I N T E R L O O P L I M I T E D

7-KM Khurrianwala, Jaranwala Road

Faisalabad, Pakistan.

PHONE#: +92 41 4360400

Fax#: +92 41 4703507

3 / 5 / 2 0 1 0

MUHAMMAD SHAFIQ

Package dyeing is a form of yarn dyeing in which yarn is

dyed in the form of packages which are loaded in carriers.

The machinery set up is same for both spun and filaments

yarn but dyes, package shape and rewinding machines are

different.

Sale is a process to deal with customer right from Inquiry

handling to dispatch. Sales and marketing act like as a

bridge between the customer and company. Also

negotiation in case of any mis-understanding done by

sales and marketing.

TRAINING REPORT

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Contents

............................................................................................

WHAT IS DYEING

WORKFLOW AT YARN DYEING

YARN DYE HOUSE

TYPE OF YARN DYEING

PRE-TREATMENT

REACTIVE DYEING

DISPERSE DYEING

VAT DYEING

ACID DYEING

NYLON DYEING

INQUIRY HANDLING & ORDER FINALIZATION (LOCAL)

INQUIRY HANDLING & ORDER FINALIZATION (EXPORT)

ISSUANCE OF SALE ORDERS

ISSUANCE OF DELIVERY ORDERS

DELIVERY NOTE

DAILY REPORTS

MONTHLY REPORTS

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WHAT IS DYEING

Textile dyeing is a process which involves uniform, single solid coloration of the material using

an appropriate dye.

The dyeing should be such that it withstands the external environmental conditions of light, heat

and moisture and does not loose its strength and does not change its shade. Dyes used should

also have high tinctorial strength to minimize dye consumption.

WORK FLOW AT YARN DYEING:

According to the requirement , PPC forward query to inventory, which is then forwarded to supplies department from Inventory. Supplies department make purchase order in ERP and inform Sales & Marketing through e-mail. Sales & Marketing department make sales order against this P.O. and the working of yarn dyeing department starts right here.

Against this purchase order the yarn dyeing department take quantity from main store and keep it in yarn dyeing store. Then according to production planning the process of soft winding started. Soft winding is necessary for even dyeing as dye liquor have equal interaction and penetration. If the density of package is not uniform, then even dyeing can not be achieved, same is the case when density of the package is high .

PPC query to Inventory

Inventory to supplies

Supply to MKT for negotiation

Supplies make P.O.

Sales & Marketing make sales order

Yarn Dye House (production)

Yarn Dyeing Store

Dispatch

Invoicing

Payment

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Two types of winding are used in yarn dyeing department:

1. Muff package(filament yarn package without cone OR spring inside allowing fibers free orientation and recovery) winding for filament yarns

2. Cone package winding for spun yarns on dyeing spring packages

Package weight ranges from 900grams........ 1100 grams (spun yarn)

Process Cycle

Following is the over all process cycle:

Yarn issue from YD sore

Soft winding

Loading in Carriers

Pressing by machine/manual

Loading of carriers in machines

Dyeing process

Hydro-Extractor

Dyeing by RF dryer

Rewinding

Packaging

dispatch

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Winding

Winding is a process in which the cone packages(yarn wounded on tapered paper cones having a specific taper angle) are converted to required packages that are used in dyeing process. These packages are made to achieve required package weight and density, it will help in achieving required specs.

Type of winders

1. SSM winder (ITALY) for spun yarn packages with 340-360 mg/cm3 density 2. FADIS winder for muff packages with 90-100 mg/cm3 density

SSM winder (ITALY)

Total number of machines= 3 (double side machines=2 & single sided machine=1)

Number of spindles in each side= 30

Total number of spindles=30*5= 150

Winding speed= 1100 meters/min

Splicing device(take both ends of broken yarn, untwist and again re-twist) for each side= 1

Capacity = 4.5 tons

Efficiency = 80% - 90%

Flyer (used to make traverse) is used to achieve the required winding angle. An inverter (an electronic card which pick program from main panel for individual spindle) is also used for executing program and spindle stopping purpose when there is no yarn due to yarn breakage OR when creel package(unwounded package) ends up. Tensioner is also used for achieving required tension in yarn.

