QUALITY MANUAL

COMPANY NAME

(Quality Procedure –Standing Operation Procedure) (SOP)

 

We are following the below (SOP)--Standing Operation Procedure during our bulk production section by section.

 

 

 

1. Section: Winding / Yarn

 

*After in-house the yarn. We make the knitting swatch each color & each lot from the bulk yarn then we do wash as per customer requirements .we see carefully & it has match with approved swatch then we have receive such yarn to store. And maintain other functional formula as well.

 

If found any Quality discrepancy (beyond tolerance) from approval swatch then such faulty yarn lot / lots is send back to the yarn supplier for replacement with correct Quality according to QCs reports.

 

• Maintain the yarn inspection report specific style, color & lot wise.

 

 

 

1. Section : Store

 

After in-house all trims / Accessories (before received) from the supplier, factory QCs check the all kinds of trims / accessories randomly by the follow our standard AQL. Above 500 pcs quantities we check 10% & below 500 pcs quantities we check 100% the trims / accessories based on approved trims card by concern merchandiser.

 

(We accept the faults (Major = 2.00% & Minor = 4.00%) only for accessories.)

 

Without QC pass report store peoples did not accept / received such accessories. Send back such accessories to the supplier for replacement with correct Quality according to QCs reports.

 

• Maintain the QC inspection report style wise.

 

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1. Section: Knitting

 

 

• At first make the size set (if approved) and arranged PP meeting with production, Quality, Merchandising, store, IE & Planning staff based on customers PPS comments & our internal size set comments , we will start bulk production with respect such comments .

 

 

• QA Department pickup 200 pcs -250 pcs garments for every style (each color & sizes) from 1st Pilot run knitting production to check overall quality after done the finishing. And keep the quality records & inform to the all section head such pilot run result accordingly.

 

 

• During knitting time Knitting QCs do the Quality check ( Styling, knitting tension, weight, measurements etc) as per approved samples & knitting chart randomly machine to machine & keep the inline quality check report & inform to the operator / knitter, supervisor , Knitting in-charge to take corrective action as per QCs comments.

 

 

• All knitted panels / parts, neck, placket, pocket etc check at the knitting section by knitting Quality inspectors (100% panels / parts, neck, placket, pocket etc). If found any defects / faults then inform to the operator, supervisor, line QCs, section in charge to take necessary corrective action & send back such faulty / defective panel / part to concern operators / machines for rectify or re making.

 

• The knitting QI /Quality Inspectors maintain the faults analysis record style wise daily basis.

 

 

• If passed the knitted panel / parts neck, placket, pocket etc by Quality Inspectors then such knitted parts / panels kept storage color & size wise.

 

 

• QCs do the AQL (as per AQL LEVEL = 2 / Major = 1.5 & Minor = 2.5) style wise. If pass then send to the Linking section for do the Linking. If failed by QCs then such panels / parts recheck & rectify required to conduct further AQL before send to the Linking section for do the Linking operation.

 

 

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1. Section: Make-up.

 

 

 

LINKING

 

• Linking will be start the production base on in our internal size set comments as per customers approved PP sample & comments with follow as our IE procedure.

 

 

• During linking time, all knitted panels are storage at input box, operators collect knitted panels from input box and doing linking as per chaining process / operation bulleting which are provide by IE department.

 

• We hanged the styling counter samples with approved pp comments for each section & also hanged semi mockup such as Neck shape , armhole shape, pocket shape , shoulder shape etc for each operation area/ zone.

 

• As the linking ground one QA is moving for Quality supervision at running way & keep record with inform to module head / supervisor time to time to take necessary corrective action as per his comments.

 

• After complete the linking operation one QI / Quality Inspectors check 100% garments at end of the line & faulty garments are send back to the operators for rectify & okay garments are send to the next process.

 

• The linking QI / Quality Inspectors maintain the faults analysis record style wise daily basis.

 

 

OVER LOCK

 

• Over lock operator done the over lock process as per requirements places with keep maintain the approved PPS Quality by him self & send to the next process operating.

 

 

BAR TUCK

 

• Bar tuck operator done the bar tuck process as per requirements places with keep maintain the approved PPS Quality by him self & send to the next process operating.

