Best Practice of Garments Washing Factory

Best Practice of Garments Washing Factory in Apparel Industry

The best practice is a manufacturing methodology or technique which is developed by longtime research and accepted as the best method to do a particular job. Here I am giving best practice followed by Garments washing factory, you may set them as a standard operating procedure (SOP) for the whole washing process. Hope this article would help you enrich your knowledge of best practices of Garments Washing Factory.

Best Practice of Garments Washing Factory Commonly Used

Pre-Production /Sample Development Stage of Garments Washing Factory

  1. Set a detailed SOP for sample development and pre-production procedure and team organogram for proceedings, make visible for all.
  2. Your factory should have a separate department or a team (R&D) for handling samples development and duplication.
  3. Development samples, and then duplicated samples are kept with records/recipe for future follow up.
  4. Development team reviews the PDM & check requirements before start shade band/the first batch.
  5. Developments samples are scan and reviewed by supervisor/manager before submitting for approval to buying-house.
  6. Trims and Leather patches being reviewed/Wash standard Checked prior to development.
  7. Risk Analysis meeting is to be held in factory or vendor to take necessary precautions before bulk & maintain the records.
  8. Washing recipes are set with record according to approved samples/standards/recipe/work order.
  9. Samples are reviewed under lightbox in dark room with identified light sources from an individual customer for color matching.
  10. Shade blankets/Shrinkage test done properly as per Wash standard.
  11. Always run a 1st batch trial and review it in detail, for measurements, appearance & shade, before running bulk production. Make a detailed report.
Garments Washing Machine, Modern Garments Washing Machine

Production Control -Dry and Wet process in Garments Washing Factory

  1. Inspecting Garments in before wash stage to check part shading, work hole, spot and shade segregation.
  2. Approved samples for each dry process available (with date & signature) and posted in front of the operator.
  3. Inspection procedure by AQL check for defects, keeping a daily updated report of pcs checked & defects found, use min 1,000 lux illumination, proper records kept before proceeding to next process.
  4. Quality Improvement efforts with Quality meetings, Defects Summaries, Pareto Analysis and Follow up. Use statistical data, to analyze quality results & make decisions to improve it. Review results & plan future corrective actions based on root cause analysis (should be visible in production lines), Pareto graph and follow up on top 5 defects. Compare results by day, week, month and by-line, section, dept., etc. You need to also keep track of the progress of at least 1 most recurring defect
  5. First bulk lot procedure is available in wash plant with a color-coding system.
  6. Garments are properly prepared and weighed/load size accordingly to suit for machine sizes and work order prepared.
  7. Approved recipe are properly prepared and posted for operators guide on each particular finish/machine.
  8. Garments are checked for scratch, color matched to standard before applying next step of wash/soften bath.
  9. You should have an in-house lab testing room, important Lab testing carried out at internal Lab e.g.: pH /tearing/washing fastness/crocking etc.
  10. Washing standards and shade bands available for each style/color and stored properly by dark ploy in a locked box.
  11. Measurements checked on every batch before and after washing, using a correct ruler and calibrated tape measurement and reported.
  12. The implementation of Preventive Maintenance system to reduce machine downtime and maximize machine fitness.
  13. Color evaluation Lab is maintained with buying house standard light source, CWF & D65 preferable.
  14. Implement 5’s method as a base to implement lean procedures. Must do weekly 5’s audits, give & post rating to each area. Do formal training & keep training records.
  15. Set up ETP and WTP to remove effluent from water and processing wastewater.
After Washing Garments Dryer Machine

Chemicals/ Dyestuff Control and Storage in Garments Factory

  1. Set a detailed SOP on chemical storage, dispatching and chemical handling safety procedure to visualize in floor.
  2. Temperature and humidity control, Storage area ventilation and floor set in good condition.
  3. All containers, big & small must be properly labeled to indicate which chemical they contain.
  4. Chemicals arrangement in good condition to avoid accidental/hazardous/inflammable mixing.
  5. Keep a log of chemicals dispatched to bulk production, quantity & chemicals specs must match washing recipe.
  6. RSL, MRSL reports must be handily available on site for each chemical. GOTS certificate, MSD and TDS documents should have in chemical and Dyestuff store.
  7. Warnings signs are posted on shelf or wall for, specially chemicals in storage.
  8. Dispensers are properly labeled for separate application to avoid chemicals Contamination.
  9. Weight machine or digital balance in use, Scales must be calibrated for accuracy.
  10. Chemicals are well prepared and weighted in advance for bulk production load.
  11. Stockkeeper in control of chemicals used.
  12. Chemical are labeled to containers/bags of purchase date or expiry date.

