STANDARD OPERATION PROCEDURES (S.O.P.) FOR PRE-PRODUCTION ACTIVITIES

STANDARD   OPERATION   PROCEDURES  (S.O.P.)

 FOR   PRE-PRODUCTION ACTIVITIES

FABRIC INSPECTION

FABRIC INSPECTION: Fabric inspection will be done to assure the fabrics which are going to be used for the bulk production are as per the acceptable QUALITY STANDARD.

SYSTEMS TO FOLLOW:

1. Merchandising department must provide Fabric invoice with complete packing list, Approved color swatches to Q.A. Department.   
2. Fabric inspection will be conducted for 4 point system.
3. Must sort-out 10% out of the quantity received from each style/color/lot for the   inspection as SAMPLE quantity.
4. Take 6” stripe cut from beginning of length of each roll to check the shade along length and width must mark the roll number in each cut piece for reference.
5. In case of different shade found then shade continuity card should be created   by taking a small swatch of each roll representing the shade and listing the continuity shade card by roll number to identify in the cutting.

6.   Fabric must be inspected in the lighting level of at least 800 – 1200 lux for over head lights. Have to use under bed lights which will highlight weaving faults, holes and yarn fault.

7. If the 10% of fabric inspection is failed, have to go for another 15% fabric inspection.
8. If 15% Fabric inspection also failed, have to go for 100% panel inspection.
9. In fabric inspection acceptable points will be 28 per 100 square yards. If any roll or bale gets penalty points beyond 28 per 100 Sq.yds. Entire roll or bale also be   rejected. (for rolls and bales acceptable points per roll may varies from buyer to  buyer)
10. Fabric width, length, weight, GSM matching should be checked for each roll/bale and record in the report.
11. In the event of any fabric rejection, Q.A. Manager, Merchandising Manager, G.M., dying manager should be informed immediately with complete report for the decisions.
12. Defect fabric rolls and bales must be marked by yellow color sticker and reject fabric will be marked by red color sticker.
13. Fabric Inspection format must be duly filled completely with observation and findings in details. 
14. Inspection report must be submitted to the Q.A. Manger’s approval and then submit to G.M/Director.
15. Fabric defect type display chart with all defect samples should be placed at the inspection table.

Follow the bellow given details to conduct the 4 point fabric inspection.

How to do 4 point fabric inspection?

1. Must have adequate lighting level of 800 to 1200 lux of good quality day light bulbs.

2. Vertical and Horizontal defects defined for the 4 point rating?

Vertical Defects (Along the length)		Horizontal Defects (Along the width)
Length	Points	Width	Points
0.2 to 3.0 inch     (0.1 to 8.0 cm)	1	0.2 to 3.0 inch    (0.1 to 8.0 cm)	1
3.1 to 6.0 inch   (8.1 to 15.0  cm)	2	3.1 to 6.0 inch (8.1 to 15.0 cm)	2        2
6.1 to 9.0 inch   (15.1 to 23.0 cm)	3	6.1 to 9.0 inch (15.1 to 23.0cm)	3
9.1 to 36.0inch  (23.1 to 92.0 cm)	4	9.1 to 36.0 inch(23.1 to 92.0cm)	4

  

3. What is the calculation formula for 4 point system for 4 POINTS FABRIC INSPECTION?

    

Total points         x           36 Inches    x 100(yds)   =   POINTS PER 100 SQUARE YDS. No. of yds inspected           Fabric width

 What is the acceptable level of quality in the fabrics inspection using the 4 point?

   System?    It is 28 POINTS per 100 SQUIRE YARDS.

                                   

                                                          Grades of fabric

A+	01-05	C+	31-35
A	06-10	C	36-40
A-	11-15	C-	41-45
B+	16-20	D+	46-50
B	21-25	D	51-55
B-	26-30	D-	56-60

  SHADE BAND PREPARATION AND RECORDING

SHADE BAND PREPARATION AND RECORDING: Purpose of this activity is to

Segregate all fabric rolls as per each shade/lot wise to obtain approval from the buyer and identify each roll to use in production to have control up to washing to maintain approved shade and maintain measurements specifications.

a)    Have to cut at least   6”x 6”swatch of each roll and mark correct roll No. with un washable ink. Must assure this marking will not be disappearing after wash. Join all swatches together as a blanket and have to wash for the buyers approved shade and standard.

b)   Next step will be to sort out and mark each shade and record all roll numbers shade wise. Have to obtain approval from buyer for each shade segregated. This shade continuity records to be passed over to Cutting and Stores with the approval of  Q.A.M. Washing and Finishing department also to be informed  by technical department and Q.A. Dept. to maintain approved shades.

