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.
🏭 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:
🛠️Navigate to the Setup section, then click on Set Other Item Details and select Setup Godown.
➕Click on Create New Godown.
✍️Enter the following details:
Mill Name (e.g., Sunrise Dye Works)
Short Name / Code (e.g., SDW01) for quick reference in dropdowns and reports
💾Save the setup.
✅ Once saved, this mill will appear in stock transfer options🔁, ledgers📘, and reports📊.
🧾 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:
Navigate to the Purchase Voucher📑.
🆕Create a new purchase entry for the Grey Fabric received from your supplier.
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
💾Save the document.
💡 Now the fabric is available in your main warehouse and ready to be issued for processing✅.
🔄 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:
Navigate to the Inventory section in the Main menu, then select Stock Transfer - Godown Wise option.
🆕Create a new transaction and select:
🏭Mill (from the list of Godowns)
➕Add the grey fabric item(s) being issued.
📏Input Quantity, Unit, and optionally link🔗 it to a Job Order.
💾Save and post the transaction.
📦 This action reduces the stock from your warehouse and moves it to the selected mill’s inventory📉.
🎨 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:
Navigate to the Inventory section and click to open Job Work - Receipt against Issue window.
Now, click on document📂 from Menu bar, and click to Retrieve from Godown Stock Transfer.
From the Stock Transfer Search window, choose the original issue document🔍 used to send fabric to the mill.
Click OK to load the transfer record.
🆕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)
💾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.
📊 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📆.
✅ Final Summary of the Mill Process Flow
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
🧷 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.
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