PO-2048 — Order Control Tower

Order value

₹38,00,000

₹380 / pc FOB

Quantity

10,000 pcs

5 colours · S–XXL

Production

74%

7,420 pcs sewn

Days to ex-factory

24 Aug 2026

Projected margin

11.58%

Quoted 22.1%

Material outside

₹4.86L

3 vendors

✓Order12 Jun

✓Material28 Jun

✓Knitting5,000 kg

!Dyeing4,820 kg

✓Fabric QC4,109 kg

✓Cutting8,400

✓Printing8,180

●Sewing7,420

Finishing6,940

Final QC6,820

Packing6,600

Dispatch0

Overview Items TNA Material Production Job Work 3 Quality Packing Shipment Invoice Profitability

Order details

Buyer

NorthStar Apparel

Buyer PO ref

NS/AW26/1184

Style

POLO-2048

Order date

12 Jun 2026

Ex-factory

24 Aug 2026

Delivery

30 Aug 2026

Inco terms

FOB Tuticorin

Payment

LC 60 days sight

Factory

Factory 01 — Nallur

Merchandiser

Karthik S

Destination

Jebel Ali, Dubai

Mode

Sea · 20 ft FCL

Progress by process

74% overall

Cutting8,400

Printing8,180

Embroidery3,620

Sewing7,420

Finishing6,940

Final QC6,820

Packed6,600

Embroidery applies to 4,000 pcs only — navy and black placket detail.

Fabric: Cotton pique 220 GSM
Colours: 5
Sizes: S – XXL
Std SMV: 14.2 min
Std cost: ₹296.00

Activity

17 Aug · 09:12

Delivery risk flagged

Sewing run rate below plan for 3 days

16 Aug · 15:20

Job work overdue — Sri Tex

640 kg navy, 6 days beyond promise

15 Aug · 11:32

Printing lot 4 received

2,180 pcs from Kaveri Printing

14 Aug · 09:12

Fabric roll issued to cutting

ROLL-7821 · 28.6 kg navy

12 Aug · 16:05

Fit sample round 2 sent

Buyer response due 19 Aug

02 Aug · 10:40

Excess dye loss booked

80 kg over allowance, ₹23,600 recovery raised

Order lines

10,000 pcs · ₹38,00,000

Colour	S	M	L	XL	XXL	Total	Value
Navy	525	875	980	770	350	3,500	₹13,30,000
White	375	625	700	550	250	2,500	₹9,50,000
Black	300	500	560	440	200	2,000	₹7,60,000
Red	150	250	280	220	100	1,000	₹3,80,000
Grey	150	250	280	220	100	1,000	₹3,80,000
Total	1,500	2,500	2,800	2,200	1,000	10,000	₹38,00,000

Sewn against ordered — by colour

Colour	Ordered	Cut	Sewn	Packed	Blocker
Navy	3,500	2,340	2,180	1,900	640 kg at dyeing vendor
White	2,500	2,500	2,240	2,000	—
Black	2,000	2,000	1,640	1,500	Embroidery queue
Red	1,000	780	700	600	—
Grey	1,000	780	660	600	—
Total	10,000	8,400	7,420	6,600

Critical path summary

Full TNA →

Tech pack releaseMerchandising16 Jun15 Jun−1 dKarthik SDone

Dyeing completeABC Dyeing Works18 Jul21 Jul+3 dRamesh PLate

Cutting completeCutting · 8,400 of 10,00002 Aug—+15 dVignesh MLate

Sewing completeLines 04 & 0720 Aug74%At riskBala SRunning

Final inspectionQuality23 Aug——Anitha PPlanned

Ex-factoryLogistics24 Aug——Deepa VPlanned

Fabric required

4,749 kg

0.448 kg/pc + 6% loss

Received & QC passed

4,109 kg

78 kg rejected on shade

Issued to cutting

3,986 kg

84% of allocation

At vendor

640 kg

Navy, Sri Tex Processors

Material against this order

Requirement sheet →

Material	Batch / lot	Required	Allocated	Issued	Balance	Location	Status
Cotton pique 220 GSM — Navy	DYE-2048	1,662 kg	1,022 kg	1,022 kg	640 kg short	Sri Tex Processors	At vendor
Cotton pique 220 GSM — White	DYE-2046	1,187 kg	1,187 kg	1,187 kg	0	WH-01	Consumed
Cotton pique 220 GSM — Black	DYE-2047	950 kg	950 kg	950 kg	0	WH-01	Consumed
Cotton pique 220 GSM — Red	DYE-2050	475 kg	475 kg	412 kg	63 kg	WH-01	In stock
Cotton pique 220 GSM — Grey	DYE-2050	475 kg	475 kg	415 kg	60 kg	WH-01	In stock
Polyester button 18L	TRM-4482	20,000 pcs	20,000	14,840	5,160	WH-02 Trims	Sufficient
Woven main label	TRM-4490	10,000 pcs	10,000	7,420	2,580	WH-02 Trims	Sufficient
Poly bag 250×350	PKG-1180	10,000 pcs	10,000	6,600	3,400	WH-03 Packing	Sufficient
5-ply export carton	PKG-1184	100 pcs	100	66	34	WH-03 Packing	Sufficient