FADIS winder (ITALY)

Total number of machines= 2

Model =2006 &2008

Number of spindles for winding in each m/c= 36

Number of spindles for rewinding in each m/c= 36

Total number of spindles for winding=36*2= 72

Total number of spindles for rewinding=36*2= 72

Winding speed= 1000 meters/min

Splicing device for each side= 1

Package weight = 500 grams

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Total Waste = 5%

Winding Waste = 1%

Capacity =500- 600kg

Efficiency = 80% - 90%

oiling roller speed:

For polyester = 2

For nylon = 1-1.5

Yarn guide is used to achieve the required winding angle. Sensors(device used for yarn presence intimation) are also used to stop when there is no yarn due to yarn breakage OR when creel package ends up.

Dyeing Cycle

Dyeing process is different for different type of yarn dyeing. Here is workflow cycle of disperse dyeing

This is workflow for lighter and medium shades, for darker shades the process of reduction clearance done by using NaoH/NaHso3

Levelling agent is used for uniform dyeing

Draining is a process of removing water/liquor from bath

Cold wash

Acid to maintain PH at 4.5

Dispersing/levelling agent

Dyeing at 130c for 30 min

Draining

shade check

cold wash

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Hydro Extractor

It works on the principal of centrifugal force. The packages are loaded in careers and are rotated at high speed with the help of below attached motor.

No. of machines= 2

Capacity at a time= 32 Cones

Cycle Time= 800 sec

Speed= 1500 rpm

Hydro extractor is used to remove moisture from yarn after dyeing and it removes about 50 to 60% moisture.

RF Dryer

Radio frequency dryer use radio waves for drying purposes. When high frequency waves strike with moisture, it is evaporated in form of steam and yarn is so dryed.

Capacity= 600 Cones

Cycle time= 3 to 4 hours

Re-winder

Total number of machines= 3 (double side machines=2 & single sided machine=1)

Number of spindles in each side= 36

Total number of spindles=36*5= 180

Winding speed= 900-1000 meters/min

Splicing device for each side= 1

One additional device attached is waxing device.

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YARN DYE-HOUSE

PRODUCTION CAPACITIES

Their capacities are as follows:

Sr. no Machine Name Capacity (Kg) Cones

Cones 1 YD-32 FONGS 540-660 600

2 YD-31 FONGS 540-660 600

3 YD-29 FONGS 270-330 300

4 YD-28 FONGS 72-88 80

5 YD-27 FONGS 36-44 40

6 YD-26 (A)Fongs 6 6

7 YD-26 (B)Fongs 6 6

TYPE OF YARN DYEING

Yarn Dyeing: When dyeing is done after the fiber has been spun into yarn, it is called Yarn dyeing. There are many forms of yarn dyeing- Skein (Hank) Dyeing, Package Dyeing, Warp-beam Dyeing, and Space Dyeing.

Package Dyeing: The yarns are wound on spools, cones or similar units and these packages of yarn are stacked on perforated rods in a rack and then immersed in a tank. In the tank, the dye is forced outward from the rods under pressure through the spools and then back to the packages towards the center to penetrate the entire yarn as thoroughly as possible.

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Skein (Hank) Dyeing: The yarns are loosely arranged in skeins or hanks. These are then hung over a rung and immersed in a dye bath in a large container. In this method, the color penetration is the best and the yarns retain a softer, loftier feel. Warp-beam Dyeing: It is similar to package dyeing but more economical. Here, yarn is wound on to a perforated warp beam, immersed in a tank and dyed under pressure. Space Dyeing: In this method, the yarn is dyed at intervals along its length. For these two procedures- knit- deknit method and OPI Space-Dye Applicator- are adopted. In the first method, the yarn is knitted on either a circular or flat-bed knitting machine and the knitted cloth is then dyed and subsequently it is deknitted. Since the dye does not readily penetrate the areas of the yarn where it crosses itself, alternated dyed and undyed spaces appear. The OPI Space-Dye Applicator technique produces multi coloured space- dyed yarns. The yarns are dyed intermittently as they run at high speeds of upto 1000 yards (900 m) per minute through spaced dye baths with continuous subjection to shock waves produced by compressed air assuming supersonic velocities

WHY DIFFERENT DYES REQUIRED W.R.T. DIFFERENT SUBSTRATES

Substrates commonly used in textile industry are:

•

Cotton

•

Nylon

•

Wool

•

Polyester •

Acrylic

•

Viscose rayon

Each of these materials are different from each other chemically as well as

physically. There may be some resemblance in the chemical structure which may

reflect similar properties to some extent. As substrate differ chemically from each

other, so different dyes are required for dyeing.

