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.
Seq. No
Body Part
Operation
Resource
SMV
Target (100%)
Cycle Time(s)
Theoretical MP
Layout MP
1
Front Part
Front leg panel attach
4T OL Auto
1.44
42
86.4
5.33
5
2
Neck
Match n Back panel attach
4T OL Auto
1.44
42
86.4
5.33
5
3
Front Part
Front Rise join
4T OL Auto
0.3
200
18
1.11
1
4
Back Part
Back rise join
4T OL Auto
0.3
200
18
1.11
1
5
Pocketing
Pocket position mark
Assistant Operator
0.32
188
19.2
1.19
1
6
Pocketing
Press welt with fusing paper n mark
Sewing Iron
0.48
125
28.8
1.78
2
7
Pocketing
Pocket welts attach
SNL Auto
0.56
107
33.6
2.07
2
8
Pocketing
Pocket liner attach behind welt
SNL Auto
0.56
107
33.6
2.07
2
9
Pocketing
Cut pocket mouth n form fishtail
Assistant Operator
0.7
86
42
2.59
2
10
Pocketing
Welt edge neaten
4T OL Auto
0.5
120
30
1.85
2
11
Pocketing
Secure fishtails
SNL Auto
0.72
83
43.2
2.67
2.25
12
Pocketing
Topstitch pocket welts with corner
SNL Auto
0.84
71
50.4
3.11
2.75
13
Pocketing
Pocket bag attach
4T OL Auto
0.6
100
36
2.22
2
14
Pocketing
Secure pocket bags OL seam
SNL Auto
0.4
150
24
1.48
1.5
15
Pocketing
Pocket bag tack at side n waist
SNL Auto
0.48
125
28.8
1.78
2
16
Assembly
Front n back part sticker match
Assistant Operator
0.28
214
16.8
1.04
1
17
Assembly
Side mark n tack
SNL Auto
0.56
107
33.6
2.07
2
18
Assembly
Sideseam join
4T OL Auto
0.76
79
45.6
2.81
3
19
Assembly
Inseam join
4T OL Auto
0.64
94
38.4
2.37
2
20
Assembly
Secure crotch point
BT
0.18
333
10.8
0.67
1
21
Assembly
Elastic press and cut to length
Sewing Iron
0.2
300
12
0.74
1
22
Assembly
Elastic join as a circle n mark
DNL Lock Switch Auto
0.3
200
18
1.11
1
23
Waist Belt
Waist band join as circle
SNDL Edg Cutter
0.26
231
15.6
0.96
1
24
Waist Belt
Mark n fusing attach
Sewing Iron
0.28
214
16.8
1.04
1
25
Waist Belt
Mark n form holes at waist band
BH Auto
0.35
171
21
1.3
1
26
Waist Belt
Elastic tack at waistbelt
SNL Auto
0.48
125
28.8
1.78
2
27
Waist Belt
Waist band topstitch form channel
KNS
0.5
120
30
1.85
2
28
Waist Belt
WB lower edge close n mark
SNL[Chain STS]
0.45
133
27
1.67
2
29
Waist Belt
Attach waist band to body
4T OL Auto
0.48
125
28.8
1.78
2
30
Assembly
Care label make
SNL Auto
0.24
250
14.4
0.89
1
31
Assembly
Label attach at back waist
SNL Auto
0.4
150
24
1.48
1.5
32
Assembly
Loop measure cut n attach at inside waist
SNL Auto
0.28
214
16.8
1.04
1
33
Cuff
Cuff join as a circleX2
SNL Auto
0.28
214
16.8
1.04
1
34
Cuff
Cuff fold into half
Assistant Operator
0.24
250
14.4
0.89
1
35
Cuff
Cuff attach at leg opening
4T OL Auto
0.5
120
30
1.85
2
36
Assembly
Sticker remove n GMTs turn
Assistant Operator
0.26
231
15.6
0.96
1
37
Waist Belt
Waist band topstitch
1NDL FL
0.46
130
27.6
1.7
2
38
Pocketing
Secure Pocket corners
BT
0.48
125
28.8
1.78
2
39
Assembly
Drawstring insert through
the waist channel
Assistant Operator
