Compliance Audit Checklist in Apparel Industry

Compliance Audit in Apparel Industry

A compliance audit is one kind of audit which is specially designed for auditing the compliance issues related with the apparel industry. Different regulatory authorities set different type of regulatory issues. And buyers of garments ask from the company whether they are following their required compliance or not. These issues are checked by the auditing process which is known as compliance audit. After a compliance audit, they provide/ issue certificate. From the Compliance Audit Checklist in Apparel Industry a garments makers will be able to know what are the things buyers may ask from the company.

Compliance Audit in Apparel Industry

Compliance Audit Checklist in Apparel Industry

Compliance Audit is very important for garments manufacturing factory. To get an order from the buyer, your company must have to pass social Compliance Audit. Buyer may cancel the order if your company fails to pass the Compliance Audit. In this article, I am giving a checklist for any buyer Compliance audit preparation.

Compliance Audit Checklist in Apparel Industry

Areas/Categories of Garments Compliance Audit

  1. Licenses, permits and Facility Information
  2. Child and under-aged worker
  3. Forced labor and Discrimination
  4. Freedom of Association and collective bargaining
  5. Right of worker
  6. Disciplinary Practice
  7. Working Hours
  8. Wages, Benefits & Compensation
  9. Workplace Safety
  10. Occupational Health & Welfare
  11. Environment Management
  12. Management Practice & Sub-contractor /supplier control
  13. Training records
  14. Company Policies

Licenses, Permits and Facility Information

  • Factory profile
  • Architectural & Structural Drawing Approval
  • Soil Test Report Approval
  • Trade license
  • Factory license
  • Fire license
  • Boiler license
  • Generator permission
  • Electrical permission/ Sub-station permission
  • TIN certificate
  • Export registration certificate and Import registration certificate
  • Export promotion bureau certificate
  • Bond license
  • Rent agreement

Child and under-aged worker

  • Child labor remediation process
  • Recruitment policy
  • Personal file
  • Agreement with the service provider/sub-contract

Forced labor and Discrimination

  • Any harassment or discrimination issues
  • Policy on a prohibition of forced labor
  • Awareness/Training register
  • Job responsibility of security guard

Freedom of Association and Collective Bargaining

  • Policy on freedom association
  • Awareness/Training register
  • Formation procedure of worker association/trade union
  • Meeting minutes of worker participatory committee
  • Register for complain /Suggestion
  • Grievance handling procedure

Right of Worker

  • Personal file of worker
  • Service book
  • Employee ID card

Disciplinary Practice

  • Policy on disciplinary practice or rules
  • Leave Record
  • Orientation training on factory code of conduct & legal requirement
  • All kind of policy
  • Disciplinary action log & record
  • Awareness/training register
  • Final settlement
  • Others legal facilities

Working Hours

  • Working hour Approval
  • Working hour record for all section
  • Overtime hour record
  • Attendance Register
  • Declared holiday list
  • Manpower list

Wages, Benefits & Compensation

  • Wages/payroll sheet (last 1 year)
  • Overtime wages sheet (last six months)
  • Payslips (last 1 year)
  • Wages Increment record
  • Maternity Benefit register & Record
  • Group Insurance with manpower update list
  • Policy on wages, overtime, payment date, calculation method, leaves & holidays etc.

Workplace Safety

  • Sub-soil/Geological investigation report
  • Building structural plan/approval
  • 3rd party assessment report
  • Firefighting training record
  • Fire drill record
  • Firefighting team
  • Firefighting equipment list
  • Fire safety plan
  • Personal file of Fire Officer
  • Electrical & Mechanical Equipment periodical checklist
  • Competency certificate of Electrician
  • Competency certificate of Boiler Operator
  • Chemical Handling Training
  • Health checkup record
  • Chemical list
  • Safely machine operating training register
  • Needle stock register, Broken & Missing Register
  • Sharp tool policy
  • Emergency evacuation diagrams
  • Emergency exit doors
  • Building structure safety
  • PPE (personal protective equipment) use
  • Aisle or Stairway