The reason that these fibrous material differ from each other chemically, they each

require a chemically distinct class of dyes to give them coloration. A wrong class of

dye will not color a fiber at similar conditions of application.

So dyes have been broadly classified according to the substrate(fiber/yarn/fabric) to be dyed which reflects the application process of that particular substrate.

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Dye Classes W.R.T. Substrates

Reactive dyes for cellulosic fibres (cotton, viscose, rayon, bamboo)

Vat dyes are also used for cellulosic fibres

Direct dyes are also used for cellulosic fibres

Acid dyes for protein (wool) and polyamide (nylon) fibres

Disperse dyes for synthetic hydrophobic (polyester) fibres

Basic dyes for acrylonitrile based fibres (acrylic)

PRE-TREATMENT

Two type of pre-treatments are used:

1. Scouring(process for removing impurities) for dark and dull shades 2. Semi/Half bleaching for bright and lighter shades

Scouring:

Detergent = 1 g/l

Alkali =3 g/l

Process time =15 min at 80c

Neutralization is done with 1 g/l citric acid for 10 min at 50 c.

Rinsing is a process in which the water is added from lower side and remove through a valve at top.

detergent+Alkali Drain Rinse Neutralization

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Semi-Bleaching/ Half Bleaching:

Nascent(at the time of production/atomic) oxygen is produced which is used for bleaching. Following ingredients are used

1. Detergent 2. Stabilizer 3. H2O2 4. NaoH

Neutralization is done with 1.5 g/l citric acid for 10 min at 50 c.

REACTIVE DYEING

Reactive dyes form a covalent bond between fibre and dye. They are classified depending on the reactive group present and the optimized conditions in which they are best used. Depending on the type of reaction, the reactive dyes are broadly divided in to two categories: A. Dyes reacting through Nucleophilic substitution reactions B. Dyes reacting through Nucleophilic addition reactions.

All the reactive dyes contain sodium sulphonate group for solubility and dissolve in water to give coloured sulphonate anions and sodium cations. Most reactive dyes have one to four of these sulphonate group, General form of reactive dye is as follows:

S------R----B----X Where, S = Water solubility group

R = Chromophore X = Reactive System B = Bond between reactive system and Chromophore

Chemistry behind Reactive Dyeing: The dyeing principle is based on fiber reactivity and involves the reaction of a functional group of the dyestuff with a site on the fiber to form a covalent link between the dye molecule and the substance. The Four structural feature of typical reactive dyes molecule are:

bleaching for 20 min at 95c

Draining Neutralization with citric Acid

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1. The chromophoric grouping, contributing the color 2. The reactive system, enabling the dye to react with hydroxy group in cellulose. 3. A bridging group that links the reactive system to the chromophore. 4. One or more solublising group, usually sulphuric acid substituent attached to the

chromophoric group for their colour, although the azo chromophore –N=N- is by itself the most important.

Process Flow(dyeing):

Total batch time = 8 Hours

pre-treatment

cold wash for 10 min

salt+leveller at 40c

dyes at 40c for 25 min

soda-ash at 40c for 30 min

dyeing at 60c for 60 min

draining

cold wash

neutralization with citric acid

soaping

hot wash

fixer

softner

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Process Flow(bleaching):

Total batch time = 3 - 4 Hours

The role of washing off agents in reactive dyeing:

Washing off agents are necessary to remove the dye from the dyed material in order to correct

the faulty dyeing. Soaping agents disperse hydrolysed dyestuff and keep them in the water

bath, preventing their re-deposition on the substrate.

