Warehouse, Fabric
& Materials Storage Control
|
Raw materials receive with proper
receive documents i.e. PI, Challan, Invoice etc.
|
Raw materials should keep in
Quarantine area before Inspection.
|
Inventory of the goods with proper
records.
|
3 days stock Capacity at the store
|
Accessories inspection should 10%
of receive Quantity for all customers, AQL 1.5 for H&M and George, AQL 2.5
for VF Asia and Perry Ellis. IF fails 15% goods need to be inspected.
|
In house accessories testing
report i.e. color fastness to wash, nickel test, Color bled test.
|
All approved trim cards /PO sheet
are available to the Inspector.
|
Roll /Batch /Lot no should be
mentioned at the roll.
|
Prepare Shade Group & Shade bands
for all buyers.
|
Color shade checking (According to
approved shade standard, end to end, side to side , Roll to roll shading )
|
Fabric Inspection should follow 4
point system of at least 10% of receive quantity for all buyers considering 28 point as pass
result except ( H&M -TC 13 point +
& cotton 18+,Perry Ellis 20,VF
-24+ will be considered as fail result).
Shrinkage tolerance for woven fabric is 3% (+,-) for all buyers, and
for knit fabric it is ( +,-) 5%. Shade Blanket wash for all buyers &
additionally non-wash for H&M. Color continuity card & Bowing test
(order wise) for all buyers.
|
Rejects goods keeping area, left
over area and non-confirming area should be lockable and record need to be
available in place.
|
All raw materials need to be kept
buyer wise, rack wise with proper identification no & well described Bin Card.
|
FIFO system of raw materials
delivery with Proper records.
|
Pareto analysis & top 5 defect
analysis.
|
Humidity kept under 60% by using
dehumidifiers, fans, heat, etc. & proper records need to be kept.
|
Visual color evaluation of trims
and bulk fabric need to be done in
Light box against color standard (Light requirements are A Light, UV Light
,TL83, TL84, D65, CW F)
|
All rolls are covered /Protected
by poly from dust, Sun light, stain
etc.
|
5S audits need to be done at least once in a
month & audit results must have with a defined goal and development plan.
There should be training records for 5's.
|
Sufficient space
|
Need proper ventilation for fabric
, accessories & warehouse
|
Supplier selection & Evaluation
|
All record must keep 1 years from
the shipment date &
broken needle record should keep 6 years.
|
All organic materials should be
kept in separate rack/place.
|
Sharp tools control policy should
be maintained properly.
|
Internal lab test requirement
|
GSM, Rubbing test, Color Fastness
to wash etc.
|
On site trained technician.
|
Work Instruction or SOP for
Rubbing test, Color Fastness to wash.
|
Sample section
|
Samples section required to have equipped
with relevant machines.
|
Need to conduct Pr-Production
meeting for all new styles and record keeping is must.
|
The sample room need to have guideline (Tech
pack, PO sheet, measurements chart/ sketch sheet, etc. for production for
each order.
|
Sample inspection report.
|
Shrinkage test report.
|
Product Risk assessment record.
|
Metal check report.
|
Marker printer calibration
100cmX100cm CHECK daily & keep records.
|
Tech packs needs translated into local
language & needs communicated to all concerned.
|
Technicians will evaluate &
make report for all samples.
|
The facility should use mannequins
to fit samples prior to sending to buyer & dummy fitting report
|
Pattern and Marker checking with records.
Maker / checker's name, signature & date.
|
All hard patterns distributed to
the production floor with pattern maker / checker's name, signature &
date.
|
Development patterns need to be
saved in different folder by the name of VF.
|
Sharp tools (Needle, Scissor,
Cutter, Gimlet, Screw Driver etc.) control system should be tagged with
central account.
|
Patterns must be amended for
different shrinkage bands to control measurements. Record must keep.
|
Sample Retention & disposition
record.
|
Accessories Inventory Record.
|
Cutting Section
|
Fabric relaxation system for
Spandex (24, 48,72 Hours depends on the fabric composition) & keep proper
record .