Occupational Health & Welfare

  • Personal file of Welfare officer
  • Drinking water test report
  • First aid training & List of the first aider
  • Medical agreement
  • Competency certificate of Doctor
  • Competency certificate of Nurse
  • Personal file of care governance
  • Childcare register
  • Canteen committee

Environment Management

  • Environmental risk assessment as per section
  • Emergency procedure to reduce risk
  • Environmental clearance certificate
  • Waste disposal agreement /procedure
  • Wastewater test report in-house and outside
  • Energy survey/ Assessment record

 Management Practice & Sub-contractor /Supplier Control

  • Awareness training record for new & old workers
  • Mid Management training record
  • Internal Audit record
  • Policy on Sub-contract control
  • Sub-contract control procedure & record

Training Records

  • Emergency evacuation & fire drill record
  • List of firefighters trained by fire service/BGMEA
  • Disciplinary Rules communication
  • First Aid training record
  • Chemical Training record
  • Machinery safety training record
  • Health and safety training record
  • Training on KIABI compliance

Company Policies

  • Child Labor Policy
  • Child labor Remediation Policy
  • Disciplinary Rules/Policy
  • CSR Policy
  • Anti-Corruption/Bribery policy
  • Sub-contractor/Supplier Monitoring
  • Grievance Procedure
  • Environmental Policy
  • Energy efficiency plan
  • Environment emergency procedure
  • Deduction for late/after lunch assentation

Compliance Audit Checklist in Apparel Industry

Written by

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

Linkedin: A.M. Amirul Islam

Garments Washing Defects

Garments Washing Defects

Garments washing is the process to improve hand feel, appearance and better outlook of garments. That’s why washing plays a vital role in garments manufacturing. Because of various washing defect, rejection of garments increases. We need to reduce the rate of washing defects/faults at a minimum level. Rejection increases the cost of overall manufacturing. For this reason, reducing washing faults is the major concern for all apparel manufacturing industry. One major KPI points are to reduce washing rejection in the apparel industry. I made a list of all types of garments washing defects so that you may have a better idea of garments defects.

Garments Washing Defects

List of Garments Washing Defects

  1. Garments Discoloration
  2. Poor Hand Sanding
  3. Care Label Fading/Damage
  4. Off Shade
  5. Shade Variation
  6. Over Washing
  7. Washing Damage
  8. Washing Spot
  9. High pH Level
  10. Poor Grinding
  11. Lycra Out
  12. Poor Sand Blasting
  13. High Abrasion Effect
  14. Color Bleeding at Pocket Bag and Label
  15. Washing Mark
  16. Poor Hand Feel

Washed Garments

Washing Defect Description

Garments Discoloration

If garments or any parts of garments discolored in washing it’s called discoloration. It is one of the common defect problems.

Garments Discoloration

Poor Hand Sanding

Because of improper hand sanding, more or less hand sanding than the actual requirement.

Hand Sanding

 

Care Label Fading or Damage

Care label is an important part of garments. Sometimes label fades or damage in washing.

Off shade

All garments have an original buyer required shade/color standard. If washing fails to meet shade standard then it is considered as off shade defect.

Off Shade Washing Defects

Shade Variation

Various types of shade in a lot, when fabrication and washing are the same for a whole lot.

Shade Variation Defects

Over Washing

There a certain limit of garments washing time and temperature. Crossing washing limit is considered as over washing and defects have arisen for this is known washing defects of over washing.

Washing Damage

Garments damage in washing is called washing damage.

Washing Damage

Washing Spot

Creating a spot in washing is called washing spot defect.

High pH Level

pH level crossed the level of higher pH limit. pH level is the most important factor in garments washing. For higher level, pH quality of garments may reduce.

Poor Grinding

Because of improper grinding, more or less grinding than the requirement.

Lycra Out

Damage Lycra or Lycra coming out in the washing of spandex fabric.

Poor Sand Blasting

Improper sandblasting, more or less sandblasting than the requirement.

High Abrasion Effect

Much abrasion effect than the requirement.