0.3
200
18
1.11
1
40
Waist Belt
Secure tie at CB waist band
BT
0.18
333
10.8
0.67
1
41
Assembly
Drawstring end knot make
Assistant Operator
0.28
214
16.8
1.04
1
42
Assembly
Thread trim
Assistant Operator
0.35
171
21
1.3
1
–
–
–
Total
19.6
–
–
72.63
72
SMV Summary of Jogger
Sewing Helper
3.69
Sewing Machine
15.92
Sewing QI
0
Finishing I/M
0
Finishing QI
0
Poly Helper
0
Packing
0
Hand Tag
0
Total
19.61
Man Power Summary of Jogger
Sewing Helper
13
Sewing Machine
59
Sewing QI
0
Finishing I/M
0
Finishing QI
0
Poly Helper
0
Packing
0
Hand Tag
0
Total
72
Machine Summary of Jogger
4T OL Auto
25
SNL Auto
21
BT
4
DNL Lock Switch Auto
1
SNDL Edg Cutter
1
BH Auto
1
KNS
2
SNL[Chain STS]
2
1NDL FL
2
Total
59
Written by
Rabin Saha PGD in Textile Management BSc. in Textile Engineering Email: [email protected] LinkedIn: Rabin Saha
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.
Operation Breakdown, SMV and Layout of Hoodies Manufacturing
Operation Balancing
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
Operation Bulletin Sheet
Seq. No
Body Part
Operation
Resource
SMV
Target (100%)
Efficiency
Cycle Time(s)
Layout MP
1
Hood
Hood upper two part attach
4T OL Auto
0.3
200
0
18
1
2
Hood
Hood upper topstitch
2NDL FL
0.28
214
0
16.8
1
3
Hood
Hood liner two part join
4T OL Auto
0.3
200
0
18
1
4
Hood
Hood upper n liner two part join
4T OL Auto
0.33
182
0
19.8
1
5
Hood
Bluffstitch hood join seam
1NDL FL
0.4
150
0
24
2
6
Hood
Hood mark n make hole
Snap
0.28
214
0
16.8
1
7
Hood
Eyelets attach at hood
Snap BA
0.35
171
0
21
1
8
Hood
Hood channel make
1NDL FL
0.42
143
0
25.2
2
9
Hood
Hood middle tack
SNL Auto
0.18
333
0
10.8
1
10
Hood
Hood lower edge close
SNL[Chain STS]
0.3
200
0
18
1
11
Hood
Hood crotch tack
SNL Auto
0.24
250
0
14.4
1
12
Pocketing
Pocket position mark
Assistant Operator
0.24
250
0
14.4
1
13
Pocketing
Pocket hem kangaroo pocket
2NDL FL
0.35
171
0
21
1
14
Pocket
Pocket edge press
Sewing Iron
0.4
150
0
24
1
15
Pocketing
Pocket attach and edge close-[Kangaroo]
SNL Auto
0.85
71
0
51
3
16
Pocketing
Pocket excess raw-edge cut
Assistant Operator
0.3
200
0
18
1
17
Pocketing
Pocket opening secure X4
BT
0.4
150
0
24
2
18
Assembly
Front n back part match
Assistant Operator
0.28
214
0
16.8
1
19
Assembly
Shoulder Join with/ without tape
4T OL Auto
0.35
171
0
21
1
20
Sleeve
Sleeve n body match
Assistant Operator
0.35
171
0
21
1
21
Sleeve
Insert Sleeves in hoodies
4T OL Auto
0.56
107
0
33.6
2
22
Sleeve
Armholes topstitch
2NDL FL
0.5
120
0
30
2
23
Label
Care label make
SNL Auto
0.24
250
0
14.4
1
24
Label
Flag label tack at side
SNL Auto
0.26
231
0
15.6
25
Assembly
Side seams ins care label
4T OL Auto
0.8
75
0
48
3
26
Cuff
Cuff join as a circleX2
SNL Auto
0.28
214
0
16.8
1
27
Cuff
Cuff fold into half
Assistant Operator
0.24
250
0
14.4
1
28
Cuff
Cuffs attach at sleeve opening
4T OL Auto
0.5
