Operation Breakdown, SMV and Layout of Jogger Manufacturing Process
A jogger is a casual bottom item; Welt pocket is an inside pocket with bone covered in the mouth. Here given all operation list sequence wise of jogger manufacturing. Here jogger total SMV is 19.61, 72 manpower required. This Operation Breakdown is done by LOGIC ERP software, used to prepare operation bulletin & m/c layout & others departmental jobs as well. There is a data bank, style SMV analysis, machine layout & operation balancing. This LOGIC ERP database can be linked with other software & web for different uses.
A hoodie cloth is a jacket, sweatshirts with hood. Kangaroo pocket is open on either side usually use in hoodies. Here given all operation list sequence wise of Hoodies Manufacturing. Here hoodies total SMV is 15.99, 59 manpower required. Operation Breakdown is done by LOGIC software. It is a tool to make style breakdown & machine layout report. There is a calculative & non-calculative method for operation breakdown. It helps to make data bank, style SMV analysis, machine layout & operation balancing. A LOGIC database can be easily interlinked with other software or medium, like Fast-react, ERP, etc.
Garments Item: Hoodies Style Ref. : V H UGH Patch Custom Style : Buyer Name : Working Hour : 1 Target : 71 Efficiency : 32 Fabric Type : Fleece , 350 gsm Line No. : Allocated MP : 59 Pitch Time : 27 Insert Date Time: Insert By : Update Date Time: Update By : Remarks : P.Q.-5000 PCs
Job Description of Sourcing Manager in Apparel Industry
Sourcing Manager: The person who is responsible for developing and executing the organization’s sourcing and procurement strategy to ensure better sourcing of the right product at the right time for the right price is known as a sourcing manager. Here in this article, we will discuss the sourcing manager job description in details.
This role will support the execution of sourcing projects and tactical procurement opportunities to help ensure the realization of cost savings objectives. Machine, machine parts/spare parts, fabric, trims and accessories, and many other things are required for the apparel industry. And sourcing of these materials is not easy if you do not have a good sourcing plan and you do not have a sourcing manager. For better sourcing, your company needs at least one sourcing manager.
This position (Sourcing Manager) is
primarily project and task driven with Managerial level supervision as
required. Additionally, the person will be responsible for all types of
sourcing that require the skills to identify cost-saving opportunities, create
competitive environments, effectively negotiate, and make contracts to assure
continuous availability of all required products to support the company demand.
Key Responsibilities of Sourcing Manager in Apparel Industry
The sourcing manager job description is mainly focused on the key responsibilities of a sourcing manager which he/she regularly need to perform. The JD of Sourcing manager includes the following key responsibilities:
Define, develop, negotiate and contract strategic sourcing solutions that meet businesses’ requirements and enhance profitability by controlling or reducing costs, improving payment terms, reducing inventory and optimizing supply chain efficiencies.
Identify situations in advanced where procurement involvement can increase.
Develop a sourcing plan for both for local and international sources, so that fast and effectively sourcing operations are possible.
Develop and administer an efficient global supply chain and monitor inventory for all global products and assist to increase growth.
Need to ensure that the decision-making process is supported by technical and functional knowledge of the category and leading-edge analytical methods which encompass people, systems and financial measures.
Challenge suppliers and internal customers to identify and implement innovative designs, value-add specification changes, concepts, and materials.
Supervise every negotiation and provide guidelines to prepare documents for purchasing and making a contract.
Monitor sourcing strategy and if any change is required to ensure better sourcing then change the strategy according to the market condition.
Collaborate with the marketing team and initiate appropriate changes to the engineering team and manage all research and development process.
Deeply Analyze your company’s requirements and evaluate each and every sourcing alternatives and then finally pick the right one.
Perform and analysis Monthly forecasting report to ensure and maintain acceptable inventory level.
Negotiate for minimizing the cost of materials and get the best possible price.
Coordinate with international logistic personnel to ensure proper shipment delivery.
Evaluate letter of credit documents and collaborate with accounting department to ensure timely financial obligations.
Develop and implement category plans for indirect spend areas that capitalize on market opportunities and aligns with functional business requirements.
Production planning, oversight, and coordination with contract manufacturers.
Assisting the team with executing new product development; develop and implement quality specifications during trial productions and beyond.
Forecasting production and supply needs, in coordination with the Sales Operations Manager, and budgeting accordingly.
Procurement of raw materials and supplies based on the company’s demand and supply.