SHRINKAGE TEST

SHRINKAGE TEST:  Purpose is to check fabric shrinkage of each roll to maintain measurements as per buyers’ specifications.

a)      Have to cut a set of blankets from each roll received (Size around 75cm x 75cm) and mark rolls number and squire for exactly 50 cm x 50 cm with an unwashable ink.

  

b)      Wash all the blankets for the SHADE approved by the buyer and Iron and MEASURE again   to find actual shrinkage LENGTH and WIDTH wise. This set to be kept in the Q.A. Department safely for reference (Distribute to other sections when necessary with accountability for receiving and returning.)

c)   Have to segregate closest lots as per shrinkage and make records very clearly for LOT NO., ROLL NO, shrinkage WIDTH wise and LENGTH wise. Q.A. Manager has to certify this record and distribute to Sample and Technical department for necessary pattern adjustments for fabric shrinkage. Cutting department should be informed by Sample/Technical department through Q.A. Department to use WHICH PATERN for given FABRIC LOT. 

FABRIC WIDTH SEGREGATION

FABRIC WIDTH SEGREGATION: To use fabric in bulk cutting for different widths for each shade to minimize fabric wastage.

a)      Stores have to segregate all rolls received for width for each shade and provide

            complete record in detail, certified by Stores in charge. This record should contain

            ROLL NUMBER, SHADE, and WIDTH clearly. (Ref. Format PP/Q/03)

TRIM INSPECTION

TRIM INSPECTION: To assure .the trims which are going to be used for the production is as per ACCEPTABLE QUALITY LEVEL.

a)  Merchandising department must provide all information such as complete PACKING LIST, approved TRIM CARD representing each item.

b)  Inspector must sort out 10% of each item and choose SAMPLING QUANTITY. For  

  c)   Inspector can determine as per sampling quantity   for A.Q.L. 1.5 inspection.

d)   Must check the size/color/quantity as per packing list and approved sample.

e)   In the event of the inspection is failed for any item have to re-inspect 100% quantity to ensure goods with in A.Q.L.

f)   Inspector must complete trim inspection report duly filled with details of all observations and findings to submit to Q.A. manager.     

 1. Approved sample: Approved sample with comments, which will be certified by Q.A.M. has to be submit to the cutting and sewing before cut the line sample (As usual 3 days before bulk cutting). After that it should displayed in line until total order completion. Have to keep this sample safely for future reference in completion of style.   

2. Cutting patterns: 

Cut patterns will be making by the Sample room/CAD. Sample room will keep the original patterns with sample room and copies issues with the signature to the cutting/Sample QC. Cutting/Sample quality staff will be check the cut pattern copies with original patterns and issue to the cutting section with signature. Cutting department should keep the original copy and make the copy by the cutting department pattern/marker maker and issued to the cutting QC with signature. Cutting QC will check the patterns before marker make.

2.     Finish Patterns: Line production staff and Work study department has to finalize required finish patterns with cut marks/notches and other work aids etc. at Line sample process and have to inform to sample department pattern makers. Finished patterns should make by the sample room pattern makers and issue with the signature to the quality department for inspection. Quality department should check the patterns and issue to the production staff with their signature. Production staff should make the copies from original finished patterns and issue to the sewing line after checking by the line QC with his signature. Original pattern will keep for the reference and for making copies only.

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 (Tech pack) and comments from buyer, Cutting instructions (CI). Style file must received before proceed the line sampling.

2. Production detail sheet:

Merchandiser has to provide “Production detail sheet” duly completed by him with all required details certified by Technical Manager, approved by G.M. to Planning/I.E. /Production/Q.A. Departments before do the line samples.

2. APPROVED TRIM CARD:  This has to be approved by the Merchandiser and certified by Q.A. Manager prior to handing over to Factory. All sections have to follow this for fabric and all trims to be used for particular style. Approved trim card must be available for Pre-production meeting.            

1.      Line sample:

           

As per the red tag or approval sample and construction details/comments, line sample will be done by the production staff with the involvement of I.E department, Q.A department. Approved trim card must be available at this stage.

