Mill Process Flows

YouTube: Mill Process Flows in Production

🧵 Complete Mill Processing Workflow Guide

This tutorial walks you through the end-to-end mill processing workflow🎯, including mill setup, fabric stock management, inter-location transfers, waste tracking, and reporting. The process is essential for manufacturers who outsource dyeing, printing, or finishing operations to external mills.

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🏭 Step 1: Mill Setup

Before issuing any fabric for processing, the system must recognize the mill as a valid location.

🔍Why this is important:

Setting up a mill as a storage or processing location (also known as a "Godown" or warehouse) ensures traceability📦 and enables seamless stock movements between your factory and third-party job workers.

📋Instructions:

1. 🛠️Navigate to the Setup section, then click on Set Other Item Details and select Setup Godown.

2. ➕Click on Create New Godown.

3. ✍️Enter the following details:

   • Mill Name (e.g., Sunrise Dye Works)

   • Short Name / Code (e.g., SDW01) for quick reference in dropdowns and reports

4. 💾Save the setup.

✅ Once saved, this mill will appear in stock transfer options🔁, ledgers📘, and reports📊.

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🧾 Step 2: Record Grey Fabric Stock (Purchase Entry)

You cannot issue fabric to a mill unless it is available in your system’s inventory📦.

🔍Why this matters:

Grey fabric is the raw material that will be dyed or finished at the mill. Logging it properly ensures accurate stock valuation and availability.

📋Instructions:

1. Navigate to the Purchase Voucher📑.

2. 🆕Create a new purchase entry for the Grey Fabric received from your supplier.

3. Input:

   • 🧾Supplier/Vendor Name

   • 🧵Fabric Item Name (e.g., 100% Cotton Grey 60x60)

   • 📏Quantity and Unit (e.g., 1,000 meters)

   • 💸Purchase Rate per unit

   • 🧾Invoice Number and Date

4. 💾Save the document.

💡 Now the fabric is available in your main warehouse and ready to be issued for processing✅.

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🔄 Step 3: Transfer Grey Fabric to Mill

Now that the grey fabric is in stock, it needs to be sent to the designated mill for job work such as dyeing🎨, printing🖨️, or finishing✨.

🔍Purpose:

This step documents the stock movement and helps generate reports📊 on material sent out for processing.

📋Instructions:

1. Navigate to the Inventory section in the Main menu, then select Stock Transfer - Godown Wise option.

2. 🆕Create a new transaction and select:

   • 🏭Mill (from the list of Godowns)

3. ➕Add the grey fabric item(s) being issued.

   • 📏Input Quantity, Unit, and optionally link🔗 it to a Job Order.

4. 💾Save and post the transaction.

📦 This action reduces the stock from your warehouse and moves it to the selected mill’s inventory📉.

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🎨 Step 4: Receive Dyed Fabric from Mill

After job work is complete, the processed fabric must be brought back into your inventory with updated value and attributes.

🔍Why this is critical:

This step ensures the transformed product is properly recorded🏠 with its new characteristics (e.g., color🟦, finish🧽), and waste or losses during processing are accounted for.

📋Instructions:

1. Navigate to the Inventory section and click to open Job Work - Receipt against Issue window.

2. Now, click on document📂 from Menu bar, and click to Retrieve from Godown Stock Transfer.

3. From the Stock Transfer Search window, choose the original issue document🔍 used to send fabric to the mill.

4. Click OK to load the transfer record.

5. 🆕Enter details of the Dyed or Finished Fabric Received:

   • 🎨New Item Name (e.g., Dyed Cotton Fabric – Navy Blue)

   • 📦Quantity Received

   • 💰Cost per Unit

   • 🧮Allocated Quantity (how much is assigned to production or storage)

6. 💾Save the document.

🗑️Auto Waste Calculation:

• The system will automatically compute the Waste Quantity as:

  Waste Quantity = Quantity Received - Allocated Quantity

• 📉This helps track material loss and improves process optimization.

📈 Recording these details accurately also affects cost calculations, stock availability, and production planning.

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📊 Step 5: Reports & Tracking

Your ERP system should provide two essential reports📁 to manage and monitor mill activity.

1. 📦Grey Fabric Inventory – Mill Wise

• Tracks current stock of unprocessed (grey) fabric issued to each mill.

• Useful for identifying delays or bottlenecks in job work🚧.

2. 📤Job Workwise Issue vs. Receipt Report

• Shows how much fabric was sent to each mill.

• Displays what has been received back, and what is still pending.

• Provides lot-wise and mill-wise transparency.

🧮📈 These reports are key for reconciliation🧾, vendor accountability📋, and production forecasting📆.

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✅ Final Summary of the Mill Process Flow

Step	Description
1	🏗️Set up mill in system via Godown configuration
2	🧾Record grey fabric receipt via purchase entry
3	🔄Transfer grey fabric to mill for job work
4	🎨Receive dyed/finished fabric from mill
5	📊Track performance using inventory and job work reports

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🧷 Best Practices & Recommendations

• Always verify mill details before transferring stock to avoid misallocation.

• Cross-check received fabric against issued lots to avoid discrepancies.

• Monitor waste🗑️ percentages regularly to flag inefficient processing or damage.

• Use job order references🔗 to link fabric movements directly to sales or production batches.

• Set up alert systems or reminders📅 for pending receipts from mills.