Color Bleeding at Pocket Bag and Label

Generally, different fabric uses for a pocket bag and labels in any garments. Due to garments body, fabric and pocket bag fabric is different, color bleeding occurred frequently in pocket bag and label.

Washing Mark

Garments marked in different washing stages, by the different washing machine, dryer. Long spot mark created in any process of washing is called washing mark defects.

Washing MarkPoor hand Feel

If you find Rough hand feels after washing of garments then that considered as a poor hand feel defects of garments washing.

Garments Washing Defects pdf

Written by

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

Linkedin: A.M. Amirul Islam

Ready Made Garments Export of Bangladesh

The condition of RMG Ready Made Garments Export of Bangladesh 2018

Bangladesh is now one of the developing countries in the world. Ready Made Garments (RMG) has a huge contribution to the economic growth of this country. The current condition of RMG – Ready Made Garments Export of Bangladesh seems good because there is a positive growth of export earnings. According to Export Promotion Bureau of Bangladesh (EPB), for the year 2017 to 2018 (July 2017 to April), Bangladesh Apparel Export is growing at the rate of 9% which seems a significant amount.

RMG Export Growth Over the Year 2010 to 2018

Here you can see that the growth rate of RMG export is always fluctuating, the reason behind this is a change in market demand, increase in the cost of making, political condition, market competitiveness, and the exchange rate of USD to BDT.

Year

Total Export Million USD

Growth
2010 14855 25%
2011 19214 29%
2012 19788 3%
2013 23501 19%
2014 24584 5%
2015 26603 8%
2016 28668 8%
2017 29213 2%

Export Growth of Ready Made Garments (RMG) of Bangladesh

Bangladesh RMG Growth for the Year 2017-2018

Ready Made Garments industry is growing at the rate of nine percent compared with the previous year. But in 2016-17 this growth rate was only 2%. So there is a significant positive change in the export.

Total RMG Export Growth 2017-2018
Year Woven Knit Total Growth
2016-2017 10,785 10,144 20,929           –
2017-2018 11,513 11,321 22,834 9%

Broad RMG Export Category of Bangladesh

Product Type Million USD Percent
Woven 11,513 50.42%
Knit 11,321 49.58%
Total 22,834 100%

We mainly divide our apparel product into two broad categories. One is knit and other is woven.

Ready Made Garments Export of Bangladesh

Monthly RMG Export Growth for the year 2017-2018

Although the growth of Ready Made Garments increased in every month there was an exception for the month of September 2017. It is not clear why suddenly growth rate reached to a negative figure.

Monthly Ready Made Garments Export Growth 2018

Main Apparel Export Items of Bangladesh for the Year 2016-2017

Bangladesh is mainly exporting Shirts, T-shirt, Trousers, Jackets Sweater among these Trousers and T-Shirt are exporting a huge amount, which is contributing at the rate of 29% and 28%. So these two products added significant value to the export earnings of Bangladesh.

Item

Million USD

Percent
Shirts 2108 10%
Trousers 6027 29%
Jackets 3547 17%
T-Shirt 5862 28%
Sweater 3362 16%
Total 20905 100%

Bangladesh Main RMG Export Product Type

Bangladesh RMG Export to the World 2017-2018

Most of our RMG is Exported to the European Union, where we export about 65% of our total export of apparel. Our second biggest client is the USA and the third one in Canada.

Region

Million USD

Percent
EU Countries 14735 65%
USA 3929 17%
Canada 713 3%
Others 3457 15%
Total 22834 100%

Bangladesh RMG Export to the World

Top 10 European Union (EU) Countries Bangladesh Export their RMG

  1. Germany
  2. UK
  3. Spain
  4. France
  5. Italy
  6. Netherlands
  7. Poland
  8. Belgium
  9. Denmark
  10. Sweden

Top European Union Ready Made Garments (RMG) Buyers of Bangladesh

Export of RMG by Bangladesh in European Union (EU)

Here look into this list that for the last 10 month EU countries is contributing 14734.69 million dollars. So there is no question of EU is the largest buyers of garments in our country.