Controlling parameters for reactive dyeing:

Process parameters:

Internal fabric/yarn pH Working liquor ratio on the machine Effective salt concentration (actual) Effective alkali concentration (actual) Rate of heating Rate of cooling Fixation temperature Fixation pH Fixation time

Hot wash at 80c for 10 min

Detergent+stabilizer+per-oxide at 60c for 10 min

Caustic soda at 60c for 10 min

Brightner at 70c for 15 min

Bleaching at 110c for 45 min

Drain

Hot wash

Neutralization with citric acid

Softner

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Raw materials:

Man (training, understanding, supervision) Water Common chemicals (Salt, Alkali) Specialty chemicals (Auxillaries) Reactive dyestuffs

After treatments:

After the completion of the dyeing process the dyed substrate is rinsed with cold water. Then soaping is carried out to remove the hydrolysed dye present on the fibre. This is the dye, which is reacted with the water molecule, hence called as the hydrolysed dye. This dye remains unreacted on the fibre surface. Soaping treatment thus removes the unreacted dye present on the fibre thus improving the brilliancy of the fibre. After the soaping treatment few hot washes are given and with one cold wash the substrate is sent for drying.

DISPERSE DYEING

No pre-treatment done for this process

1. Recipe:

Dyes = foron, ciba, Dynix

pH = 4-4.5 (with acid)

Temp. = 130c

Dispersing agent = Lyocol

Dyeing Process:

Polyester textiles require a Heat Setting operation before dyeing. Heat setting eliminates the internal tensions within the fiber generated during manufacture and the new state can be fixed by rapid cooling. This heat setting fixes the fabric/yarn in the relaxed state and thus avoids subsequent shrinkage or creasing of fabric.

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Process Flow:

Total batch time: 3 - 4 hours

Reduction Clearing:

This is the process to improve the fastness of the dyed material by removing all the dyestuff that is superficially adhearing to the fabric/yarn and staining the cotton portion of the blend. The reduction clearance process is done for dark shades.

Recipe:

Sodium hydro-sulphite = 3 gpl

NaoH = 4 gpl

The process is done at 90c for 20 min

Acetic Acid(for neutralization) = 1.5 g/l

Treat the fabric at 70°C for 10 minutes. Do hot wash and cold wash. Drain and unload the batch.

Dispersing/leveling agent at 40c

Acid to maintain pH at 4-4.5

dyeing

hot wash at 130c for 30 min

Draining at 80c

Reduction clearance for Dark shades

Neutralization

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Double dyeing:

Double portion dyeing is used for blends. In double portion dyeing first polyester/Nylon is dyed and then cotton yarn. The process flow is same as for individuals.

Total time required = 10 - 12 Hrs

VAT DYEING

Vat dyes are an ancient class of dyes, based on the natural dye, indigo, which is now produced synthetically

The process "vat dyeing" refers to dyeing in a bucket or vat. It can be performed whenever a liquid, even shade over the entire garment is desired. Almost any dye can be used, including fiber reactive dyes, direct dyes, and acid dyes. One alternative to vat dyeing is direct dye application, such as the process used for tie dyeing. "Vat dyes" are a special class of dyes that work with a special chemistry. Cotton, wool, and other fibers can be all dyed with vat dyes. Note that not all vat dyeing is done with vat dyes.

Most vat dyes are less suitable than fiber reactive dyes for the home dyers, as they are difficult to work with; they require a reducing agent to solubilize them. The dye is soluble only in its reduced (oxygen-free) form. The fiber is immersed repeatedly in this oxygen-free dyebath, then exposed to the air, whereupon the water-soluble reduced form changes color as oxygen turns it to the water-insoluble form. Indigo is an example of this dye class; it changes from yellow, in the dyebath, to green and then blue as the air hits it.

Application of vat Dyes

Application of vat dyestuff is not so easy like direct or reactive dyes. The application involves a lot of chemistry - such as oxidation, reduction, pH control and so on. Even the dissolution of the dyestuff involves a great technique of reduction using adequate quantities of caustic soda and sodium hydrosulphite.