 

 

 

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TRIMMING

 

• Trimming operators done their Trimming process as per customers requirements places with keep maintain the approved PPS Quality by them self & send to the next process operating.

 

 

 

 

1st LIGHT CHECK

 

• Light check operator do the light check 100% garments to identify the needle drop, side seam open / breakage, any single ply etc. & mark with use contrast color yarn at faulty places & send to the next process operating.

 

 

 

1st MENDING

 

• After received the garments from Light check section the Mending operators do the pulls first at neck, placket, piping etc areas & marks with use contrast color yarn, then they are rectify the faulty areas which marked was contrast color yarn accordingly. And make sure the Quality them self & send to the next process operating.

 

 

 

MENDING INSPECTION

 

 

• After rectify mending such okay garments one QI / Quality Inspectors check 100% garments at end of the module / line & faulty garments are send back to the operators for rectify & okay garments are send to the Distribution room to conduct the AQL before washing process operating.

 

 

• The mending QI / Quality Inspectors maintain the faults analysis record style wise daily basis.

 

 

 

 

 

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AQL TABLE

 

 

 

• QA Departments do the AQL as per company standard (AQL LEVEL -2, Major = 1.5 & Minor=2.5) such mending inspected okay stock goods daily basis. If pass then goods are allowed for sewing section, if failed these goods then send back to the mending inspection for re checking & rectifying. Further AQL is required for that case.

 

 

 

 

 

 

 

 

1. Section: Finishing.

 

 

WASHING

 

 

• After received the AQL pass garments from makeup distribution  the Wash supervisor collect the wash recipe from technical department & done the washing some pcs garments (inside out) from each style & color with follow customers approved PPS / hanger fabric Quality standard, shade, hand feel etc accordingly. If match with Buyer approved standard swatch then QA department / sample department has given written approval with sign to start bulk production.

 

• An approved sample is hanged with comments & wash recipe instruction at wash section to easy working & understanding. Section supervisor make sure/ maintain the Quality as per approved standard during bulk production. If the Quality okay then such goods send to the next process operating.

 

 

SPECIAL / ADDITIONAL WORKS

 

1. Button hole & Button stitch:---

 

 

• Before the start bulk production section supervisor make samples with follow as per approved PPS / customer comments & take approval from sample department / QA department accordingly. He never starts bulk production without take any approval from concern departments.

 

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• Before start button hole & button stitch bulk production we have done / maintain our internal button attachment procedure as example ( TTF-Test To Failure ) pull test report each style & color wise at  60N, 70N, 90N button strength or as per customers requirements by the pull test machine.

 

 

1. Other all kinds of Attachments:--- (Such as, Back neck tape, Elbow patch, Shoulder patch, Pockets, Back moon/ Bag buggy, Flag label, Badge label, Button loop, eye let, snap button, metal badge, inner fabric, fur, taffeta, ETC).

 

• Before the start bulk production section supervisor make samples with follow as per approved PPS / customer comments & take approval from sample department / QA department accordingly. He never starts bulk production without take any approval from concern departments.

 

• After complete the all attachment works the section QI / Quality inspectors do 100% garments Quality check before send to the next process to operating.

 

• The Attachment QI / Quality Inspectors maintain the faults analysis record style wise daily basis.

 

 

 

 

2Nd LIGHT CHECK

 

 

• Light check operator do the light check 100% garments to identify the needle drop, side seam open / breakage, any single ply etc. & mark with use contrast color yarn at faulty places & send to the next process to operating.

 

 

2nd MENDING

 

• After received the garments with faulty marks from Light check the Mending operators do the pulls first at neck, placket, piping etc areas & marks with use contrast color yarn, then they are rectify the faulty areas which marked was contrast color yarn accordingly. And make sure the Quality them self & send to the next process operating.

 

 

 

 

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AQL TABLE

 

 

• QA Departments do the AQL as per company standard (AQL LEVEL -2, Major = 1.5 & Minor=2.5) such mending inspected okay goods daily basis. If pass then goods are allowed for washing, if failed these goods then send back to the 2nd Light check for re-checking & rectifying. Further AQL is required for that case.

 

 

 

SEWING/ LABELING

 

 

• Sewing operators has done all labels attach as per customers approved PPS or customers requirement placement & instruction wise. And they make sure the Quality by their self before send to the next process to operating.

