Control Procedure of Sewing Quality

Purpose is to establish a standardized work process for good team working.  Scope is the procedure will help to achieve our particular Goal.

Responsible section in charge is responsible to implement the policy in production unit.

Preparation of Input:

v  As per Input plan QA’s CMS, Trims Card, Construction Sheet, How to Measure, collects BOM, measurement spec.

v  As per production plan Quality Manager Will collects approved sample.

v  QA, QAM, TC, MC & Production Responsible attend in the PP meeting. Meeting minutes Translate in local language to line supervisor & Quality inspector.

Layout time:

v  All Lay-out Responsible (Quality, M/C, T/C, and Line QC Prod.) should be present in the line.

v  QA & technician give technical measurement on process.

v  Quality & production T/C gives process standard on each process. QA will counter check that standard is correct.

v  After completed 1^st bundle Quality Executive & Quality Manager will check measurement & each process with Measurement Chart and styling.

v  Quality Manager calls 1^st production meeting with all respective people & give cutting permission also.

In Process Quality Control:

v  After received new input In line QA checks cut panel with the paper pattern & accessories with approved Trim Card 

v  Every day morning In line QA checks all needle point, SPI, tension by loose fabric. If found any problem inform mechanic with record.

v  Checks new operator in process.

v  Check all technical measurement in process has corrected with record.

v  Checks end table QC reports & finding problems. Take action in process as per their finding.

v  Do completed garments measurements & share with QC if there any discrepancy.

In Process Traffic light:

v  QA pull from the bundle 10/7 Pcs Randomly.

v  QA Checks with operation standard about workmanship & measurements, if there no defects QA keeps the garments in same place & fill ups her audit sheet by marking green color.

v  If QA gets at least one piece defects, he calls supervisor & show him. By the time she fill ups her audit sheet by marking Yellow color with defect code,

v  If QA gets at 2 piece or more defects, he calls supervisor & show him. By the time she fill ups her audit sheet by marking RED color with defect code & stop the machine. Note – For Traffic Light refer to “Traffic Light System” post.

v  Production Executive & Technician goes the process & advise the operator, he also corrected the process as per standard & put his signature on audit sheet by mentioning reason of problem & how to rectify. Then operator makes another Bundle and calls QA for inspection.

v  QA checks 10/7 pcs by same method if there no defects operator works continue but she should rectify the finding defects by QA. QA fill ups her audit sheet a Green marks. If QA gets again problems then QA Marks again red on her audit sheet & stopped the operation. QA informs Quality Manager & technician and Production Manager, they take necessary steps.

v  Being operator gets one yellow; QA goes that process for next bundle / follow up. He/she checks 10/7 pcs randomly. If there no defects QI fill ups her audit sheets by another Green mark.

v  Line QA Make a Measurement Report.

v  End of the day in process QA makes highest three defective process & make report to submit QA Manager.

Inspection by End-Line QC:

v  End table QA will do measurement 100 % Garments on Leg, Waist, Under bust, Chest, Bottom or specially mention point.

v  If he/she gets any discrepancy inform to inline QA or Line Production Controller.

v  End table QC has taken clear idea from QA Executive and Quality Manager about her check point & how to measure from 1^st production of a style.

v  End table QC follows Clock wise Checking Method.

v  She collects necessary documents: End table audit sheets, CMS, measurement spec, PO chart, measurement tape, arrow sticker, etc. from QA executive

v  She/he checks garments by the sequence as per advised.

v  She/he fill ups hourly Inspection report.

v  End table QC gives production Controller hourly defect quantity by taking signature from her.

v  End-line QC also taken rectifies quantity from production controller by estimated time & put record on Inspection report.

v  End table QC confirms hourly QC pass on her audit sheet.

v  In case of any damage garments QC keeps those are separately, end of day she gives all damaged garments to Quality Executive.

C.P.R:

v  Line QA Check all cut panel when coming from cutting.

v  If found the any cut panel reject he or she recorded on inspection sheet.

v  Segregate all reject cut panel.

v  Cut Panel inspection Record with reject parts show in front of Quality Manager.

v  Quality Manager will call Cutting responsible and discus with them how to control it and when need to re-cut.

v  All Reject Panel Return to cutting with record.

v  P. R should be re-cut daily basis and return to sewing floor PO wise.

C.B.R:

v  Quality Manager will review reject garments and segregate which one is repairable and which one is need to re-cut.

v  To take reject garments discussed with cutting responsible and advice how many pieces need to re-cut when will complete the re-cut.

v  Quality manager make sure all CBR should be re-cut complete PO wise don’t waiting for next PO.

v  If have no fabric available in cutting discussed with Merchandiser and fabric responsible, they are confirm is available or not.

v  If have fabric is available in fabric store quality manager will make a Po sheet and send the mail to merchandiser with fabric responsible.

v  If have no Fabric is available in fabric store or merchandiser discuss with GM and get the approval from him for dying and inform to cutting after dying should be complete all CBR as per PO.

v 

Quality Manager will monitoring this process will complete as per schedule