Evaluation of quality of raw materials so that right quality materials can source.
Implementation of systems to pre-empt, identify and promptly correct any operational or quality issues.
Work on special projects as requested by management; supports all levels of department management and may participate in specific workgroups as requested.
Skills Required for Sourcing Manager
Sourcing manager should have strong analytical, negotiation, contracting and communication skills.
Should have adequate skills to develop and implement sourcing and negotiation strategies for the company.
Ability to think strategically so that the company can take advantage of business processes, industry dynamics, supplier experiences, and manufacturing practices, and general market conditions, etc.
Ability to perform financial analysis of the cost of every sourcing.
Ability to work with various levels of the supplier from the local and international market.
Excellent teamwork skills and proven aptitude to partner effectively with a wide range of stakeholders (i.e., top management, colleagues, suppliers, and internal/external customers).
Ability to work independently, prioritize and multi-task while maintaining a positive and collaborative attitude.
After reading this, hopefully, you will have a clear idea of sourcing manager job description. Remember one thing is that, the job description of a sourcing manager is not limited to the above responsibilities. These may varies from company to company and industry to industry.
PP Meeting Requirements and Procedure in Apparel Industry
PP meeting is a very important part of Garments manufacturing process, a part of the pre-production process to be completed in the right time for smooth Garments manufacturing process. A process where buyer QC/Merchandiser are also involve in checking accuracy. Generally, PP meeting conducted by buyer QC, internal PP meeting by garments manufacturer before that, is a good practice to avoid the risk of failing, meeting location factory conference room or inspection room.
Quality Team Responsibility before PP Meeting
Assigned Quality controller receives all
approvals and records them on “PP
Meeting checklist”. QA also records expected date of receiving non-available
approvals and follows up accordingly with Production merchandiser.
The QA marks “NA” (not applicable) in case of
anything not being used for the particular style.
Need to do internal PP meeting by factory QA
manager with his QC and production before submitting sample for buyer QC PP
expected fabrication issues especially those highlighted by during fabric
inspection report & sample process.
production problems according to fabric behavior.
Operation Breakdown of Pant (Bottom) Finishing Process
After completion of the sewing process, what process remain to complete finished garments is called garments finishing the process, also a different section. Not only the sewing process, but also finishing also important and have lots of process like trimming, pressing, and quality inspection, ticketing, folding and packing. Finishing is the last step for before shipping garments. Here I am giving all process lists, SMV, Layout, and process wise production target. Hopefully, you will have detail idea of Layout, SMV and Operation Breakdown of Garments Finishing Process.
Process Layout and Production Target of Pant Finishing
Loop cut (5pcs 5 point)
Thread cut (top+in
side+Side seam+Hem fray clean)
Body carrying to iron
section & iron section to Q.I table
Body turnover+ Gmts
Top side check
Body carrying to btn
section & btn section to Q,I table
Responsibilities of Garments HR Compliance Department
Compliance is a big part to make an efficient apparel industry. Human resources
compliance department deals with several rules, employees’ legal right, laws
and acts to consider, such as the Fair Labor Standards Act, abuse and sexual
harassment, antidiscrimination laws, employee’s salary and many more. In export
garments manufacturing factory need to be 100% compliant to get order. HR is a
part of administration.
Job Titles of HR Compliance Department
Admin & Compliance
Executive (HR & Compliance)
Assistant Manager, Manger
(HR & Compliance)
GM- HR, Admin and Compliance
responsibilities of Garments HR Compliance Department
Developing, implementing and managing an organization’s
Preparing and presenting clear and concise compliance
reports to the Board.
Interacting with regulators on compliance issues.
Coordinating efforts related to audits, reviews, and
Program Prepare and keep the documentation related to
audit and compliance.
Assist in developing, implementing, maintaining and
reviewing of company policies, rules and regulations in compliance with all
applicable employment laws and regulations.
To monitor the floor for checking all kinds of compliance
To motivate the employees for maintaining all kind of
Train up all employees on all safety awareness issue; maintain
all kinds of training records.
To aware the employees regarding health and safety
Ensure the factories are compliance with social ethics
& health and safety requirements, etc.
To find out the non-compliance issues by the daily
monitoring & internal audit in the factory. Conduct internal audit in the
light of Labor Law, Factory Rules buyers COC & other national &
international legal instruments.
Monitor compliance certification BSCI, ICS, SEDEX, NEXT,
INDITEX, PRIMEMARK, ACCORD & Alliance etc. and handle their different
audits with requirements.