120
0
30
2
29
Hood
Hood n body match n mark
Assistant Operator
0.3
200
0
18
1
30
Assembly
Hood tack at neck
SNL Auto
0.24
250
0
14.4
1
31
Hood
Hood attach to body
4T OL Auto
0.35
171
0
21
1
32
Assembly
Front neck topstitch
2NDL FL
0.3
200
0
18
1
33
Neck
Tape attach at back neck
SNL Auto
0.35
171
0
21
1
34
Neck
Back neck top stitch
SNL Auto
0.45
133
0
27
2
35
Label
Label make
SNL Auto
0.24
250
0
14.4
1
36
Label
Attach main label at back neck
SNL Auto
0.3
200
0
18
1
37
Assembly
Bottom band join as circle
SNDL Edg, Cutter
0.24
250
0
14.4
1
38
Assembly
Bottom band edges close and mark
SNL[Chain STS]
0.45
133
0
27
2
39
Assembly
Bottom band attach to body
4T OL Auto
0.47
128
0
28.2
2
40
Assembly
Sticker remove and GMTs turn
Assistant Operator
0.26
231
0
15.6
1
41
Cuff
Cuffs topstitch [circular]
2NDL FL
0.45
133
0
27
2
42
Assembly
Bottom band topstitch
2NDL FL
0.45
133
0
27
2
43
Neck
Tie insert at hood chennel
Assistant Operator
0.28
214
0
16.8
1
44
Hood
Secure tie at c/frt hood
BT
0.18
333
0
10.8
1
45
Assembly
Threads trim
Assistant Operator
0.4
150
0
24
1
−
−
−
Total
16
−
−
−
59
SMV Summary of Hoodies
Sewing Helper
3.05
Sewing Machine
12.94
Sewing QI
0
Finishing I/M
0
Finishing QI
0
Poly Helper
0
Packing
0
Hand Tag
0
Total
15.99
Man Power Summary of Hoodies
Sewing Helper
10
Sewing Machine
49
Sewing QI
0
Finishing I/M
0
Finishing QI
0
Poly Helper
0
Packing
0
Hand Tag
0
Total
59
Machine Summary of Hoodies
4T OL Auto
14
2NDL FL
9
1NDL FL
4
Snap
1
Snap BA
1
SNL Auto
13
SNL[Chain STS]
3
BT
3
SNDL Edg Cutter
1
Total
49
Sharmin Akther Diba Industrial & Production Engineer Rajshahi University of Engineering & Technology Email: [email protected] LinkedIn: Sharmin Akther Diba
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.
Factory
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
meeting.
PP Meeting
Activities
Fabrication &
Finish Issues
All
expected fabrication issues especially those highlighted by during fabric
inspection report & sample process.
Potential
production problems according to fabric behavior.
All cutting related issues to be highlighted –fabric
relaxation, spreading elongation and tension, panel checking and records
measurements variation, plaid matching, pattern adjustment etc.
Grading of pocket, panels, inserts, notches etc.
Embellishment Issues
All potential issues
in application of embellishment i.e. print, embroidery, rhinestone, heat transfer label, decorative patches etc. are discussed.
Construction and
Stitching Issues
Sample
comments regarding sewing issues and every operation of concerned style is
discussed.
Emphasis
is on critical operations. All out of routine operations are discussed with
sampling master which finalized in vendor pre-production meeting.
Difficult
operations are highlighted and displayed for every style and doing risk
analysis report.