Chemicals used:

Vat leveller, cotton leveller

NoaH

Sodium Hydro-sulphite

H2O2 for oxidation

Meropan XRN

Pre-treatment = H/B

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Why we use Vat dyes:

Excellent light fastness

Excellent wash fastness

Chlorine bleach stable

Process Flow:

Process time = 9 - 10 Hrs

pretreatment H/B

leveller at 40c for 15 min

Dyes at 40c for 25 min

NaoH 40c for 10 min

Sodium hydro-sulphite at 40c for 10 min

dyeing at 60c for 60 min

Drain

Rinse

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ACID DYEING

An acid dye is a dye in which the coloring component is in the anion. They are often applied from an acidic solution in order to intensify the staining. In the laboratory the acid used in the dyebath is often vinegar (acetic acid) or citric acid. The uptake rate of the dye is controlled with the use of sodium chloride.

In textiles, acid dyes are effective on protein fibers, i.e. animal hair fibers like wool, alpaca and mohair. They are also effective on silk. They are effective in dyeing the synthetic fiber nylon but of minimal interest in dyeing any other synthetic fibers.

Acid dyes are generally divided into three classes which depend on fastness requirements, level dyeing properties and economy. The classes overlap and generally depend on type of fiber to be coloured and also the process used.

Acid dyes are thought to fix to fibers by hydrogen bonding, Van der Waals forces and ionic bonding. They are normally sold as the Sodium salt therefore they are in solution anionic. Animal protein fibers and synthetic Nylon fibers contain many cationic sites therefore there is an attraction of anionic dye molecule to a cationic site on the fiber. The strength (fastness) of this bond is related to the desire/ chemistry of the dye to remain dissolved in water over fixation to the fiber.

The chemistry of acid dyes is quite complex. Dyes are normally very large aromatic molecules consisting of many linked rings. Acid dyes usually have a sulfo or carboxy group on the molecule making them soluble in water. Water is the medium in which dyeing takes place. Most acid dyes are related in basic structure to the following:

Anthraquinone type:

Anthraquinone

Many acid dyes are synthesized from chemical intermediates which form anthraquinone-like structures as their final state. Many blue dyes have this structure as their basic shape. The structure predominates in the levelling class of acid dye.

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Azo dyes: The structure of azo dyes is based on azobenzene, Ph-N=N-Ph (see right showing cis/ trans isomers) Although Azo dyes are a separate class of dyesuff mainly used in the dyeing of cotton (cellulose) fibers, many acid dyes have a similar structure, and most are red in color.

Triphenylmethane related:

Triphenylmethane

Acid dyes having structures related to triphenylmethane predominate in the milling class of dye. There are many yellow and green dyes commercially applied to fibers that are related to triphenylmethane.

NYLON DYEING

The dyes which are use for nylon dyeing are different from cotton dyeing, and the process is also different from reactive dyeing. The dyes which are used for nylon are called acid dyes. These dyes are applied at pH 4.5

The recipe procedure is same as in cotton, the difference is only of dyes

Machine running time is 30 min at 90c.Rewin KNR fixer is used in nylon dyeing process to improve the washing and crocking test.

Blend Dyeing:

In blend form first filament is dyed and if required shade is achieved then cotton yarn dyeing is started. The process flow is as under:

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COMPARISON OF DIFFERENT DYEING VARIABLES

Variables Reactive dyeing Disperse dyeing Vat dyeing Blend dyeing

Time 8 hrs 3-4 hrs for light and 5-6 for dark shades

9-10 hrs 10-12 hrs

Temperature 60c 130c 60c

Substrate Cellulose Nylon/polyester cellulose

PH 10.2-11 4.5-5 -

Scouring at 70c for 10 min

Cold wash

Draining

Dyeing at 40c

Increase temp. to 60c

cold wash

Neutralization

Hot wash

cold wash

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INQUIRY HANDLING &ORDER FINALIZATION (LOCAL)

When customer put forward a query directly OR through an agent, the sales and marketing people do their home work against this query to respond properly and efficiently. After calculating cost and finding out feasibility, sales and marketing person communicate with that person through e-mail/phone who put forward the query and give all those information, which he/she required. The workflow is somewhat different for local and export sales.