Technical requirement of cutting and Fabrics

  1. Garments dry process and wet process procedures
  2. Garments washing procedure
  3. Garments washing best practice
  4. Benchmarking Garments washing.
  5. Technical Requirement of Cutting and Fabrics

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Garments Quality SOP

Garments Quality SOP

Garments quality SOP is the standard operating procedure for quality control in Garments manufacturing. Setting Standard procedure for garments is very much important to get up to the mark of readymade garments. In a garments quality SOP, a clear description for every working system and requirement to get the best possible result is written. Following SOP, we can do any work in a standard way and know what to do to complete the whole operation. Garments buyer also gives SOP for handling their order. It is makers responsibility to follow while making their garments. Every garments factory has own SOP for every process they are involved with. Basically, a garments quality SOP is the written guidelines of standard procedure to do a particular work for making garments. Time to time standard process may change because garments involve with making different garments different times. Actually, a good standard operating procedure increases productivity by reducing the system loss or operating losses. In a garments factory a quality control department is responsible for ensuring the best quality of garments, so they always follow a standard process for monitoring and controlling process and products.

Garments Quality SOP, Garments Quality Standard Operating Procedure

List of SOP Needed for Garments Quality

Listed SOP hyperlinked with needed SOP, you can read by clicking.

  1. Fabrics inspection SOP
  2. Shade band procedure
  3. Fabrics process before cutting
  4. Trim and accessories inspection SOP
  5. Garments pattern making SOP
  6. Fabrics relaxation, spreading and cutting procedure SOP
  7. Sewing quality procedure
  8. Garments measurement SOP
  9. Needle controlling SOP
  10. Sharp edge controlling SOP
  11. Button pull test SOP
  12. Button pinch setting SOP
  13. Metal detection SOP
  14. Mold prevention SOP
  15. Finishing SOP
  16. Quality control manual or SOP

If you need any SOP for a specific process/ task related with quality or you want to develop a quality manual or any technical thing of garments manufacturing, please feel free to contact with me through sending mail to the following address.

Garments quality SOP pdf

Written by

A.M. Amirul Islam (Washim)
Email: [email protected]

Linkedin: A.M. Amirul Islam

Apparel Industry SOP

Apparel Industry SOP

Now one of the most growing industry in the world is the apparel industry. As the apparel industry is growing it is required to increase its operating efficiency. For increasing operating efficiency in textile and garments must need to ensure the use of Standard Operating Procedure (SOP) in every operating section. Apparel industry SOP is necessary because it is a written step by step guidelines or as a form of flow diagram with proper explanation. If you are involved with the apparel industry (textile and garments) you must know what is Standard Operating Procedure (SOP) in Garments. Actually, SOP is one type of manual which provides guidelines for operating procedure or working procedure. Earlier it is not mandatory to follow standard operating procedure but now because of the huge benefits, each and every industry trying to use. One problem is there are many people who do not have a proper idea of how to develop an SOP for their textile and garments and how they can make a functional SOP. So it will be a good decision if you hire an experienced professional who can develop a standard operating procedure for your factory. SOP should be put in a working place where it will be easily visible. SOP should be printed form with proper lamination on it to avoid damage.

Apparel Industry SOP

Remember Two Things when You Develop an SOP for Apparel Industry

  1. Make it Concise: Proper Description must be given to clarify the process or working procedure.
  2. Make it as written and as well as visual: Use easy language so that worker can understand and side by side hang a flow chart also to make it visual.

Textile and Garments Should Develop SOP for Each and Every Operating Section

  1. SOP for Spinning
  2. SOP for Knitting
  3. SOP for Dyeing
  4. SOP for Printing
  5. SOP for Garments Cutting
  6. SOP for Sewing
  7. SOP for Finishing
  8. SOP for Quality Check (Q.C)
  9. SOP for Packing
  10. SOP for Store Management
  11. SOP of Sampling
  12. SOP for Every Other Functional Operation

Benefits of Using Standard Operating Procedure (SOP) in Apparel Industry

  1. Ensure Standardized in Operation
  2. Provide Standard Guidelines
  3. Easy to Understand the Process and Adaptation
  4. Fastness in Operation
  5. Ensure Consistency of Output
  6. Helps to solve basic problem and take effective actions
  7. Reduce wastage of materials

SOP for Textile and Garments pdf