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STANDARD MANUFACTURING PROCEDURE
Fabric
Storage: Store Manager
Fabrics are kept off the floor and on the palettes and according to dye-lots to avoid mixing up. The uncovered/unprotected rolls are also covered with cloth. See pic # 1.
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Trims & Accessories
Storage: Store Manager
Trims & accessories are properly stored by style & in good condition. See Picture # 4.
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Trim Card: Store Manager
A Master Trims Card is made from approved trims and additional Copy Trim Cards are also made and passed onto relevant production sections.
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Document Control
Factory Merchandiser
A Production Control Card is made by Merchandising Department based on all the information required that is relevant to production such as fabric & trims details, order details, product spec sheet, etc. etc. Copies of the same Production Control Card are also passed to concerned Department Head.
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Sampling & Pattern
Types of Sample: Technical Manager
Samples for different purposes such as Development Sample, Approval / Sealed Sample, Size Set Sample are made in the Technical Section. Samples are clearly identified and marked / attached with relevant comments.
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Approved / Sealed Sample: Technical Manager
Approval Sample or Sealed Sample is made in the Technical Section based on Pattern and Spec sheet provided by Buyer.
Approved Sealed Sample along with updated sample comments and technical sheets are then passed to relevant departments for follow up reference.
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Production / Shipment Sample: Q.A. Manager
Production / Shipment Sample is extracted from bulk production and then thoroughly checked by a Q.C. / Q.A. Manager before they are sent out to customer for shipment approval.
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Pattern Development: Technical Manager
All kinds of pattern can be made or graded either by manually or by CAD / CAM to different size based on spec sheet, paper pattern or hard board pattern given by customer.
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Pre-Production Meeting
Buyer’s Pre-Production Meeting: GM (Production)
A Pre-Production Meeting is held between production staff and BuyerÂ’’s Q.C./ Merchandiser prior to starting production. Meeting summaries highlighting all critical issues is kept for ready reference and follow up action.
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Factory’s Pre-Production Meeting: GM (Production)
Another Pre-Production Meeting is held among the concerned production staff, merchandiser, technical and quality department prior to starting production. The meeting goes through the summary report and all critical issues check list. The copy of the list is passed on to all concerned department for follow up action.
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Fusing
Supervisor
Interlining Fusing Guideline from interlining supplier is provided & fusing standard is set according to individual fusing machine condition.
Fusing machines are well maintained. Machine is serviced and calibrated by professional service provider.
Parts are properly fused and batched in correct number sequence.
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Trial / Pilot Run
Technical Manager
A Trial / Pilot run is done on 300 pcs covering all colors & sizes on a specific style before commencing any bulk production.
Necessary adjustment is made on pattern, machinery setting, seam allowance, sewing, washing & pressing methods etc. by Technical Manager, prior to bulk cutting / production.
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Bulk Production
Cutting: Cutting Manager
Markers are made using CAD / CAM machine (Lectra).
Fabric relaxation is done for those having elasticity in nature on the cutting table for at least 24 hours prior to spreading.
Cutting plan is made according to packing ratio recorded in Cutting Schedule & then registered in Cutting Register after completion of cutting.
Fabric shade lots are separated with paper while spreading to avoid dye lot or shade mix up.
All cut parts are numbered & bundled to avoid shading issue & lot number is indicated on cut tickets for follow up reference.
Sufficient fabric ends are reserved & properly kept with details of lot number and roll number for cut panel replacement.
All cut pieces in bundle form are issued to sewing floor with details recorded in the Bundle Issuing Report.
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Sewing: Sewing Manager
Sewing section is properly set with sufficient lighting & in accordance to processflow & bundles and garments are kept clean & undamaged while moving between sections & departments.
Sealed sample comment & sample are readily available in the production area & kept in good condition for immediate reference.
Numbering system & shade-lot control is properly followed during all sewing processes to avoid shading & mixing shade-lots problems.
Trimming is done in each process in the sewing line to cut all thread ends prior to pressing.
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Finishing: Finishing Manager
Appropriate pressing equipments including vacuum tables with heater, arm pads etc. are installed for pressing the right products.
Proper methods are used to control garment shapes and measurements and protective tools such as Teflon shoes are also used to avoid shinning mark during pressing.
All pressing equipments, tables, arm pads & covers are kept clean & free from rusting to avoid staining onto garments.
Spot Removing & Cleaning Room area is properly set & appropriate procedure is implemented. Garments are thoroughly dried prior to folding & packing.
Proper packing tables / racks/ shelves are installed & sufficient area is arranged for packing section.
Approved shade-band is provided & properly followed for shade sorting prior to packing.
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Machine Maintenance: Assistant Manager
Proper machine repair & maintenance programs are set to ensure all machines are in good working condition & with checklist & record for reference.
Appropriate machinery is equipped for critical operations to avoid quality issues & increase efficiency.
Proper oil leaking test procedure is implemented & with record for reference.
Appropriate machine attachments, guides & folders etc., are used to properly control seam allowance & workmanship standard.
Other machinery such as fusing machine, needle detectors, gas boilers are periodically checked by qualified technician for general servicing and calibration.
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Fabric Inspection:
Quality Controller
Fabric inspection is done on an appropriate inspection frame / machine using 4-Point System at appropriate speed and under sufficient lighting.