|
Fabric needs unrolled by the relax
M/c for every order.
|
Markers prepared efficiently with
minimum wastage. Record Must.
|
The lighting level adequate over
the cutting tables.
|
If fabric is within one shade it
will be cut in a single lay. In case of mixed up shade facility should use
paper separators for every roll being spread.
|
Fabric width never be less than
markers width.
|
Spreading fabric with reasonable ply height
e.g (Lay of T,C fabric is 300 lay
& ply height 3 inch & Lay of CVC fabric is 300 lay & ply height 2
inch ).
|
Weights & clamps used over the
marker to secure plies while cutting.
|
For manual cutting, ensure 8 inch
Knife.
|
Cut accuracy audit need to be
performed for ensuring accuracy of panels (top/middle/bottom)
|
100% cut panel inspection.
|
PP meeting record for test cutting.
|
Knife Replacement record.
|
All small parts need to be cut
with Secure band knife M/c.
|
Numbering & bundling area need to be separated
|
Visual instruction and
relevant SOP need present both in English & in local language.
|
There should be Preventive
Maintenance Plan/Schedule in place. Show updated plan vs actual.
|
There should be quality
improvement efforts with quality meetings, defects Summaries, Pareto analyses
and follow up (Follow SOP) activities.
|
Housekeeping & 5s audit report
|
Cutting Approval sample need hang
on workplace.
|
Work in process will not more than
1 days if no value addition like print, embroidery, wash etc. If products are with value addition, Work
in process remains for 2 days at best.
|
Sharp tools control policy
|
White color parts should be cover
by poly/separation.
|
|
Sewing section
|
PP meeting report on new styles with
attendance record of participants & pp sample reports need available
|
Pilot Run procedure on new styles before
Bulk starts & Show reports.
|
1st output bundle review & report.
|
The concern should follow minimum
requirement during the production.
|
Visual
( Approved sample ,Tech Pag ,mock-ups, sketches or pictures) showing
construction detail clearly displayed on each operation for the running style
& in local language
|
Seam sealing / down / laser / bonding / all
sewing operations process will follow bulletin.
|
There should be checking system
for all operation by QC like In line inspection, end line inspection, Traffic
Light checking system & Measurement system.
|
The factory need have rejected
pics/bundle follow up procedure.
|
Segregation of defective garments in bins or boxes etc.
|
There should be processed
measurements done daily considering tolerances with calibrated meas. Tape.
Proper record must have.
|
Approved sample (with signature & date)
need present in sewing floor/line for each running style.
|
Product spec & approved trim
cards will available on the line for each running style
|
Broken needle record kept marked
with Date/Time, Order no, Needle, Action taken, Supervisor sign.
|
Sample responsible will inspect the first
complete garments at sewing.
|
Product Quality – (Check 5 PCs at
random of first output) - PASS for Visual / Major Defects.
|
Preventive Maintenance Plan/Schedule in
place for Daily, weekly, Monthly or periodically. Show updated plan vs
actual.
|
Quality Improvement efforts with Quality
meetings, Defects Summaries, Pareto Analyses and Follow up & Monthly 5s
audit etc.
|
The facility should have on site IE
& planning department.
|
Production lines well balanced and
set up in systematic process, without bottlenecks by the IE department &
Maximum 1 Day work in process is allowable.
|
The workers using Personal
Protective Equipment relevant to the area.
|
Effective inventory system at
sewing sub -store as like as central store.
|
Excess /Rejects accessories must
be back to the central store.
|
QA/QC department have an independent
reporting structure.
|
Visual records to show operator's hourly
production.
|
AQL inspection system (Level 2,
AQL 1.5 )
|
Key point measurement of 3
garments per size (Length, Sleeve Length, Chest, Hem, Shoulder. Bottoms:
Waist, Front Rise, Back Rise, In seam/Out seam). If fail, 3 pics garments
need to check again.
|
Visual and relevant SOP
present both in English & local in language in place.