EU Countries Million USD Percent
Germany 4205 28.537%
U.K. 2847 19.322%
Spain 1714 11.633%
France 1328 9.012%
Italy 1086 7.371%
Netherlands 717 4.866%
Poland 645 4.381%
Belgium 534 3.626%
Denmark 504 3.420%
Sweden 395 2.679%
The Czech Republic 352 2.386%
Ireland 131 0.890%
Slovakia 64 0.433%
Portugal 50 0.338%
Slovenia 44 0.298%
Greece 40 0.270%
Finland 22 0.152%
Austria 22 0.147%
Romania 13 0.086%
Croatia 10 0.069%
Malta 5 0.033%
Bulgaria 2 0.013%
Hungary 2 0.012%
Lithuania 2 0.011%
Cyprus 1 0.006%
Estonia 1 0.006%
Latvia 0.5 0.004%
Total 14735 100%

RMG Export Market of Bangladesh Source: Export Promotion Bureau of Bangladesh, BGMEA

Written by

Md. Nahian Mahmud Shaikat

Email: [email protected]

List of Machinery for Knit Composite Dyeing and Garments Factory

List of Machinery for Knit Composite Dyeing and Garments Factory

List of Machinery for Knit Composite Dyeing and Garments Factory

 

Knit Composite Factory

Generally knit composite receive yarn from spinning. The process starts with yarn dyeing and finishes with fully knitted garments ready to send to the customer. Different stages and process involved in a knit composite factory. In this article, I made a List of Machinery for Knit Composite Dyeing and Garments Factory which will be required for doing the process of a composite factory. Machinery and Equipment may have different brands sourcing from the different country, its varies from factory to factory but working principle is more or less same.

Process List of Knit Composite Factory

Process of Knit Composite Factory

  1. Yarn Dyeing
  2. Knitting section
  3. Knit fabrics dyeing
  4. Dyeing finishing
  5. Washing section
  6. Allover print section
  7. Screenprint
  8. Embroidery section
  9. Knit Garments Cutting section
  10. Knit Garments sewing section
  11. Knit Garments Finishing section
  12. Factory utility section

List of Machine for Yarn Dyeing

  1. Yarn Dyeing
  2. Hydro
  3. Dryer
  4. Random Winding
  5. Soft Winding
  6. Sewing Thread
  7. Lab Dyeing
  8. Lab Dryer
  9. Lab Washing

List of Machine for Knitting Section

  1. Single Jersey
  2. Rib / Interlock
  3. Three Thread Fleece & Heavy Jersey
  4. Auto Stripes
  5. Flat Knit
  6. Fabrics Inspection

List of Machine in Knit Fabrics Dyeing

Only dyeing machine is used in this section

  1. Dyeing

List of Machine in Knit Fabric Dyeing Finishing

Not only in garments, finishing is mandatory after fabrics dyeing as well

  1. Stenter
  2. Compactor
  3. Dryer
  4. Active Stabilizing Dryer
  5. Slitter
  6. Squeezer
  7. Fabric Turning
  8. Seuding
  9. Raising
  10. Fabric Heat Setting
  11. Enzyme Cleaning
  12. Fabric Inspection

List of Machine for Knit Washing Section

  1. Washing M/c
  2. Sample Washing
  3. Deep Dyeing
  4. Ozone
  5. Jeanologia
  6. Tonello
  7. Tumbler Dryer
  8. Oven Dryer
  9. Hydro M/c

List of Machine in Allover Print Section

  1. Rotary Print Machine
  2. Flat Bed Print
  3. Loop Steamer
  4. Wash Machine
  5. Stenter Machine
  6. Compactor Machine
  7. Screen washing Dry Machine
  8. Flat Screen Dryer Machine
  9. Flat Screen Coating Machine
  10. Screen Engraver
  11. Screen Banding
  12. Luscher Blu Diod Exposing
  13. Fimafe Screen Preparation Units
  14. Rotary Sample Paint Machine
  15. Color Kitchen Units

List of Machine in Screen Print

  1. Light Expose
  2. Grunig
  3. Mixer Unit
  4. Flash Cure
  5. V-2002 EX
  6. Easy
  7. Manual
  8. Curing Oven
  9. Hit Press
  10. Traveling Carriage
  11. Stone

List of Machine in Embroidery Section

  1. Sun Star
  2. Wuhan Golden
  3. Wuhan Golden
  4. Yueming
  5. Hashima
  6. Dichi
  7. Laser Cutter

List of Machine of Knit Garments Section

As like woven Garments, there cutting, sewing and finishing section in knit garments. Please see below section wise machine list.

