PROCESS MAPPING 
IN 
CLOTHING MANUFACTURING 
S.M.D.S.D. SETUNGE 
A dissertation submitted to the Department of Textile & Clothing Technology of the 
University of Moratuwa in partial fulfillment of the requirements for the degree of 
MASTER OF SCIENCE £ 7 7 C>4 
IN 
TEXTILE AND CLOTHING MANAGEMENT 
Department of Textile & Clothing Technology 
University of Moratuwa. 
Sri Lanka 
June 2004 
M TheSiS col 
University of M o r a t u w a ^ J >3 
81232 
S l ? 3 2 
PROCESS MAPPING 
IN 
CLOTHING MANUFACTURING 
MASTER OF SCIENCE 
IN 
TEXTILE AND CLOTHING MANAGEMENT 
S.M.D.S.D.SETUNGE 
UNIVERSITY OF MORATUWA 
SRI LANKA 
JUNE 2004 
II 
The work presented in the dissertation in part or whole, has not been submitted for 
any other academic qualification at any institution 
S.M.r|rS>rj>S^t.ge 
(Candidate) 
Dr. (Mrs) N. Heenkenda 
(Supervisor) 
III 
ABSTRACT 
PROCESS MAPPING IN CLOTHING MANUFACTURING 
By S.M.D.S.D.Setunge (MSc/PG/T/CM/01/00) 
Process mapping is a new technique for looking at the way a process is being 
performed and allows redesign that process for greater efficiency and productivity 
Process maps are diagrams that show varying levels of detail what an entity does and 
how it delivers services. This research show the step by step approach in mapping the 
major processes in place, the key activities that make each process, the sequencing of 
those activities, the inputs and resources required and the out puts produced by each 
activity. 
Finally this research giving a complete process map for a organization which cover 
from design to delivery in apparel industry after going through a step by step 
evaluation in the industry. One can develop further the final value flow to suit 
individual requirement. Having developed the final map for any organization can be 
used for the same mapping to allocate responsibilities and to calculate the man power 
requirement. 
IV 
ACKNOWLEDGEMENT 
I have pleasure in giving my honour to Dr (Mrs) Nirmalee de Silva, Head Department 
of Textile and Clothing, University of Moratuwa for the privilege given to follow the 
M.Sc. in Textile and Clothing Management course. 
1 offer most sincere thanks to the Course coordinator Mr. D.P.D. Dissanayake, Senior 
Lecture Department of Textile and Clothing University of Moratuwa for his 
encouragement, guidance given to me during this course. 
I wish to express my gratitude to the project supervisor Dr (Mrs) Nilanthie 
Heenkenda, Senior Lecture Department of Textile and Clothing University of 
Moratuwa. the assistance given to me in various ways for the completion of this 
project paper 
I am much thank full to the Mr. Nihal Wanigathunga Senior Lecture Textile and 
Clothing Department University of Moratuwa for his guidance and advice generously 
given me at the latter part of my project. 
v 
LIST OF FIGURES 
01. A Process 02 
02. Illustrative flow chart and process definition chart 05 
03. Levels of flow chart 08 
04. High-level flow chart 09 
05. Activity flow chart 10 
06. Task flow chart 11 
07. Standard flow chart symbols 12 
08. Task flow chart (Phone repair) 13 
09. Deployment flow chart 15 
10. Process definition chart 16 
11. SAP R3 Focus on Key Areas in the Business 17 
12. Support Systems at Various Levels of 18 
Organization Hierarchy 
13. Various Modules of SAP 19 
14. Block Diagram of Customer Order Processing 30 
15. Order Planning & Cutting Instructions Execution 31 
16. Production Planning 32 
17. Shop floor order execution 33 
18. Value flow 36 
List of Tables 
01. SAP Modules Implemented in the 20 
Administrative System Project 
vi 
CONTENT 
1.0 Introduction 01 
1.1 What is Process Mapping 01 
1.2 What is a Process 02 
2.0 Literature Review 04 
2.1 Why is Processing Mapping Important 05 
2.2 Process flowchart 07 
2.2.1 High level flow chart 09 
2.2.2 Activity flow chart 10 
2.2.3 Task flow chart 10 
2.2.4 Deployment flow chart 14 
2.2.5 Process definition chart 16 
2.3 What is SAP 17 
3.0 Methodology 22 
3.1 Steps in process mapping 22 
3.1.1 Reasons for process mapping 22 
3.1.2 Selection of the process to map 22 
3.1.3 Selection of the people for process mapping 23 
3.1.4 Produce the flowcharts and maps 23 
3.1.5 Understand the own processes 24 
3.1.6 Importance of processes link with business partners 24 
3.1.7 Bench mark the processes 25 
3.1.8 Improve the processes 25 
4.0 Application of process of mapping in Production Planning 27 
4.1 Why Organizations need production plan 27 
4.1.1 production Planning 27 
4.2 Description of the production process 30 
4.2.1 Customer Order Processing 30 
4.3 Order Planning & cutting instruction execution 31 
4.4 Production Planning 32 
4.5 Shop floor execution 33 
5.0 Conclusion 35 
6.0 References 37 
VII