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Cutting Quality Control & Re-cut procedure.

Cutting Quality Control:

To be established a work process by which QC personnel able to run in a same path for continuous improvement. 

The procedure can be control / feedback to cutting to produce smoothly & Good Quality production.

Responsibility:  The responsible person in-charge of related department.

Preparation for Bulk cutting:
v  According cutting plan cutting Executive collects Approved sample, manufacturing order sheet, approved paper pattern / hard pattern & Marker paper with ratio chart.
v  As per Order Qty. cutting Executive collects fabrics from WH & relaxes the fabric according estimated time.
v  QA checks between ratio paper, marker paper, hard pattern & fabric inspection report. He confirms the marker with signature.
v  QC makes mock up by style related parts to be check & ensure parts Shading. If have taken approval from Quality Manager or Merchandiser.
v  According cutting plan cutting Quality Executive collects Fabric inspection report, shade band chart & separated the shades as per groups. Shade groups roll number he provides the Cutting Executive. Layer time cutting Executive follows accordingly.
v  According cutting plan cutting Quality Executive collects Fabric inspection report, shade band chart & separated the shades as per groups. Shade groups roll number he provides the Cutting Executive. Layer time cutting Executive follows accordingly.
v  QA ensures, fabric relaxation time is enough as per required hour.
v  Before cutting, QA Executive check Approved sample & present in PP meeting to be ensured that if there any new comments.
v  For new order cutting In charge cuts (pilot run) all sizes (50 – 200) pcs. After pilot run sewing completed QA Executive provides a report to cutting Executive with the comments bulk cutting permission.

Layering time:
v  Spreading time QI checks 10 points: *Table Marking * Ends *Leaning * Tension * Narrow Goods * Remnants * Counts * Fly height * Marker Placing * Fabric Fault. QC makes the reports as per finding. If any roll fails for layer time finding faults, QI declare the rolls for cut panel check.
v  QA also confirm that the layering roll is same shade.
v  QA checks inside roll quantity by calculating (lay length x lay qty.). If gets any shortage he makes roll inside short report & submit to cutting in charge.
v  QA also confirms that all layering rolls fabric width has family standard.

After cutting:
v  After cutting QI checks size wise Top, Middle,& Bottom  blocks (all parts) base on 5 points: * Pattern check. * Miss Cut. * Rugged Cut. * Notches. & * Marker Placing. If lot fails then QA makes report with percentage.
v  QA shows the report to cutting Executive / In charge. Acknowledge them with the signature.
v  Cutting In charge takes necessary steps for re- checking & rectify. After re check / rectify cutting in charge calls QA for re audit. QI takes re inspection; if lot accepts then lot allowed to making bundle. If lot again fails then QA share with QA Executive / Quality Manager, they will take necessary steps.

Bundling check:
v  After completed bundle in placed; QC’s takes size wise 1.5 AQL bundle & checks: Color, size, Quantity, left / right & bundle card. If found any one bundle mistakes, lot fails.
v  QC’s makes report & informs Cutting In charge. Cutting In charge takes necessary steps for re checking & rectification.  After re check / rectify cutting In charge calls QC’s for re audit. QC’s takes re inspection; if lot accepts then lot allowed passing to sewing Input.

Report:
v  QC’s responsible to make Daily Basis Report and to take sign, from cutting Manger and Cutting quality manager.
v  Daily record kept and analyzes data with review top 3 defect and find-out the actual root cause and to take corrective action with preventive measure. 
v  QC’s makes Cut panel inspection reject percentage report and inform to cutting In-charge.
v  If any rejection report comes from sewing floor QC’s verify that report & confirms the accuracy.

Re-cut procedure:
The purpose of this procedure is to ensure all non-conforming bundles are reprocessed at the cutting room.

This procedure applies to all cut fabric on all styles.

Responsibility and authority: the Technical Manager, Quality Assurance Manager and the 

Cutting Room Manager are responsible for ensuring this procedure is carried out.

PROCEDURE
v  When the cutting room auditor identifies a non - conformity she records it on the pattern inspection record document as a reject.
v  She then initiates the corrective / preventive action by filling in the cutwork rejection sheet.
v  The non-confirming work is placed in a secure marked cage.

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