Maintain and implement Accord/Alliance (fire, electrical
& structural) standard for creating a safe working place.
Communicate, maintain, handle and implement all social
audits whether buyer & certification/membership audit as, ICS, SEDEX, NEXT,
INDITEX, PRIMEMARK, ACCORD etc.
Maintain every compliance mechanism/tools internally;
through weekly, monthly and yearly comparative statistical report & tools.
Give Suggestions to the management regarding several
important pronouncement and decisions of Law & other COC.
Conduct in house training for all employees on OH&S,
EMS, Fire Safety, Grievance etc. as advised by factory management,
To adopt, maintain and implement environmental, chemical
standard as, Higg Index for the sake of the organization in a sustainable
Conduct internal H&S and Environmental assessments in
a regular interval.
Review and update all legal documents/certificate/license
time to time by communicating with the specific authorities.
Update to management all compliance reports in regular
HR Job Functions/Activities in Textile and Apparel Industry
termination (closing) and in-service procedures
sorting and generating periodic reports.
coordination training and orientation sessions.
absent status management.
Maintain and Update
Employee Personal Files.
coordinate Recruitment & Selection.
data entries into HRMS.
Resignation, Exit Interview, Clearance, Closing Activation and Final Settlement
matters, legal affairs & industrial relations related issues for all the
factories. -Authorized to sign all kinds of letters related with administrative
activities & disciplinary procedures.
Maintain employee’s (Factory) PF investment.
Promotion, Increment and associate matters.
Arrange all the
event management issues for the office in different occasion such as- Best
Employee, Birthday and Farewell Program.
Quality Management System in Garments Manufacturing
Garments Quality Management
A garments manufacturing quality
management system (QMS) is related to quality control and assurance system that
documents (quality manual) processes (Online and offline), procedures, system,
planning, responsibilities and task for achieving quality goal and policies to meet
buyer requirements. A quality management
system is focus on customer requirement and satisfaction through combine effort
of whole organization management by setting up a work standard. A quality
management system helps a factory to coordinate and instruct an organization’s functions/activities
to meet buyer requirements and improve its effectiveness and efficiency on a continuous
basis quality control and improvement. A good quality management can guide a
factory to the right path of quality goal, to keep standard
of export garments quality; a good quality management system should be
of Garments Quality Management
Strict Materials inspection
Approved trim card
Keeping pattern log, library and evaluation report
Calibrate machine, process, and manpower
Follow SOP and Keeping version names
Visualize quality tools, sample, and metrics
Process audit or AQL inspection
Keeping packing approval
Zero defects station
Review quality result and taking corrective action
Training and evaluate QC
Internal pre-final Audit before Final Inspection
Quality department’s first
responsibility is reporting, and then taking action. If they report is doing
properly, easy to work on it.
Strict Materials Inspection
Most of times needed raw materials
like fabrics; accessories of a garment need to buy from a supplier, so it’s
important to inspect all raw materials and ask supplier if there any defects.
Because once you make a garment, it’s almost impossible to replace if their
faulty fabrics or trims.
Following approved Trim card in store,
cutting, sewing and finishing ensuring correct materials and fabrics are
joining for every lot.
Pattern Log, Library and Evaluation Report
Pattern is very sensitive, standard is to keep a pattern
library, track and change log of every stage as like before and after size set.
Calibrate Machine,Process and Manpower
Yearly or half yearly calibration of machines to check machine
is fit enough, performing well or not. Need to check calibration by 3rd
party or machine supplier of CAD plotter, Fabrics inspection machine, shading
checking light box, Fusing machine, needle detector machine, pull testing machine
and others lab testing machines.
and Keeping Version Names
Follow a SOP for every process and section, keeping SOP
change log and version name. ISO method is to keep SOP version name.
Quality Tools, Sample and Metrics
Visualizing all quality tools, analysis, and quality metrics
will make aware about everyone’s performance and responsibilities will help to
take decision easily.
Audit or AQL Inspection
Inspection garments by AQL audit system before moving
garments to next step or process to check process accuracy, passing goods from
every section by passing in audit, if audit fail goods back for reprocessing.
A system to approve a garment by authorize person (buyer QC,
merchandiser or QA manager) before start packing of every lot
Set up zero defect station by through 100% garments quality
inspection in sewing and finishing.