The process flow of inquiry handling for local sale is as under:

Query: From customer for getting various kind of information related to inquiry

Lab Dips: According to the standard given by the customer, lab dips of 3 shades that are very

near OR exactly same according to standard shade are produced

Costing & Feasibility: The costing for the required shade is done and also the feasibility that

whether the required shade and quantity be produced or not is done so that before responding

to customer, we must know all facts and figure.

Factors required for costing are:

Recipe cost

process cost

Yarn rate (for processed yarn)

Wastages

Query from customer/Agent

Lab dips approval

Costing & Feasibility

If neede sample approval

Negotiation for price and other terms & conditions

Finalization of sales contract

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Commission

Overheads & margin

Packaging cost

Sample approval & Finalization: After the above finalization, if customer said for samples then

the samples are sent to them. If the samples are up to the mark and fulfill the requirements of

the customer, then the contract is finalized but sometimes contract is finalized subject to the

approval of samples. .

Production Planning: According to commitment of delivery, the production is planned keeping

in mind priorities and dispatching dates. the production planning is done by sales & marketing

department and forwarded to production people for execution. Arrangement of ecru yarn also

done by sales and marketing department according as whether customer required processed

yarn OR services.

Issuance of delivery order: After completing the production of a specific order, the production

people inform sales & marketing department. The sales department issue delivery order against

this production, which is forwarded to store through ERP system and also through e-mail. The

store people make delivery note according to delivery order and dyed yarn is dispatched to

customers.

GST Invoices: The delivery note generated against this dispatch is delivered to finance

department. The finance department make GST invoice and forward it to sales department.

Sales department kept a copy of GST and send original to customer.

Commission payment procedure: Mostly an agent is involved in contracts with different

customers, especially in case of export. Commission to agent is given through TT/DD/pay order

against the amount after receiving full contracted payment of sale and with specific percentage

which is mentioned in contract. A note is forwarded by sales person to Director Finance, through

DGM sales for making the commission payment.

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WORKFLOW CYCLE FOR LOCAL SALES

Inquiry handling

Bargaining

Finalization of contract

Production Planning

Production Monitoring

Issuance of delivery order

Dispatching GST invoices

Follow up of payments

Commision Payment

Parties Ledger reconciliation

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INQUIRY HANDLING &ORDER FINALIZATION (EXPORT)

The process of inquiry handling at initial level is almost the same for export and local. In case of

export, the agent put forward the query from customer side. Sales person respond to this query

after checking feasibility same way as done in local sales. Also if needed by customer, then lab

dips (For approval of shade) and samples are produced for approval from customer.

The process flow of inquiry handling for export sale is as under:

Query: From customer for getting various kind of information related to inquiry.

Costing & Feasibility: The costing for the required shade is done and also the feasibility that

whether the required shade and quantity be produced or not is done so that before responding

to customer, we must know all facts and figure for better communication.

Factors required for costing are:

Recipe cost

process cost

Yarn rate (for processed yarn)

Wastages

Overheads & margin

Packaging cost

In-land and sea freight

Clearing and forwarding

Query from customer/Agent

sample approval

Costing & Feasibility

Negotiation for price and other terms & conditions

Finalization of sales contract

Issuance of performa Invoice

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Bank Charges

Insurance

With-holding tax

Excise duty surcharge

Commission

Sample approval & Finalization: After the above finalization, if customer said for samples then

the samples are sent to them. If the samples are up to the mark and fulfill the requirements of

the customer, then the contract is finalized.

Issuance of Performa Invoice: After the finalization of contract, Performa-invoice is issued to

customer containing all the information required for LC opening.

LC (Letter of Credit): It is a mode of payment in which two banks are involved, one from

customer side and other from seller side. The customer's bank assure the seller's bank for

payment from customer side. LC is actually a mutual contract between seller and buyer through

banks.

Documents required for LC are:

Bill of exchange

Bill of lading

Packaging list

Commercial Invoice

Certificate of origin

Beneficiary certificates if needed by customer

Inspection certificates if needed by customer

Production Planning: According to commitment of delivery, the production is planned keeping

in mind priorities and dispatching dates. the production planning is done by sales & marketing

department and forwarded to production people for execution. Arrangement of ecru yarn also

done by sales and marketing department according as whether customer required processed

yarn OR services.