Cutting

84%

Cut order: CO-8821
Required: 10,000 pcs
Cut: 8,400 pcs
Balance: 1,600 pcs
Marker efficiency: 84.5%
Fabric waste: 8.2%
Bundles made: 168

Sewing

Running

Lines: 04 and 07
Daily plan: 1,200 pcs
Yesterday: 356 pcs
Cumulative: 7,420 pcs
Efficiency: 83.4%
Rework: 112 pcs
Required rate: 430 pcs/day

Finishing & packing

66%

Finished: 6,940 pcs
Pressed: 6,880 pcs
Metal detected: 6,820 pcs
Packed: 6,600 pcs
Cartons: 66 of 100
Bay: Packing bay 2

Daily output — last 10 working days

Behind plan

62004

78005

84006

91007

88008

76011

64012

52013

41214

35616

Pieces sewn per day against a plan of 1,200 · fabric starvation from 12 August

Job work against PO-2048

All job work →

Job work	Vendor	Process	Issued	Received	Balance	Value out	Due	Status
JW-8821	ABC Dyeing Works	Dyeing	5,000 kg	4,820 kg	0	₹0	18 Jul	Reconcile
JW-8846	Sri Tex Processors	Dyeing — navy re-lot	700 kg	60 kg	640 kg	₹2,62,400	11 Aug	6 days late
JW-8852	Kaveri Printing	Screen printing	8,400 pcs	8,180 pcs	220 pcs	₹83,600	18 Aug	Running
JW-8858	Prime Embroidery	Embroidery	4,000 pcs	3,620 pcs	380 pcs	₹1,40,600	16 Aug	1 day late
Material value outside factory against this order						₹4,86,600

Excess loss recovery

1 open

5,000

Issued kg

4,900

Expected kg

4,820

Received kg

Excess loss kg

₹23,600

Recoverable

Open reconciliation

Inspections

4 inline · 14 end line

First pass

91.4%

Target 92%

Rework

462 pcs

6.2% of sewn

Rejected

178 pcs

2.4% of sewn

Inspection history

Quality module →

Inspection	Type	Date	Stage	Sample	Defects	AQL	Result
QC-20481	Final	16 Aug 2026	Packed lot 1	200	8	2.5 · Ac 10	Pass
QC-20476	Inline	08 Aug 2026	Sewing line 04	120	14	—	Corrective action
QC-20468	Fabric	23 Jul 2026	Lot DYE-2048	4-point	18 pts	≤ 20	Pass
QC-20464	Fabric	22 Jul 2026	Lot DYE-2048 shade	78 kg	—	Grade 4	Rejected

Cartons packed

66 / 100

100 pcs per carton

Pieces packed

6,600

66% of order

Net weight

1,485 kg

0.225 kg per piece

Gross weight

1,610 kg

24.4 kg per carton

Carton summary

Packing list →

Carton range	Colour	Assortment	Cartons	Pieces	Gross kg	Status
C-2048-001 to 019	Navy	S2 : M3 : L3 : XL2	19	1,900	463.6	Sealed
C-2048-020 to 039	White	S2 : M3 : L3 : XL2	20	2,000	488.0	Sealed
C-2048-040 to 054	Black	S2 : M3 : L3 : XL2	15	1,500	366.0	Sealed
C-2048-055 to 060	Red	S2 : M3 : L3 : XL2	6	600	146.4	Sealed
C-2048-061 to 066	Grey	S2 : M3 : L3 : XL2	6	600	146.4	1 open
Packed to date			66	6,600	1,610.4

Shipment plan

Split proposed

Shipment	Cartons	Pieces	Ex-factory	Mode	Status
SHP-2048-A	66	6,600	24 Aug 2026	Sea · Jebel Ali	Ready
SHP-2048-B	34	3,400	04 Sep 2026	Sea · Jebel Ali	Planned

Export documents

Packing listSHP-2048-A · 66 cartonsReady Commercial invoiceINV-2048/AReady Shipping billFiled by CHAIn process Certificate of originChamber of commerceNot started Bill of ladingAfter vessel sailingNot started

Invoicing

Open invoice →

Invoice	Type	Date	Pieces	Amount	Due	Status
INV-2048/A	Commercial · shipment A	24 Aug 2026	6,600	₹25,08,000	23 Oct 2026	Draft
INV-2048/B	Commercial · shipment B	04 Sep 2026	3,400	₹12,92,000	03 Nov 2026	Not raised
Order value			10,000	₹38,00,000

Revenue

₹38,00,000

10,000 pcs @ ₹380

Cost — projected

₹33,60,000

Estimate was ₹29,60,000

Profit

₹4,40,000

Estimate was ₹8,40,000

Margin

11.58%

▼ 10.52 pts vs quote

Where the margin went

Full analysis →

Fabric over-run₹1.00L

Job work extra₹1.00L

Overhead absorption₹0.70L

Transport & air freight₹0.60L

Production overtime₹0.30L

Packing₹0.30L

Trims₹0.10L

Total cost over-run ₹4.00L against the approved cost sheet.