STANDARD
OPERATION PROCEDURE FOR SEWING PRODUCTION SYSTEM
1.
Department Structure and Attendance:
Factory must have complete department structure comprising of all relevant
categories to have smooth operational function. Daily attendance details
certified by P.M. must be available in each section for management information.
2.
Style file (Folder): Merchandising
department must provide style file with complete details to all concerned
departments. This file must be contained with latest technical specifications and
comments from buyer.
3.
Sewing production plan: Planning department
must provide the production plan for each order to all concerned departments.
Any changes or revisions will be made due to any reason; planning department has
to update all concerned parties immediately.
4.
Approved sample: Approved sample with
comments, which will be certified by Q.A.M. has to be displayed in line until
total order completion. Have to keep this sample safely for future reference in
completion of style.
5.
Finish Patterns: Line production staff has
to finalize required finish patterns with cut marks/notches and other work aids
at Line sample process and have to certify by Sample
/ Technical department & QA Manager.
6.
Line sample:
i.
Production staff has to collect all the details,
actual fabrics and trims for the preparation of line sample. This should be at
least 3 days prier to line feeding.
ii.
This sample to be done with the involvement of
line in charge, line supervisor, line Q.C, work study officer, Mechanic &
technical/sample room. Have to follow buyer’s sample, comments and operational
break down prepared by work study officer.
iii.
This sample to be evaluated by line Q.C. and
sample evaluation report will be submitted to Q. A. M. to comments at the P.P.
meeting.
7.
Pre production Meeting ( Internal):
i.
P.P. meeting (internal) to be held with the
involvement of F.M., P.M., Q.A.M., I.E department, Sample / Technical
department, production staff of the line, Finishing, merchandiser, mechanic,
Stores etc.
ii.
Comments in the line sample evaluation and buyer’s latest comments to be reviewed
very closely and taken care.
iii.
Fabric and trim inventory report to be obtained
by the stores prior to conduct P.P. meeting.
iv.
Must have received all lab dips, fabric
shrinkage, shade band, color continuity card, pull test etc at this stage.
v.
Complete order file to be received by line staff
prior to P.P. meeting.
vi.
PP meeting minutes should be recorded & all
participants must sign and acknowledge the PP meeting minute record.
8.
Line lay out and manpower allocation: Have
to get machine layout from I.E. department and required machinery and
attachments from maintenance department. Have to sort out suitable operators
with consultation of P.M., Line in charge and Work study officer by referring
the Skill Inventory.
9.
Stores requisition: These requisitions to
be prepared by section supervisor and have to obtain signature of P.M for
authorization.
10. In put: Line supervisor is responsible to receive in
put as per Bundle chart and have to assure quantity receiving is correct. Also
have to issue input to the line as per the sequence in the Bundle chart and the
same to be maintained in each operation up to out put.
11. Style feeding:
Have to feed each operation with correct demonstration to operator. Must
complete line feeding report by line Q.C. to accept and agree with line
supervisor, Work study officer and other prod. Staff to proceed with each
operation.
i.
Have to maintain Style feeding time record
by the Work Study Officer.
ii.
With the leadership of line chief all operators
and helpers to be educated about each job that has to be performed before
proceeding with bulk. Necessary work aids, Mockups, Sketches with illustrations
pertaining to operation will be helpful to operator to follow.
12. Hourly individual production: To be
recorded by supervisor. In case of finding any production drop by operator due
to any reason action to be taken immediately and have to keep line in charge
and P.M informed
13. Bundle
Tracking: In line Work in
progress & Output quantities to be monitored against bundle chart which
will be used from input.
14. Daily
Manpower Allocation & Transfer records should be maintained daily by Line wise. This record to be certified by
Line Chief, Work Study Officer & Production Manager.
15. Daily line
forecast meeting: Daily line
forecast meeting to be conducted by P.M., Q.A.M., Line Q.C., Work Study Officer
with production staff and mechanic to review status of running production. Suggest
participation of F.M. in this meeting. Important points to be recorded &
followed up.
16. Revision of
S.M.V.’s: Line chief has to discuss about individual targets with
Work Study Officer in case of revision needed for S.M.V within three days after
feeding the line.
17. Over time
authorization: This record is to be certified by supervisory staff
and section heads. O.T plan to be prepared after reviewing working progress and
request to be made by Line chief, certified by work study officer to submit PM
/ GM for authorization.
18. Loss time
recording: Work study
officer should record line wise loss time (Non productive time). Line chief
& the responsible department for the each loss time should sign &
confirm this record.
19. Bottle neck
solving procedure: Line supervisor and work study officer have to
review line working progress. With consultation of P.M. and I.E. manager, plan
to be made for bottle neck solving. Have to obtain prior approval from F.M. for
Over Time. Also the lost time with records to be considered by the management
for this extra time required to be used and corrective action to be taken to
minimize lost time.
20. Daily
Efficiency report: Daily line efficiency report to be prepared by
I.E Department and to be submitted to GM before 9.30am daily. Action to be taken in the daily forecast
meeting will be reviewed through this report.
21. Skill
development procedure: I.E department will take the initiative of
grading workers and recommending to P.M. for skill development. Worker will be
trained under the training instructor and details of training period and
performance to be recorded by the training department. I.E. department will
evaluate training worker for necessary grading and G.M. / F.M will authorize to
H.R formalities. Have to maintain skill inventory for each line.
22. Weekly
progress meeting: This meeting to be conducted by G.M/F.M with the
involvement of all departmental heads on last
working day of the week to update the status of all running orders and
corrective action to be taken before the beginning of next week. All key
productivity indicators to be reviewed in this meeting.
23. Visual
production board: Production board will be displayed in front of
each line and production recorder or line supervisor is responsible for record
with correct figures hourly.
24. Goods
transfer record: Sewing section have to maintain detailed goods
transfer record for goods sending for washing / finishing.
25. Style
reconciliation: Line chief has to
submit style reconciliation report in completion of production for each style
to G.M. through P.M.
Prepared By: Md. Tarikul Islam
01912885383
jonytex073@gmail.com
good job.. carry on bro .. :)
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