Issuance of delivery order: After completing the production of a specific order, the production

people inform sales & marketing department. The sales department issue delivery order against

this production, which is forwarded to store through ERP system and also through e-mail. The

store people make delivery note according to delivery order and dyed yarn is dispatched to

customers.

Container Arrangement: When the production is ready for dispatch, the sales department

contact city office and they arrange container of the required capacity through shipping line

which is most feasible for shipment. Feasibility of shipment line is analyzed by the following

factors:

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Buyer's acceptable

Line freight should be minimum

Transit time should be minimum

GST Invoices: The delivery note generated against this dispatch is delivered to finance

department. The finance department make GST invoice and forward it to sales department.

Sales department kept a copy of GST and send original to customer.

Commission payment procedure: Mostly an agent is involved in contracts with different

customers, especially in case of export. Commission to agent is given through TT/DD against

the amount of sale and with specific percentage which is mentioned in contract. A note is

forwarded by sales person to Director Finance, through DGM sales.

Contract Finalization

Issue performa-Invoice

LC opening by customer

Sourcing of raw yarn

Production planning

Production Monitoring

Issue delivery order

Container arrangement

Pre-shipmentdocuments

Post-shipment documents

Follow up of final realization

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WORKING IN ERP

ISSUANCE OF SALES ORDER:

After the finalization of contract sales order is issued by sales department. Following terms and

conditions are mentioned in sales order:

Order type and number

Customer and seller's description

Description and quantity of items

Payment mode

Payment terms

Shipping terms

Packaging instructions

Rate and currency

ISSUANCE OF DELIVERY ORDER:

When the production against the order is ready, the production department informs sales

people. Sales people issue delivery order against this production to dispatch to the customer.

Following informations are provided in delivery order:

Item code & description

Quantity and unit of measurement

Customer's name & ship to address

Packaging instructions

Contract # and shipping date

DELIVERY NOTE:

When this delivery order received in store, the store person issue delivery note against this

D.O. and yarn is dispatched accordingly.

Following informations are provided in delivery note:

Item code, quantity and description

Customer's address

Sales person

Packaging instructions

Shipping instructions

Delivery note # & date

Vehicle, Bilty and gate pass number

Lot, order and P.O. number

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DAILY REPORTS

These reports are updated on daily basis to understand daily status of various things like

production, dispatch, total and pending order etc. The reports generated/updated on daily basis

are as under

1- ORDER LEVEL & PRODUCTION LEVEL REPORT:

This report tell us about the following factors for individual customers as well as in whole:

Yarn dyeing plant utilization

Cotton & filament yarn dyeing production

Production and dispatch Month to date

Stock in hand

Last day production

Last day dispatch & new contract

Total and pending orders

Expected loading dates and pending ratio of order

2- PRODUCTION & DISPATCH REPORT:

This report is generated by production people, which tell all production details according to

machines (shade, batch #, yarn type and production). This report also gives information about

current day dispatch. The main features covered in this report are:

Machine wise production

Customer name for production and dispatch

Yarn type dyed and dispatched

Delivery amount

Muhammad Shafiq (GPP) YARN DYEING (Training Report)

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MONTHLY REPORTS

Some reports are generated on monthly basis to check monthly status and to compare with set

targets. These reports are comprehensive and one can get monthly detail easily from these

reports. Following are the reports that are produced on monthly basis:

1- CUSTOMER AND PRODUCT WISE SALE REPORT:

This report tells us about the following on individual customer basis:

Monthly dispatch

Monthly Return

Net quantity & amount

Percentage share of each customer

Item description for each customer in

Grand total of monthly dispatch, return and net value

2- ITEM WISE PRODUCTION & SALES REPORT:

This report gives us information of production and sales along with the description of each item.

The major aspects covered by this report are the followings:

Item description being produced and dispatched

Type of dyeing

Average rate of each item

Total value of production and sales

Monthly total production and dispatched for all items