                                                              i.      Production staff has to collect all the details, actual fabrics and trims for the preparation of line sample. If using available fabric and trims due to any reason, need to get approval from the Q.A. Manager. This should be at least 2 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.

                                                          iii.      Have to follow buyer’s sample, comments and operational break down prepared by work study department.

                                                          iv.      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. 

2.         Pre production Meeting ( Internal):

·         P.P. Meeting (internal) has to be conducted prior to pilot cut with the involvement of all concerned departments in the manufacturing unit.

·       On this line sample evaluation, Q.A manager must have a complete report to discuss about the construction and other requirements up to the packing.

Merchandising department has to prepare a complete order file inclusive of buyer’s latest information and details and comments, Fabric and trim status with inventory report. Finally all departments have to come to a conclusion and be agreed to proceed with the bulk production in the appropriate method.

                                                              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, Trim 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.

 3.      Line lay out and manpower allocation:

·         Operation breakdown to be finalized at the time of doing line sample to plan the line layout.

·         Line layout should be prepared by the IE department

·         IE department will discussed the line layout with production staff and assign the workers according to the expected output and skill inventory.

·         Line layout to be finalized before line feeding and have to hand over to all related production and quality staff. (Finalized layout plan must sign by the production, quality and maintenance dpt.)

·         Maintenance department will arrange the machinery, attachments etc for required no of lines as per the production plan. Physical line arrangements will do by the maintenance department with the guidance of production and IE staff.

5. Issuing plan

·         Production in charge will distribute quantity to be sewn each line (If the same style to be feed in more than one sewing line) according to plan and must maintain the bundle chart.

·         Line supervisor is responsible for receiving correct quantity of each bundle. If any panel is missing due to rejection in printing or embroidery, panel must be replaced and bundle must be completed.

6.      Pilot / size set and Bulk cut approval

Pilot cut approval to be given by P.M. with the confirmation from technical manager or Q.A.M. to proceed with production after reviewing P.P. approval from buyer. Bulk cut approval to be given by F.M. with certified by Merchandising Manager QAM, by Cut Issue format (CI).  

           

5.     LINE FEEDING:

When the technician/Line chief feeding the line, work study officer, line in charge, line supervisor, line Q.C has to get involved in this activity. 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.

 Have to submit line feeding report to Q.A manager and I.E. manager upon completion of line feeding.

                

6.   MOCKUP PREPARATION FOR CRITICAL OPERATION:

• Necessary mockups have to be prepared by the technical department with the involvement of quality and I.E. department. These mockups have to be approved by the Q.A manager to introduce to the line.(Mockups and the instruction sheet have to be hung at the machine)
• Sketches pertaining to critical operation’s can be clearly given to the operator as a work aid and educate them for the particular operation.      

7.         MACHINE CHECK LIST: Line Q.C along with the mechanic has to check each and every    machine after feeding any operation and certify all in order. The same format has to be used twice a day (morning and afternoon) for machine checking in line.

8.         PILOT/Size set/TRIAL RUN and First 50 meeting           :

               The line production staff, line Q.C, Work study officer have to follow up this activity in complete process. Line Q.C with line QI has to evaluate first 50pcs for construction and measurement. After completion of Pilot/Size set/trial run or first 50pcs, first 50 meeting will be held with PM,QAM,WS, Maintenance (This meeting can held in front of the sewing line also as a basic discussion meeting). Have to submit Pilot/Size set/trial run or first 50 inspection report to the Q.A Manager and take corrective actions if any.

          

9.         Q/C, Q/I INSTRUCTIONS:

• Q/A department have to provide complete instructions about the style/garments running in line, Clock wise/sequence checking of garment, about ZONES of the garment to consider defects to be analyzed and clear instructions to be given to Q.C’s and Q.I.’s
• Q/C and Q/I should be instructed clearly about measuring points as per the particular buyers’ measurement guide. 

10.       Line feeding completion

           

            After the first 50, trial, size set meeting line qc will prepare the first 50 meeting report which include all the remarks, corrections to be done and corrective actions with responsible person and signatures .

            Line QC and WSO should follow the actions to be done in the meeting report and update the status on the report.

After completely re-corect all the required places up to required levels, the report will be direct to PM, IEM, QAM to accept and complete the line feeding.

                                                                                      Prepared By: Md. Tarikul Islam

                                                                                                    01912885383

                                                                                            jonytex073@gmail.com