Difficult
operations checklist is maintained and verified during production.
Finishing Issues
All
expected finishing and packing issues to be highlighted & discussed with
vendor. This includes garment shape, pressing, folding, packing etc.
Pressing,
measuring, QA check, folding & packing instructions are placed and clearly
demonstrated to ensure PDM instructions are properly followed.
Factory
specs men are advised how to measure before pressing & after pressing &
keep records.
Buyer QC
emphasizes on vendor pre-production meeting points during inline inspections.
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
Process
NO
Operation/Process
Names
Type of
MNL OPR
100%
Worker
Count
TGT
–
–
Worker
SMV
TGT
–
–
–
1
Loop cut (5pcs 5 point)
H
0.25
240
1.13
1
240
2
Thread cut (top+in
side+Side seam+Hem fray clean)
H
1.2
50
5.44
5
250
3
Pkt clean(5pcs)
H
0.25
240
1.13
1
240
4
Re-Inforcement cut
(06 point)
H
0.2
300
0.91
1
300
5
Body carrying to iron
section & iron section to Q.I table
H
–
–
–
–
–
6
Inside Iron
IRN
0.25
240
1.13
1
240
7
Inside check
QI
0.4
150
1.81
2
300
8
Body turnover+ Gmts
counting
H
0.15
400
0.68
1
400
9
Top side check
QI
0.4
150
1.81
2
300
10
Alter rcetify
(Gmts+Label)
OP
0.25
240
1.13
1
240
11
Body carrying to btn
section & btn section to Q,I table
Job
Responsibilities of Garments HR Compliance Department
HR and
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
officer
Executive (HR & Compliance)
Assistant Manager, Manger
(HR & Compliance)
GM- HR, Admin and Compliance
Job
responsibilities of Garments HR Compliance Department
Developing, implementing and managing an organization’s
compliance standard.
Preparing and presenting clear and concise compliance
reports to the Board.
Interacting with regulators on compliance issues.
Coordinating efforts related to audits, reviews, and
examinations.
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
issues.
To motivate the employees for maintaining all kind of
personal safety.
Train up all employees on all safety awareness issue; maintain
all kinds of training records.
To aware the employees regarding health and safety
issues.
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
manner etc.
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
interval etc.
HR Job Functions/Activities in Textile and Apparel Industry
Coordinate
interview process.
Conducting appointment,
termination (closing) and in-service procedures
New employee
orientation.
Compiling,
sorting and generating periodic reports.
Scheduling and
coordination training and orientation sessions.
Attendance and
absent status management.
Maintain and Update
Employee Personal Files.
Assist to
coordinate Recruitment & Selection.
Manpower
Planning.
Management &
data entries into HRMS.
Handle Employee
Resignation, Exit Interview, Clearance, Closing Activation and Final Settlement
as required.
Handle disciplinary
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.
Performance Appraisal.
Confirmation,
Promotion, Increment and associate matters.
Employee
counseling.
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
System (QMS)
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
implemented.
Key Factors
of Garments Quality Management
Proper reporting
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
Proper Reporting
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.
Approved
Trim Card
Following approved Trim card in store,
cutting, sewing and finishing ensuring correct materials and fabrics are
joining for every lot.
Keeping
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.
Follow SOP
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.
Visualize
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.
Process
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.
Keeping
Packing Approval
A system to approve a garment by authorize person (buyer QC,
merchandiser or QA manager) before start packing of every lot
Zero Defects
Station
Set up zero defect station by through 100% garments quality
inspection in sewing and finishing.
Review
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.
Training
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.
Internal Pre-Final
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
Department
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
Type of
Extinguisher
Refilling
Date
Due Date
Location
Access in
maintained.
Locking Pin
in place.
Charge
indicator in green area.
Pressure
Hose in good condition.
Inspection
tag of the existing.
Expired date
should be one Month.