List of Machine in Knit Cutting Section

  1. Cloth Cutter
  2. Plotter
  3. Auto Cutter
  4. Auto Spreader
  5. Spreader
  6. Plotter
  7. Pattern Cutter

List of Machine in Knit Sewing Section

  1. Single Needle Lock Stitch machine
  2. Two Needle Vertical
  3. Two Needle Lock Stitch machine
  4. Three thread Over Lock Machine
  5. Four thread Over Lock Machine
  6. Six thread Over Lock Machine
  7. Flat Lock Cylinder Bed
  8. Flat Lock Small Head
  9. Flat Lock Fabric Trimmer
  10. Flat Lock Tape Binding
  11. Flat Lock Narrow Head
  12. Flat Lock Top Feeder
  13. Flat Bed Machine
  14. Latch Attaching
  15. Back Tape Attaching
  16. Single Needle –Two Thread Overlock machine
  17. Single Needle Chain stitch machine
  18. Button Attaching
  19. Cycle Sewing
  20. Picoting & Fagoting
  21. Buttonhole machine
  22. Single Needle Zigzag
  23. Bartack
  24. Snap Button
  25. Rib Cutter
  26. 4 Needle Flat Seamer
  27. VT Fit of the Arm (Flat-Lock)
  28. 2 Needle Fit of the Arm
  29. 3 Needle Fit of the Arms
  30. Shirring & Smoking Machine
  31. 11 Needle Plan Machine
  32. 18 Needle Pre-Close Elastic Machine
  33. Elastic Attaching Machine

List of Machine in Knit Garments Finishing Section

  1. Iron
  2. Vacuum board
  3. Thread sucking matching
  4. Needle defect machine
  5. Strapping machine

List of Machine in Garments Utility Section

  1. Generator
  2. Boiler
  3. Air Compressor
  4. Air Dryer
  5. Water Pump

Written by

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

Linkedin

Calculate Garments Cost of Making

One of the highest manufacturing industry is garments manufacturing industry where different types of garments are manufactured. Calculate Garments cost of making time to time is the right decision because the main motive of garments manufacturer is to make a profit where they manufacture garments and then sell it. But the problem is, what should be the required price of that item and how to calculate garments cost of making. To solve this problem first, you have to know the cost of garments making then add your markup price to set the selling price. Here cost of making means cost of manufacturing garments. Monitoring garments making cost is necessary so that trends of the cost of making can be identified and you can actually know whether your garments making cost is increasing or decreasing. Based on your change in garments cost of making you may take decision accordingly.

Calculate Garments Cost of Making

How to Calculate Garments Cost of Making

Pre Requirement of Calculation of  Garments Cost of Making

Before you start your costing you need to know the followings:

  1. Total Cost (TC) = Fixed Cost (FC) + Variable Cost (VC)
  2. Production Capacity of Your Machine (Hourly)
  3. Total Effective Working Hours Per Day
  4. Number of Days Operation in a Month

Fixed Cost of Garments Making

Fixed Cost are those cost of garments manufacturing which are fixed in nature. With the increase of a number of unit of production, your per unit fixed cost will be reduced. Some example of fixed cost is; salaries and wages, interest expense of bank loan, a rental expense of your factory building, depreciation expense of your fixed assets etc.

Variable Cost of Garments Making

Variable cost is the cost which is change over an additional number of unit of production. But per unit variable cost is fixed. The variable expense of garments making is; Utility (Electricity cost, Water cost, steam cost, Air cost) Expenditures, transportation cost, repair, and maintenance expense etc. Here the most crucial variable cost is utility cost. We need to carefully handle utility section to minimize utility cost.