 

 

 

IRON / PRESSING

 

 

• After received the goods from sewing section Iron supervisor do arranged the Iron board (size set) & take approval from QA Manager prior to start bulk production as follow approved size spec & comments.

 

• Iron operators should be used approved Iron pattern board which approved by QA Manager.

 

• Iron operators should be used Iron cover /Teflon shoes at Iron to avoid any shining marks / pressing marks.

 

• After complete the Iron such goods are send to the Measurements table to check the primary measurements & Quality.

 

• The Iron QI / Quality Inspectors do 100% garments check as per approved measurements spec & samples. If the Quality is okay & measurements are within tolerance then goods are sends to the next process to operating.

 

• The Iron QI / Quality Inspectors maintain the Quality records style wise randomly daily basis.

 

 

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GET-UP TABLE

 

 

• After received the Iron pass goods they do check overall process 100% garments & send such pass / okay garments to next process to operating & send back to such faulty garments process wise for rectify & collect such rectified garments their self and again check as well, if okay then send to the next process to operating.

 

 

 

FINAL MEASUREMENT TABLE

 

 

• The Iron QI / Quality Inspectors do 100% garments check as per approved measurements spec & samples especially main 05 to 06 fundamental points ( like as Chest, Length, shoulder, bottom, sleeve length, front/back breadth etc). If the Quality is okay & measurements are within tolerance then goods are sends to the next process to operating.

 

• If the measurements are without tolerance then garments will send back to the Iron / pressing section for rectifies the measurements by Ironing.

 

 

 

AQL TABLE

 

 

 

• QA Departments do the AQL as per company standard (AQL LEVEL -2, Major = 1.5 & Minor = 2.5) such finishing completes garments for each running Quantities / Lots. If pass then goods are allowed for packing, if failed these goods, then send back to the previous process for re-checking & rectifying. Further AQL is required for those cases.

 

 

Page # 08 of 10

 

 

HUNG TAG TABLE

 

 

 

• After received the AQL Pass garments from AQL table, hangtag operators do the attach hangtag/ price ticket-style, color & size wise as per PPS / customer required places.

 

• After hang tag / price ticket attached, one or two Packing QI / Quality Inspectors do check the 100% garments main label, care label, size label, hang tag, price ticket, barcode, color, styles etc are okay or not. If not found any discrepancy then such goods are send through the metal detector machine for metal check purpose. If found any discrepancy then such defective garments has kept a separate box with maintain register & send back such defective garments to previous concern section for rectify. 

 

 

METAL CHECK

 

 

 

• At first metal operator do machine start & check 1st as per procedure.

 

• Do the metal check 100% garments before poly packing pc by pc & keep metal checked Quantities & rejection records style wise.

 

• During production time metal operator conduct 09 point system machine calibration with used metal sample card 1.2mm per hour & keep records as well. If the metal sample card did not pass by the metal machine with alarming signal then should understand that, the machine is okay for working but if the metal sample card is pass easily then should understand that, the machine is out of order. Meantime the operator informs to supervisor / in charge / QAM / PM to take necessary step immediately.

 

• That time production will be stop & don’t pass any garments to packing section without metal check & operator keep records such loss time.

 

 

 

 

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PACKAGING

 

 

 (Packing section will follow as per customers packing method & instruction before start packing).

 

• After finished the metal check operation then goods are held in Quarantine area. Then such goods are sends to the dust removing process to clean the dust by machine before folding.

 

 

• After received the goods from dust cleaning stage, then we can start shade segregation process style & color wise in segregation table. The allocated packing operators are done these & send such goods to the next process for maintain the all packaging process as per customer requirements / packing method.

 

• During the packaging process time packing QA check the packaging system randomly as per packing method & keep records accordingly.

 

 

• After 60 or 80 % garments packing complete then GPQ / AQM / QAM do the pre final as per AQL table rules wise (Level-02, Major 1.5 Minor 2.5) or as per customer’s requirements AQL wise. If  garments will passed then garments will hand over for final inspection to the customers & If failed the garments then garments are Re- check before handover the final inspection to the customers ( subject to further pre final passed).

 

 

 

 

 

------   Thanks    -----

 

 

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