|
Fusing section
|
Temperature and bonding strength are checked
every 4 hours by temperature strips or digital/ analogue calibrated
temperature checking device. Reports needs available in place.
|
Fusing check report.
|
Shrinkage report.
|
Lot wise before fusing & after
fusing record.
|
|
Button attach
|
All buttons must attached with lock stitch
machine.
|
If operator off the machine for
any reason for a certain time, he will do
the mock up while starting the work again in the machine.
|
Pull test
|
Pull test after 2 Hours ,
H&M 3 (90N, 10 sec)
|
Visual and relevant SOP
present both English & local
language
|
|
Snap Button
|
Snap /rivet Attachment machines
must be pneumatic and not manual.
|
Technical Data Sheet’ must be
available at the machine.
|
Physical standard (Mock up) of the
positioning must be available at the machine.
|
Pinch Gauge testing or pinch
thickness must be done by trained staff.
|
All machines must be positioned on
a ‘Griddle Floor’ to allow for the capture of any split parts.
|
|
Finishing &
Pressing
|
Pressing heads, pads, and
supporting structure need to clean
daily
|
Pressing standard at place.
|
After pressing 1 hours Cooling
with record.
|
Inspection report & defect repairing
record.
|
100% measurement record on
Critical process (Length, Sleeve Length, Chest, Hem, Shoulder. Bottoms:
Waist, Front Rise, Back Rise, In seam/Out seam & out of tolerance record
|
All packaging labels are stored
securely and independently by style size and color and issued/used on a
style, size and color basis.
|
Size, color, order wise Ironing, folding, Packing etc.
|
Excess /Reject accessories back to
central store.
|
All accessories are attached
before metal detection.
|
100 % metal detection of the goods
with 9-point check system.
Hourly basis check with proper record keeping.
|
If product fails to pass through
detection system, ensure re-inspection of the goods & ensure keeping the
reject goods at the metal contaminated box with proper record.
|
Calibration record & all
Inspection record must keep 6 years from the shipment.
|
All the goods keep in 1 hour
Quarantine area (1 Hour keeping area)
|
There should be approved (sign
& date) packing samples, Tech pack, or PO sheet for each running style
present in Finishing section.
|
100% presentation check &
hourly lot pass report & packing check report according to the sample
,Tech pack & trims card.
|
100% bar-code checking by the
bar-code scanning device
|
Net weight & gross weight
measured by digital weight machine.
|
Quality Improvement efforts with
Quality meetings, Defects Summaries, Pareto Analyses and Follow up
|
5S audits done at least once/month &
need to show results and plan for each area.
|
The factory has sufficient well-equipped
inspection room.
|
Internal per-final or final report
by the concern GPQ ( (Level 2, AQL2.5 for Major & 4.0 for minor )
|
Master File including PO, fabric
/yarn standard, trims card, wash approval , print approval, specification
sheet, product claims documentation, pilot run/size set, sample production
records, risk assessment report,
red/green seal fit comments etc. have to have a facility in FCCA audit.
|
Housekeeping need to be free of
color contamination, over-dumping, work in process, previous style's
accessories at floor etc.
|
Visual and relevant SOP
present both in English & in local language.
|
Finished Goods area
|
Finished Goods should kept in rack
or on pallet
|
Finished Goods should be kept with
buyer wise identification.
|
All carton should be closed at the
finished goods area.
|
Humidity control by ventilation or
fans/heat or dehumidifier (Less than 60% )
|
All goods are dry and clean when packed.
|
Prevention of mold part of the
production process according to Supplier portal/ Logistics/ Packing
instructions/ Mold prevention
|
Sharp tools control policy for all
section.
|
Pest control
|
Pest control internally or externally from
certified company. We are doing pest control periodically ( 6 month )
|
Daily checklist of pest control
monitoring.
|
Insect net to be used in finishing
area/ packing area/ metal free zone and to close/cover doors and windows.
|
Insect killer device available and
always functional. Maintenance regularly is must.
|
Management system
|
Document control system (Version
no, date of issue, revision date )
|
Critical path management for
each PO and analysis of performance for improvement.