Hourly Total Production Capacity of  Garments Machinery

To identify hourly total production capacity, you need to identify the total number of machine and capacity of each machine. After that, you need to multiply the hourly capacity with machine number.

Daily Production Capacity of  Garments

For calculating daily production of your garments, you need to multiply your hourly effective production capacity into working hours each day.

Monthly Production Capacity of Garments

To calculate monthly production capacity you have to multiply your daily production capacity with the number of working days in a month.

Costing of Utility of Garments

  • Electricity: To get electricity cost you need to identify total kW consumption of your factory and then multiply total KW with Price of per Kw electricity. Remember the cost of electricity is much higher in case of fuel generator and local REB compared with Gus Generator.
  • Water: Water cost is the cost of collecting water and the filtering cost. Normally in textile and garments, De-Mineralized (DM) water is used.
  • Steam: First identify total consumption of steam per machine each hour and then multiply with the number of machines.
  • Compressed Air: In case of air you have to identify the compressed air cost for per cubic meter then multiplies with the total consumption.

The formula of Calculating Garments Cost of Making

Monthly Garments Cost of Making (GCM) = (Monthly Total Cost of Garments Operation)/Monthly Total Output Produced by the Factory.

  • Here Total Cost include both fixed and variable Cost of your garments factory for one month
  • Monthly total Production is the output produced by the factory.

Example: Suppose Your Factory Costing Related Information are;

  • Salary & Wages Expense Tk. 20,000,000
  • Monthly Interest on Bank Loan Tk. 100,000
  • Depreciation Expense is Tk. 50,000
  • Rental Expense of Building is Tk. 200,000
  • Transportation Cost is Tk. 150,000
  • Repair & Maintenance Expense is Tk. 50,000
  • Utility Expense is Tk 100,000, where Electricity Cost is Tk 500,000, Steam Tk. 200,000, Water Cost is Tk. 100,000, Chiller Cost Tk. 100,000, Compressed Air Cost is Tk. 100,000.
  • Total Number of Machine is 150
  • Hourly Production Capacity of Each Machine 30
  • The total Working hour is 8 hours per day
  • The number of working days in a month is 26 Days.

Total Cost = 20,000,000 + 100,000 + 50,000 + 200,000 + 150,000 + 50,000 +1,000,000 = 21,550,000

Total Production = 150 * 30 * 8 * 26 = 936,000

Cost of Garments Making Per Piece of Garments = (21,550,000/936,000) = Tk. 23.02 (Piece)

After reading this hopefully you understand how to calculate garments cost of making. If you have any confusion then please let me know, I will try to clarify further.

Note: All these costing information is arbitrarily taken, so these values are not actual costing value.

Flow Chart of Apparel Dyeing

Apparel Dyeing is a process by which color is applied on apparel. Basically through the dyeing process color is applied on fabric. Dyeing is used for giving fashionable look on fabric, and using these fabric, garments manufacture denim, t-shirt, sweater, Shirt, jackets etc.

Objectives of Dyeing

  • To produce fashionable garments by changing the outlook.
  • Comparatively low cost
  • Different shade can be accepted in same batch

Basic Dyeing Process of Garments

Process Flow Garments Dyeing

Mainly dyeing process is applied on grey fabric and after completing the whole process we get colored fabric. But remember one thing that after Dyeing you have to wash your fabrics.

Flow Chart of Apparel Dyeing

Flow Chart of Apparel Dyeing

If closely see the flow process of complete Dyeing of fabric, then you may identify the following procedure. Earlier I said that Dyeing process starts with grey fabrics/garments then loading into Dyeing machine, after that pre-treatment and bleaching garments, then Dyeing, fixing (after treatment) and finally we will get finished dyed fabrics.

Flow Chart of Apparel Dyeing

Written by

Md. Mashud Rana Opurbo

Industrial Engineer.

Email: [email protected]

Cell: 01928-186429

Calculation of Earnings and Loss for Garments Industry

Calculation of Earnings and Loss for Garments Industry

Calculation of earnings and loss for garments industry is required to monitor whether factory operation is generation expected revenue or not. Based on your calculation of earnings and loss you can set production target to meet your expected level of profit for your business.

