban Audit to be done by Counter auditor as Per AQL.
2. Pass Kanban to move to dispatch with Green seal from Counter auditor.
3. Failed Kanban to be rescreened by sewing team.
Step 5: Kanban Closure
1. Dispatch team to count and collect counter Audit passed kanban from sewing
line as per Kanban Mentioned Audit.
2. Feeding helper to return closed Kanban sticker to Cutting Supermarket to get
net bundle of cutting
Finishing module - line structure in Finishing Section

• Kanban will be in similar lines of Sewing and same

Kanban will be moved to finishing for Cut to pack
style.

• Each Style will be given 6 Kanban’s / Line.

Embroidery Kanban Flow Washing Kanban Flow
Softener Wash – 55kg ± 5kg
Based on wash type, Enzyme Wash – 55kg ± 5kg
Kanban lot has to be Denim Wash – 45kg ± 5kg
made & sent to washing Garment Dyeing – 50kg ± 5kg
Acid Wash – 50kg ± 5kg
Bundle of 40 pcs 2 be
CPL – 55Kg ± 5kg
made @factory &
sent to Emb.

After washing, quality &

quantity seal will be put &
sent to factory
After emb. Quality &
quantity seal will be
put & sent back to
factory

Recd emb. Kanban to

be again merged with
the remaining cut
parts & issued to line
Received Kanban to be issued
for further process