|
All sample & sample
related document keep 10 years &
Broken
needle record keep 6 years
|
Key performance indicator (For all
department), Department wise goal & Goal follow up data.
|
Working flow chart must know all
the employees.
|
Visual and relevant SOP present
both in English & in local language.
|
Lighting in all areas like all inspection
area 1000 + Lux, Needle point 1000+Lux , Cutting 600-800 Lux, Iron Table,
Fusing, Marking table & Packing area 600-800 Lux.
|
Management review record &
Internal audit periodically ( monthly
or 3 Monthly )
|
Goods/Raw materials disposition
record.
|
Facility requirement
|
Factory perimeter with fencing
wall.
|
Wastage area must be identified
like Glass keeping area, Poly keeping area.
|
Visitor in out resister
|
Personnel locker for each
employee.
|
Access control for Packing, Store
& Finished goods area.
|
9 Point Inspection report by the
security.
|
Lighting in all areas like all
inspection area 1000 + Lux,
Needle point 1000+Lux , Cutting 600-800 Lux, Iron Table, Fusing, Marking
table & Packing area 600-800 Lux.
|
Basic Fire safety, First aid,
Drinking water, Health safety policy & Environment policy, (EIA) etc.
|
Employee is changing room.
|
Pin, Drawing Pins, Staples &
Metal staples must not be used any part or the manufacturing unit.
|
ETI base code & protector line
must be hanged on the facility.
|
People Management
|
Training Plan & feedback
system for all QC & Operator.
|
On Job training for all employees.
|
Mensal test for all employee.
|
Maintenance
|
Planned preventative maintenance
(PPM) program that covers all equipment with maintaining records.
|
Workshops/maintenance room must
have a barrier across the doorway and rubber floor mat located outside the
door.
|
Calibration of all measuring equipment and
testing equipment (e.g. balance ,tape, light box, pull test ,metal detector ,
fusing , fabric inspection, snap attach )
|
Calibration master list or matrix
of equipment.
|
Spot cleaning
|
Spot cleaning record.
|
Spot cleaner must use PPE &
industrial eye shower need to have at the area.
|
Spot will be removed only by water
& detergent for kids item.
|
Housekeeping should be okay.
Critical NC 's for
all buyer
|
Critical NC's definition: Failure
to meet a product safety standard or a legal standard; where this failure
puts the customer integrity at risk.
|
Skilled sample room technician available and
capable of modification of patterns when required and responsible for pattern
handover to production floor with record available (Critical )
|
All fabrics / yarns / trims /
accessories organized and stored indoors, off of floors, and remain covered /
protected until ready for use and has required space( Critical )
|
Inventory system (Fabric &
Accessories) at the warehouse & proper ventilation system at warehouse,
Finished Goods area. (Critical )
|
Pest control by net or pest killer
device. (Critical )
|
There should be a proper system to record broken / damaged
needles, tag gun needles & hand stitching needle etc. at both sample room
and production floor.(Critical )
|
Adequate systems used to isolate
defective and / or repaired products. (Critical )
|
Sharp objects such as trimmers and
scissors effectively tracked e.g. that they are permanently attached to the machines
during production and there is regular monitoring, so missing of 'attached'
sharp objects will not go unnoticed.(Critical )
|
Factory have inspection system at
inline and end line. Factory measure
complete garments. Completed garments are measured at least at Level 1 at AQL
1.5 or 20 pieces minimum from total production covering color &
size daily all through the day and records kept. (Critical )
|
QA/QC department have an
independent reporting structure &
all QA/ QCs trained regularly.
(Critical )
|
There should be a 100% final
checking after finishing and is there a random audit done after finishing.
There also should be a 100%
measurement for key points like
Length, Sleeve Length, Chest, Hem, Shoulder, Bottoms: Waist, Front
Rise, Back Rise, Inseam/Out seam) & audit done after finishing.
