Production can only cut and sew what the store can find and issue on time. A well-run store means no line waits for trims, no fabric roll is lost, and the order closes with a clean reconciliation.
The stores in a garment factory
| Store | Holds | Issues to |
|---|---|---|
| Fabric store | Rolls by order, colour, lot/shade | Cutting |
| Trims / accessories store | Thread, labels, buttons, zippers, interlining, poly bags, cartons | Sewing, finishing, packing |
| Finished goods warehouse | Packed cartons by PO and destination | Shipment |
| Machine-parts store | Needles, hooks, spare parts, oil | Maintenance |
| General / chemical store | Stationery, cleaning items, washing and ETP chemicals | All departments |
The flow and its documents
- Supplier delivery - delivery challan, invoice, packing list.
- Receiving - count rolls/cartons, check labels, issue a GRN (goods received note).
- Inspection - QC checks fabric (4-point, shade, GSM) and trims (against the trim card). Pass → store; fail → HOLD area with a red tag.
- Storage - each item gets a bin location; the bin card or system shows balance.
- Issue - only against a signed requisition for a specific order and quantity.
- Leftover return - unused material comes back with a return note.
- Reconciliation - at order closing, booked vs received vs issued vs used.
Store KPIs
| KPI | What it shows |
|---|---|
| Stock accuracy % (physical = system) | Discipline in receiving and issue |
| Issue lead time (requisition to delivery) | Whether lines wait for materials |
| Material in-house on time % | Supplier and merchandising follow-up |
| Leftover value at order closing | Booking accuracy and planning |
| Dead stock (no movement for 6-12 months) | Money tied up |
Tip: Never issue "on phone". A requisition with order number, quantity and signature is the only way stock on paper stays equal to stock on the rack.
Key points
- Separate stores for fabric, trims, finished goods and parts.
- Every movement has a document: GRN, bin card, requisition, return note.
- Measure stock accuracy and issue lead time - production feels both.
