How to maintain Product identification and traceability.

This is to define and maintain a documented procedure for identification and traceability of Raw Materials, Semi Finished Products and Finished Products. This procedure covers the Identification and traceability of Raw Materials, Semi Finished Products and Finished Products.

Responsibility and Authority: Compliance Manager, MIS Manager, Production Manager, Sourcing Manager, Store Manager, QA Manager

Procedure: Identification and Traceability of Raw Material, Semi-Finished Products and finished products during work in progress, Finished Products and excess of finished products are maintaining by following stages;

Fabric:

v  The Commercial department provides the information to the store regarding which invoice is coming.

v  The truck comes to the factory. The challan should have the same invoice no. which has been provided by the commercial department.

v  The challan also contains a Lock No. which is verified with the actual lock by the security.

v  Fabric roll contains the information of consignee, fabric code, and roll no. Quantity, color and shade lot. All the rolls are kept in the fabric store.

v  Blanket cutting is done for each roll and tags are attached to each and every roll by the fabric lab.

v  All blankets are sent for wash by the lab for shade and shrinkage test. After this, shade report is prepared and sent to store.

v  According to the shade report, the store segregates the rolls and keeps the rolls in racks shade wise.

v  10% rolls are checked for quality using 4 point system. During inspection, the defects are marked by arrow sticker. Random inspection report is prepared for the fabric rolls being inspected.

Trims:

v  The Commercial department provides the information to the store regarding which invoice is coming.

v  The truck comes to the factory. The challan should have the same invoice no. which has been provided by the commercial department.

v  Trims contains the information of consignee, Trims supplier, code, Lot / Batch no., quantity, color. All the Trims are kept in the Trims store.

v  Check third party test report & internal test report.

v  According to the Consignment the store segregates the trims item wise and keeps the trims on racks with bin card.

v  10% are checked non-countable and AQL 2.5 Follow for Countable Items. Random inspection report is prepared for the trims lots being inspected.

v  Labels & Trims are issued to production to the job card quantity each time.

Cutting:

v  After receiving, the fabric rolls are opened for relaxation. The rolls are checked with the shade report and the required fabric rolls laying is done shade wise/ group wise.

v  The marker contains the details of style, marker name, marker length, marker ratio, marker width, marker type and shrinkage. Each part on the marker contains the details of part name, pattern shrinkage, date, size, group and style.

v  Marking and spreading check report is prepared which contains the details of style, lay no., cut no., fabric swatch, color, marker width, marker length, spreading length, ply height, marker no., size, ratio,  roll no., fabric width,  no. of ply, name of spreading person and cutting person along with starting time and ending time.

v  The cut parts are quality checked as per buyer requirement. On the cutting quality report contains the details of date, day, cut no., lay, shade, marker ratio, marker length, marker width, defect name, size details, total lot qty. & checked qty.

v  Random 1.5 AQL Check.

v  After complete the quality checked cut parts are keep cut bank area according to lot / batch no. , shade, quantity, style, PO, country wise.

Sewing:

v  When receive the input from cutting to sewing Quality department will verify as per GRN & MRN. 

v  In the sewing line, each bundle goes with a bundle ticket which contains the details of part, bundle no., cut no., size, quantity, order no., style, Country name, PO no., color, buyer, shade lot and total qty.

v  All the trims are verified with Trim Card and Red Tag sample before attaching.

v  Each garment is attached with shade label (provided by cutting section) and stitching will complete as per buyer requirement.

v  Complete garments quality check end of the line with approval sample.

v  The garments are checked in End of the line for quality and all q/c pass garments are marked with a q/c pass sticker. This sticker contains a unique no. which is specific to a particular q/c and so all q/c pass garments can be tracked back that which q/c has passed a particular garment.

Packing:

v  Packing input is taken shade wise/ ratio wise, Po wise, style wise, country wise.

v  The hourly auditor conducts an audit on the completely packed garments and if the lot gets passed, the lot is offered to the Pre-final GPQ.

v  The internal auditor conducts the audit randomly based on AQL 1.5 sampling level and puts a stamp on all the cartons which are passed.

v  After being passed the internal audit, cartons are sent for External audit.

v  External audit is conducted for 100% of the cartons where each and every single garment is inspected for correct packing trims. Once the external audit is passed, the carton is secured by tape.

v  The carton contains the details of style, PO no. , quantity, Shipping mark, and manufacturing country.

v  Carton stacking is done in the carton cage size wise, color wise, PO wise, style wise.

v  Inspection is conducted by the buyer QA and after being passed the cartons is ready for shipment.

Shipment:

v  Commercial department informs the store via mail regarding the shipments for the day.

v  The commercial department provides the packing list (received from merchandiser after confirmation by factory).

v  The Finished goods store manager cross checks the Style, quantity, PO, Country also gets the confirmation whether the inspection is passed or not.

v  After confirmation, the packing list is cross checked with the actual carton quantity.

v  Commercial department confirms the Vehicle no. for loading.

v  The respective vehicle is checked by store executive and security (whether vehicle is OK for security of the garments).

v   After security check, loading is done.

v  After loading vehicle will lock and sealed in the vehicle containing same no. on both ends.

v  Gate pass is prepared containing details of destination, sending person, date and serial no., description of goods, quantity and remarks. It has the signature of receiver, security, authorized personnel and manager.

v  Two copies of the gate pass are provided to the driver, one copy is sent to commercial department and one copy is kept in store for reference.

v  Accordingly, challan is made containing details of date, name, and address, our bond no. and party bond no., subcontract bond no., serial no., description of garments/ product traceability and quantity.

v  One copy of the challan is kept by security, one copy is provided to the driver and one copy is kept by store for reference of product identification