Quality Result and Taking Corrective Action
Review every sections quality result by a daily or weekly basis and taking corrective action to not to happen and improve in the future. A general meeting can be called with related production and maintenance department and giving responsibilities to improve quality as a part of corrective action.
and Evaluate QC
Training is one of the major part garments quality management, Kaoru Ishikawa said: “Quality control starts and ends with training.” Continuously train up whole quality team about various quality matters and evaluate their understanding.
Audit before Final Inspection
Pre-final Audit or an audit before Final quality inspection
procedure as per final inspection procedure to confirms final inspection will
be passed of every lot.
The commercial department involves with export and import raw materials and finished garments, manage and provide necessary export and import documents for smooth export-import process in garments manufacturing. Their role is very vital, deal with merchandising and accounts department for their working procedure.
Job Responsibilities of Garments Commercial
Work with the Export Promotion Bureau
Work with Bank
Work with BGMEA
Buying House Management
Freight Forwarder/Shipping Agent Management
Clearing & Forwarding agent Management
Customs Bond work
Regular Office Work
Commercial Department Job Responsibilities in Apparel Industry
(i) Export Promotion
Bureau Work like: “Certificate of Origin (C.O.), Visa Commercial
Invoice, Quota issue, SAPTA Certificate, Mexico Certificate, GSP,
Metropolitan/Dhaka Chamber (C.O.), etc.
(ii) Banking work
like: Master/Export L/C Collection, Master/Export L/C lien to Bank, L/C
Transfer to another party, BTB L/C open and its Amendment, Import Doc’s Collect
from Bank and Endorsement, Letter of Guarantee/Bank Guarantee for release the
Import consignment, Document Purchase for fund, Export Documents submit for
payment realization, Bank Bill/Reference Number taken, DHL/FedEx courier
Number/Receipt collect, Follow up about Proceed Realization, Import Bill
Acceptance & give the maturity date, Payment of BTB LC at maturity, Local
Agent Commission Paid, miscellaneous certificate collect, PRC, Bank loan
adjustment duly, Bank statement & Voucher collect, renewal & extension
of Bank Liability & sanction and so on.
(iii) BGMEA work like: Fabrics and Accessories Utilization Declaration and its Amendment work, Balance Fabrics/Raw material Adjustment, Export Order for export the Stock Lot or Un exported Goods, UD certificate collect, Interbond transfer for Sub-Contract work, BGMEA Certificate collect for “Free of Cost” goods Import, Sample Pass Book renewal for sample goods import, BGMEA License Renewal, Auto-Renewal of Bond License, all types of BGMEA Certificate as needs, yearly member’s ID renewal and so on.
(iv) Buying House
Management: Follow-up about order procurement, Master L/C or L/C Transfer
Collect, Collect the Cost Break Up for calculation, Collect the Order Sheet,
Sketch & Measurement collect from Merchandiser, Proforma Invoice Collect,
BTB L/C & its Amendment mail/send to them, Export Document send for collect
IC, Bank Bill/Reference Number and DHL/FedEx Courier Receipt number send/Fax to
them, buying commission (LAC) paid.
(v) Freight Forwarder/Shipping Agent Management: Online Shipment Booking to Export for Air and Sea, Shipping Advise collect, Dummy B/L or AWB collect for EPB work, Original doc’s send to them for shipped goods release at the destination, Original B/L or AWB collect as well surrender of export document.
(VI) Clearing & Forwarding agent Management: Import Doc’s Handover to C&F Agent with Bank Endorsement for Clearing the Imported Goods. Shipping Doc’s handover to C & F agent for Export, follow up about Assessment and Examine, collect the Bill of Entry/ Shipping Bill as authenticated Import & Export record.
(vii) Office Work: Correspondence with Foreign and Local Buyer & Buying House, follow up to suppliers about production status as well their booking, shipment and import documents, Export Documents Ready, follow up about finished goods for export progress, E-Mailing regarding several issue, corporate meeting, managing relevant party regarding arising issue as situation, etc.
(Viii) Customs Bond work: For Up-to-Date General Bond, Customs Audit Export Proceed Realization (PRC) statement ready, all certificate and documents submitted to Customs according to Customs Office instruction, Ownership change, Permanent Bond Transfer, Machineries Indemnity Bond release, Lien Bank Change/Addition, Factory Building Extension/Replacement, UP, In-Bond & Ex-Bond work for chemical and for deemed exporter and so on.