Calculation of Earnings and Loss Template

As sewing is one of the main operation of garments, you can take sewing as a factor and calculate earnings accordingly. You can use same formula for calculating profit or loss of your industry after shipment of your final product.

Calculation of Earnings and Loss for Garments Industry

Let’s see the calculation at a glance.

Suppose, Your Factory’s last 3 Month Expenditure= 1466400$

So, Per month Expenditure = (1466400$/3) = 488800$

So, Daily Expenditure = (488800$/26) = 18800$ [if fty run 26 days per month]

Your fty produced = 8800 Units per day

Per GMTS CM= 2.20$ (It’s vary style to style, you need to calculate style wise from buyer given CM)

Then, Daily Earnings = (8800 X2.20$) $ = 19360$

So, Your Daily Earnings = (19360$-18800$) = 560$

Production Report

Template for Calculating Earnings and Loss for Garments Industry

I have developed an excel template to calculate earnings and loss for your convenience. You can use this template for any industry; specially for your daily garments production. I hope this will give you well understanding.  You can download this template for free, just click on daily production & CM earnings report.

Daily Production & CM Earning Report

This template includes:

  1. Production report
  2. Production chart
  3. Earning calculation and report
  4. Per unit CM (Style wise)

This template can be very helpful for any Garments professional. Based on the output of this template you can prepare your report maintaining professionalism.

You will get not only earnings and loss report but also production report. In this way it will be helpful for everybody to see actual status of a factory. If you face any problem of understanding then please do not hesitate to contact with me.

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim

Phone:+8801929643301
E-mail: [email protected]

Quality Improvement Techniques in Apparel Industry

Quality Improvement Techniques in Apparel Industry or Garments Industry

As quality is one of the key success factors, managers always try to devote their effort for improving the quality of garments. In this article we will show you how quality improvement techniques in apparel industry can be ensured.  Not only productivity but also quality improvement getting most importance in apparel industry. Without ensuring quality you should not make shipment of your goods to the customer’s destination. We have seen that sometimes our valuable customers reject the goods or hang the payment because of low quality goods which is not in accordance with the specification. Although there is continuous efforts is given but there may have some problem which is not correctable/repairable. So it would be a right decision to take all precautionary measures to avoid unexpected fault of your garments and ensure right quality.

Quality Improvement Techniques in Apparel Industry

Garments Quality depends on these Quality Factors

If you want to ensure quality and continuous improvement then you have to avoid the following defects of the garments.

  1. Fabric defect
  2. Trims and accessories defect
  3. Cutting defect
  4. Construction and placement Defect
  5. Seam and Stitching Defect
  6. Finishing defect
  7. Packing defect

Let’s have a short discussion about these quality factors/matters

Fabric Defect

Fabric cost is at least 60% out of total garment Cost. Apparel Industry inspect fabric roll for quality matter. If your fabric roll fail in inspection you should return to fabric supplier and replace with the quality one. If your finished garment contains fabric defect, you are the one who will be responsible for that not fabric supplier.

Trims and Accessories Defect

Apparel industry should check all trims and accessories after in housed. If they found any problem, they should return to suppliers for replacement.

Cutting Defect

As per Running shade and Selvage report, marker will make for bulk cutting. Otherwise garments will contain part shading. All cut components should match with marker.

Construction and Placement Defect

You will sewing garments as per buyer’s approved sample for bulk production. All stitching of every process should same as sample. Different parts placement should accurate. Up-down is not acceptable.

Seam and Stitching Defect

All sewing machine should fit for sewing with accurate tension. Otherwise there are possibilities of skip stitches, puckering. Garments should be clear of some other stitching defects like: broken stitch, over stitch, down stitch, jam stitch, and joint stitch.

Finishing Defect

After pressing Garments there should be no crease mark, puckering. Keeping good appearance is also necessary for garments.

Packing Defect

There are zero tolerance any types of packing defect. Incorrect size, incorrect PO, incorrect quantity, folding defect include in packing defect. You should be careful about these defects.

