Running head: PROCESS IMPROVEMENT FLOWCHART WK 1 1

Process Improvement Flowchart wk1

Student’s Name

University of Phoenix

Name of the instructor

Flow Chart of the as-is Process (Absecon Mills inc)-1

Order Received

Planning Sampling
Manpower Sourcing Material
Machine Size set& fit
Material sampling

Sample Approval
Fabric & Trim-in
House
PP meeting

FAIL
Cutting
Material
Inspection
Embroidery & Sewing
Printing

Checking
Repair/Alterati
Garments
on
PASS FAIL

Washing

Finishing
Checking
Garments
FAIL Alteration/R
epair
Packing

PASS

FAIL Shipment
Audit

PASS

Shipment
Dispatch
 PROCESS IMPROVEMENT FLOWCHART WK 1 3

Process Improvement flowchart-2

Order Received

Planning Material
Manpower PASS
Machine Inspection
Sample Approval
Material
PASS FAIL
Sampling

Cutting Fabric & Trim-in

Embroidery & Sewing

Checking
Repair/Alterati
Garments
on
PASS FAIL

Washing

Finishing
Checking
Garments

Packing

PASS

FAIL Shipment
Audit

PASS

Shipment
Dispatch
 PROCESS IMPROVEMENT FLOWCHART WK 1 4
Title:
Cause & Effect Matrix-3

Material Inspection Approval Time Repair

Inspection takes Approval from Alteration

Color
Looking for Defect
Quality
Products

Time consuming/delay

Incapability

Financing Unskilled
decision
Machine
Supplier defects Poor Finishing
search Technical
support
Finding
Required washing
Machine

Sourcing Machine Man power Methods

Summary

This process is for Absecon Textile mill (Absecon Mills, 2019). Currently, the way the process goes is that

the Company after receiving the order activates all the departments i.e. planning, sampling and material sourcing.

Company after looking for the supplier transfers raw material to the trim-in house until the approval of sample

from PP meeting. After the sample is approved and material is inspected the material can go for cutting process but

if it fails, it goes back to the fabric house. After printing and sewing the prepared material will go through the

process of checking. If it fails, then need to alter and if it passes this process, the material will pass through

washing and finishing process. The products will then check for the final time and after auditing it will be

dispatched.
 PROCESS IMPROVEMENT FLOWCHART WK 1 5

The current process does not work well to achieve organizational goals. Since, everything needs to be done

carefully without compromising on quality and design; it takes a lot of time to get a task complete from start to

finish. If the product fails at the end of the process and deadline to dispatch the product is almost over, it becomes

difficult to dispatch the final product on time, so there is need to cut the time without compromising on the quality

of end product. So, there is need to incorporate new process.

The company wants to cut the time without compromising on the quality of product. For this purpose,

cause and effect matrix is used to evaluate the process. According to cause and effect technique, it can be seen in

the diagram below that the ‘time” is the factor that need to take into account while incorporating new process. The

time of the process should be reduced without losing the quality.

The process can be improved by skipping extra and useless steps and incorporating two processes at a time

to reduce costs and time. In improved process flowchart as shown below, the material sourcing step is skipped after

the order is received. Being a garment company, the company must have suitable supplier’s contacts on hand to

avoid the time wastage at the initial point. Moreover, material inspection should be done at the initial stage to avoid

the time wastage afterwards. If the company takes time for sampling and its approval at the initial stage and found

defects in material later on, then it has to start processing from zero. Therefore, the inspection of material should be

done first, followed by sampling. In addition, when sampling is done, the authorities should approve it immediately

to start work earlier than before.

The company faces major challenge when the product is ready, but it’s defected, so the repair and alteration

is needed to deliver the quality product on time. It is important to check the garments before dispatching therefore;

we could not skip this step. But, as it can be seen from the diagram below that ‘repair and alteration’ step is

skipped after washing and finishing step. It is done to avoid time wastage. To ensure that products are not defected,

the department will make sure before packaging process. After shipment audit is passed, company can dispatch the

product without wasting extra time and within quality standards.

References
Absecon Mills, I. (2019). Retrieved from abseconmills: https://abseconmills.com/about