Social compliance deals a company’s employee health and safety others legal right from a social perspective. To makes a compliant factory, need to follow local labor law and international social compliance requirements. Social compliance Audit related to child labor, forced labor, Health and safety, Abuse and Discrimination, Disciplinary practices, Working hours, Remuneration, Freedom of association, Management systems etc. Social compliance is a vital part of the apparel industry because of social compliance Audit impact in a company’s reputation and business. Here in this article, we will share all the compliance checklist for garments industry.
Compliance Checklist for Garments Industry
Compliance Check List
There are many criteria where need a check list and follow in
routine wise in apparel industry, here I am giving these checklists and
checking criteria for your understanding.
Fire Extinguisher Checklist
indicator in green area.
Hose in good condition.
tag of the existing.
should be one Month.
Daily First Aid Box Check List
wipes (Savlon Cream)
Toilet Check List
Cleanliness of Toilet
Checklist of Drinking Water Filter
Fire Alarm & Testing Report
Fire Extinguisher Checklist
Picture of responsible person
rules to handling
Equipment Box Checklist
Gas Header ok/Not
Electrical Equipment Checklist
fire pump switch
electrical cords, plugs
Schedule Check for Electrical MDB/BD
Key & Rubber Mat Check
clean, Indicating Lamp & Cooling Check
& Nut-bolt loose Connection Check
Volt Meter Check
Temp & Load balance Check
Earth Line Cable
space in front of DB
braker/fuse/selector switch Check
Check for Exhaust Fan
Duct Line Clean
Exchanger Side Net Clean
M/C All Side
Check for Fire Pump
Water Level Check
Loose Connection Check
Pipe/Nozzle Joint Coupling Check.
& Diesel Level Check.
Non Return Valve Check.
Inspection, Test & Maintenance Requirements for Standpipe and
Unusual condition Vibration leakage noise and temptation
Service room or housing keeping
Protection System In-depth Visual Inspection Checklist
connection at junction points
& earth terminal connection is proper (intact)
damage of system component
are connected properly with surface
due to surge
change of the structure (protected structure)
resistance test perform
(arrester to mesh, mesh to down conductor, down conductor to earth conductor)
Garments factory also check compliance of housekeeping, factory
load capacity, sharp tools keeping and register,
floor temperature, humidity, quarterly pest control by third party.
Compliance Audit CAP
After a Compliance Audit, factory has to submit corrective action
plan (CAP) or preventive action plan. Every month follow up CAP improvement
with pictorial and written evidence, a report has to make for buyer.
Fusing Process and Quality Inspection of Fusing Machine in
In this article, you will learn how Fusing Process and Quality Inspection of Fusing Machine in Apparel is to be done.
Fusing is a process which attaches interlining with garments by heat and temperature, fix interlining and fabrics by bonding in garments manufacturing. The bonding strength between interlining and fabrics is the matter in the fusing process. Generally, bonding strength needs 600-700 Gram. Generally Interlining use in the waistband, pocket flap, box placket in garments.
Fusing Machine Setting
First of all, collect data sheet from an interlining supplier where has written instruction on machine temperature, time and pressure. Setting machine as per supplier recommendation and start test fusing process. And then checking bonding strength, if bonding strength match as per requirement, surely bonding recipe (temperature, pressure, and time) will be noted for a specific lot. If bonding strength does not match with requirement then some experiment needs to do by changing time, temperature and pressure to a style fusing. The thermal paper used to test machine temperature.
Supplier Technical Data Sheet for Fusing Machine
Item: Paper Dot
Fusible Interlining – White
Weight: 21 GSM
Temperature: 140 – 150 Degree Centigrade.
Pressure: 3.50 kg
to 13 Second.
*It’s an example of supplier data sheet;
you should follow your supplier data
Fusing Quality Control
Before fusing, fusing QC do an experiment to fix interning (TEMP, TIME & PRESSURE) as per supplier recommendation. Then if QC finds the buyer required bonding strength by that experiment, will be allowed to start bulk. If QC not gets required bonding strength, he will try differently by changing temp, time and pressure. So QC will set a standard for every style.
After setting of Fusing standard, QC will set mock-up, sending fusing mock-up for washing to check wash appearance.
Fusing Quality Inspection
QC inspects fusing quality under 1000+ lux, keep all inspection record. QC audit from every bundle using AQL or any other system. If there more than two bundles fail in any PO, fusing will stop immediately. There will be another experiment to solve the problem. Then bulk fusing will restart.