Inspection

You should check your quality of 100% garments in finishing. If repairable of defective garments, you should repair it quickly as you can. Before final inspection, you can do pre-final or shadow inspection to see quality of your packed garments. If you found lots of defect in packed garments, you should re-check all garments and take effective measures to resolve the quality problem of garments.

Finally quality improvement is a continuous process that’s why you have to give your effort continuously and this will be possible through proper monitoring every steps of garments manufacturing. If you can ensure monitoring and take immediate action to resolve the defects then obviously you product quality will be improved.

Written by

A.M. Amirul Islam (Washim)

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Garments Quality Standard

Garments Quality Standard

Garments Quality Standard is now one of the most important factors that need to be maintained as because people are now more conscious about the quality of garments. The quality standards may vary from company to company, market to market, but there is some common quality standard which all garments always try to maintain. Here I am going to share a list of defects which must be avoided to ensure minimum Quality Standard for garments:

Garments Quality StandardGarments should not have these defects

  1. Needle cuts
  2. Holes
  3. Slabs
  4. Snags
  5. Open seams
  6. Broken stitches
  7. Puckering
  8. Raw edges
  9. More than one skipped stitch

Garments should avoid these manufacturing defects

  1. Defective Stitching
  2. Untrimmed or loose threads
  3. Pills
  4. Cleaning solution
  5. Embroidery hoop marks
  6. Stain or soils
  7. Part Shading
  8. Any unrelated operation
  9. Pleats in any seaming
  10. Contain dirt, Lint
  11. Uneven seam
  12. Insecure stitch
  13. Pinked edge
  14. Uneven tension

Some Defect must avoid in Finished Garments

  1. Fabric Fold marks
  2. Center Crease
  3. Any Fabric defect
  4. Unspecified color, shade, and cast
  5. Sleeves or legs shall be twisted
  6. Improper pressed
  7. All tape or stickers other than inspection stickers inside the garment
  8. Clip or Clamp
  9. Wrinkles, creases or other signs of poor pressing
  10. Pressing marks shine, scorching or burn marks
  11. Unnatural creases or folds
  12. Wavy or puckered seams
  13. Appearance of Repairing

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim
E-mail: [email protected]

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Overview of Modern Auto Cone Winding Machine

Auto cone is a modern yarn winding machine. It is use to prepare bigger package from ring bobbin. It is just not only has a winding machined, there also some extra specification of this machine.

An Overview of Modern Auto Cone Winding Machine

Features of auto cone winding

•    Auto splice without knot.
•    Automatically remove yarn fault.
•    Make bigger package in minimum coast
•    Waxing devise
•    Pneumatic disc type tensioner
•    Electronic yarn clearer
•    Reserve ring bobbin

overview of modern auto cone winding machine

Parts of AUTOCONER Machine

•    Bobbin Magazine
•    Chute guide
•    Bobbin peg
•    Knit preventer
•    Bal con
•    Photo electric yarn feeler
•    Pre clearer
•    Re-tie arm/mouth
•    Yarn tensioner
•    Suction arm/mouth
•    Splicer
•    Electronic yarn clearer
•    Waxing devise
•    Drum
•    Package cradle
•    Unit start & stop switch
•    Unit indicator
•    Empty conveyor
•    Cone conveyor
•    Over head cleaner
•    Machine ON switch
•    Machine OFF switch
•    Blower ON switch
•    Blower OFF switch

Working principle / Function of auto cone machine

•    Making Cone package from cops.
•    Remove yarn fault (Thick & thin place, naps, foreign materials etc)
•    Remove knot of yarn by auto splicing.
•    To wax the materials
•    Minimize yarn imperfections
•    To wax yarn
•    Improve yarn quality
•    Give suitable shape of cone package
•    Make uniform yarn
•    Achieve higher production and less power consumption

Written by

A.M. Amirul Islam (Washim)

Facebook: Amirul Islam Washim
E-mail: [email protected]

If you like this article please do not forget to share on facebook and put your valuable comments.