Daily First Aid Box Check List
Adhesive
(Bandage)
Burn Cream
Viodin
(Cream)
Viodin
(Liquid)
Provicep
Hexisol
Anticeptic
wipes (Savlon Cream)
Anticeptic
wipes (Savlon)
Nebanol
Powder
Roller
Bandage- 2″
Roller
Bandage- 4″
Surgical
Scissors
Nix
ORS
Gauze Pcs.
cotton
Signature of
Nurse
Toilet Check List
Soap
Bucket
Sandal
Tap
Basin
Towel
Adjust Fan
Overall
Cleanliness of Toilet
Cleaner Sign
Daily
Checklist of Drinking Water Filter
If filter
clean
Water level
Water color
If water
clean
Water tap
Supply of
water
Water pipe
switch
Water
temperature
Fire Alarm & Testing Report
Condition
Action Taken
Fire Extinguisher Checklist
Nozzle
Number
Marking
Safety pin
Meter
Ziczack
Marking
Expire Date
Have the
Picture of responsible person
Have the
inspection card
Have the
rules to handling
Signature of
Inspector
Fire
Equipment Box Checklist
Fire Helmet
Gum Boot
Hand Gloves
Fire Bitter
Fire hook
Hammer
Streacher
Lock Cutter
Respiratory
Musk
Fire Blanket
Manila Roof
Gas Mask
Torch Light
Fire Heat
Proof Dress
Boiler Check
List
Boiler
Controling Area
Water Level
ok/Not ok
Pressure
Meter ok/Not
Safty Valve
ok/Not
Gas Header ok/Not
Electrical Equipment Checklist
Substation
Room
LT
Switchgear
HT
Switchgear
PFI Panel
Housekeeping
MDB
Emergency
fire pump switch
Production
Floor
All
Switchboard panels
All
emergency switch
All circuit
breakers
All
electrical cords, plugs
Combustibles
distance
Compressor
Room
Pressure
relief valve
Guarding of
belts
Blowdown
valve
Pressure
gauge
Filters
Lubrication
Generator
Room
Cleanliness
Circuit
breakers
Lubrication
Temperature
Pressure
Gauge
Filters
Schedule Check for Electrical MDB/BD
Name Plate,
Key & Rubber Mat Check
All side
clean, Indicating Lamp & Cooling Check
Cable Check
& Nut-bolt loose Connection Check
Amp. &
Volt Meter Check
Cable/Bar
Temp & Load balance Check
Earth Line Cable
Check
Keep free
space in front of DB
Ckt
braker/fuse/selector switch Check
Inside clean
Schedule
Check for Exhaust Fan
Exhaust
Blower Clean
Duct Line Clean
Heat
Exchanger Side Net Clean
M/C Inside
Clean
M/C All Side
Clean
Schedule
Check for Fire Pump
Name Plate
Check.
All side
clean
Battery
Water Level Check
Battery terminal
Loose Connection Check
Battery Auto
Charger Check
Hose
Pipe/Nozzle Joint Coupling Check.
Diesel Tank
& Diesel Level Check.
Lube Oil
Level Check.
Delivery
Valve Check.
Suction Pipe
Non Return Valve Check.
Inspection, Test & Maintenance Requirements for Standpipe and
Hose Systems
Unusual condition Vibration leakage noise and temptation
Service room or housing keeping
Lighting
Protection System In-depth Visual Inspection Checklist
Any loose
connection at junction points
Corrosion in
any part
Down Conductor
& earth terminal connection is proper (intact)
Any mechanical
damage of system component
Conductor
are connected properly with surface
Any damage
due to surge
All clamps
are tightened
Additions or
change of the structure (protected structure)
Any others
abnormalities
Earth
resistance test perform
Continuity
(arrester to mesh, mesh to down conductor, down conductor to earth conductor)
test perform
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
Apparel
In this article, you will learn how Fusing Process and Quality Inspection of Fusing Machine in Apparel is to be done.
Fusing Process
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
Time: 12
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.