At least 10% of the incoming quantity is inspected across all color / dye lots.Further inspection is done at 20%, 50% & 100% of the in-house quantity if fabric continues failing at different quantity lot.
Inspection findings are properly recorded and reviewed timely by a supervisor. Fabricdefects analyzed (e.g. including visual defects and color shading, bowing, skewing, printing, etc.) and sent to Cutting Department & Q.A. Department for follow up actions.
All fabric rolls are checked against approved color standard under customer required light sources using Light Box by trained Q.C. See picture # 2.
A Shade Card is made to control dye lot / color shade of all fabric rolls prior toplanning for cutting. A copy of the shade card is sent both to Cutting & Packing Department to avoid shade mix-up.
A Shade Blanket is made for all rolls on each dye lot with roll number marked & washed with pre-established formula for shade consistency check & approval.
Swatches are submitted for approval to Merchandising Department & the approved band is passed to relevant departments for follow up.
Shrinkage Test is done on bulk fabrics for at least 10% on all dye lots & colors. A detailed report is made for fusing shrinkage, color change and ironing shrinkage prior to cutting and sent out to Technical and Q.A. Department for follow up actions.
Fabric test reports from accredited labs available upon request.
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Trims & Accessories Inspection:
Quality Controller
Bulk trims & accessories of different delivery / dye lots are inspected by Q.C. and checked against approved trims standard to ensure quality and color continuity under sufficient lighting. Visual and qualitative defects are recorded and analyzed for follow up action.
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Fusing:
Supervisor
Appropriate control instruments e.g. thermo paper / meter, pull scale and Fusing Testing Guideline are available. Necessary testing is done to verify fusing standard is met with record kept for reference.
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Trial / Pilot Run:
Trial / Pilot run garments are carefully assessed on construction, making up method,machines used, measurement, washing & pressing effect etc., & report is kept for reference.
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Cutting:
Quality Controller
Markers are checked for Style & P.O. number, width, components, grain line, pattern/ nap direction, notches & sizes, etc., prior to cutting. A Marker Check Report is maintained.
Spreading is properly done manually & without pulling on fabric or creating wrinkles / creased & piles height is controlled according to fabrication. Different shade lot if cut together then a paper is laid to separate out 2 different shade lots. A Spreading Quality Report is maintained after completion of spreading.
Appropriate cutting equipment / method is used according to fabrication & matching requirements. Cutting quality is also checked and a record is also maintained.
Cut parts shape & defects are checked by QA under sufficient lighting & Cut Panel Check Reports are kept for reference.
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Sewing:
Quality Controller
Job specifications are made for each operation to ensure that the workmanship standard is fully understood by all operators & to be followed. A mock up is provided to each and every operator as ready reference.
Proper procedure is made to verify stitch density (SPI) & tension on each machine.
Traffic Light System is implemented to where a Quality Inspector randomly checks 7 garments, 4 times a day on each operation (machine) daily with detailed report for follow up reference. This report is file in the personal file of the machine operator for performance review.
Defective garments are properly identified, labeled & segregated by defect types for review, repair & follow up actions.
100% in-line checking is set at critical points (Q.I. Station) to ensure the garments meets quality standard at different stages of assembly process. A detailed report (SPC) is maintained to find out root cause of problem and to take corrective & preventive actions by Line supervisors. The data from the report is analyzed and reviewed by Q.C., Q.C. Manager and Director for quality improvement.
All Inspectors use proper and same predetermined method for inspection of different garment types to avoid missing any area.
Inspections are conducted on appropriate tables with clean & undamaged surface and under sufficient lighting.
Q.C. prepares a daily In-Line Quality summary report on overall sewing quality.
Measurement Check is done every 2 hr in each sewing line randomly on 2 pieces of garments across any colors or sizes prior to sending to washing or finishing sections. A detailed report is kept for follow up reference. Proper measurement method is used.
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Finishing:
Quality Controller
A pressing method and a sample are given as pressing standard for reference.
Garments are 100% checked after pressing & prior to packing.
Inspections are conducted on appropriate tables with clean & undamaged surface and under sufficient lighting.
Checkers are identified with ID number. A detailed report is maintained to identify type of defects. The data from the report is analyzed and reviewed by Q.C., Q.C. Manager and Director for quality improvement.
A pictorial folding method is given in folding section to follow proper folding method. A sample is provided for each style for folding and packaging standard. Spec sheet and paper patterns are also used to check the packing standard.
Q.C. prepares a daily In-Line Quality report on overall quality of packed garments.
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Pre-Final:
AGM (Technical) & Manager (Quality Assurance)
Inspections are conducted on appropriate tables with clean & undamaged surface and under sufficient lighting.
Using correct AQL procedure of 2.5 or below for pre-final
Approved sample, acceptable & rejected standard are provided & clearly understood by all checkers.
Detailed pre- final inspection report is maintained for review & necessary follow up actions.
Measurement is checked for all sizes across colors & detailed report is kept for necessary follow up actions.
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Final Inspection:
Buyer Q.C. conducts final inspections in factory.
Individual QA team is set to carry out all final audits & audit room is properly equipped under sufficient lighting.
Final audit is conducted with detailed report to be reviewed & for necessary follow up actions prior to buyer's final audit.
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