- Records are available. (Critical )
|
Factory conduct final audit based
on AQL inspection level 2, AQL 2.5 for major & 4 for Minor
of buyer. There is pre-final
inspection after packing with acceptable sampling method in both size &
color for all PO. After 80%-100% packed, QA will do pre-final inspection
based on buyer's requirement .( AQL
inspection level 2 ,AQL 2.5 for major & 4 for Minor ) (Critical )
|
Factory has a sufficient &
proper metal detection process for all the products &
Metal detection is Mandatory for all products .(Critical )
|
Factory use lock stitch for button
attach Mandatory for children wear dept. 26, 24, 33, score 10-0 and adult
10-5-0 hence scoring dept. 26, 24, 33,
score 10-0 and adult 10-5-0 (Critical )
|
Snap/Rivet (or any metal fastener)
attaching process & machinery in the factory.
|
There should be arrangement for disposal of non-conforming
goods & materials- Red Tag area is Physically designated and marked, labeled or tags
Area for Non-conforming goods & materials which are easily visible for all such
nonconforming products.
-Found Red Tagged/ designated and marked areas in metal detector area, pull
testing area for buttons/snaps/rivet or any other fastener, button attaching/
lock stitching area, snap/riveting or any metal fastener attaching area
- Found all non-confirming goods/materials stored separately.( Critical )
|
Factory maintain chemical test for
printing items
( For children-wear for US dept. 26,
24, 33) For George UK : How is chemical control process in line with REACH
chemical policy.(Critical )
|
Pull test report hourly (90 N 10 sec) (Critical )
|
Finished carton must be close
& access control system at the finished
goods area .(Critical )
|
Light requirement A Light,UV Light
,TL83,TL84,D65,CW F Must be calibrated
(Critical )
|
|
|
|
Critical NC's definition :
|
|
Failure to meet a product safety standard or
a legal standard; where this failure puts the customer integrity at risk.
|
|
Example: Inventory system (Fabric
& Accessories) at the warehouse & proper ventilation system at
warehouse, Finished Goods area . (Critical )
|
|
|
|
Major NC's definition :
|
|
A deficiency which requires prompt
attention to prevent a potential product safety failure or legal issue from
arising; where this failure may potentially put customers or brand integrity
at risk
|
|
|
|
Example: Though plant tour it was
noted that factory attached all finishing label like hang tag, packing
sticker etc. after metal pass at metal free area. During plant tour it was
observed that the garments cannot pass through metal detector due to RFID
hang tag but it was not discussed with Tesco concern person.
|
|
|
|
Minor NC's definition :
|
|
A deficiency which requires attention to
improve Good Manufacturing Practice standards, Due Diligence documentation
(our ability to defend a legal challenge) or to achieve compliance with Tesco
standards
|
|
Example: Factory does not check
cut panel against master pattern for solid fabric, they used to check the cut
panel by master pattern for strip fabric.
|
Grading of Tesco system.
|
Tesco refers two types of audit
|
1.Approval audit 2.Maintenance
audit
|
Approval audit : a) 0 critical non-conformance s b)0-3 major non-performances
c)There is no limit on the number of minor non-performances
|
Not approved : a)1 or more
critical non-conformance b) 4 or more major non-performances c)35 or more
total non-performances where at least 2 are major
|
2.Maintenance audit
|
§Blue – Outstanding ( 0-4 minor non-performances only )
|
§ Green – Good (5-14 minor non-performances only )
|
Amber or Double Amber – Needs
Improvement a) 0 critical non-performances b)
0-3 major non-performances c)
15-34 minor non-performances d) No more than 34 non-performances in
total )
|
§ Red – Stop Supply a)1 or more
critical non-conformance b) 4 or more major non-performances c) 35 or more
total non-performances where at least 2 are majors )
|
|
Audit rating system of Perry Elis
|
A-Very good ( Score >90% mark
is considered as a A Grade )
|
B-Good ( 75-89% mark is considered as a B grade )
C-Acceptable but need lots of improvement (55-74% score is considered as
a C grade )
|
D-Very Poor (score < 54 mark is
considered as a D grade )
Aftermath thanks in advanced.
Best regards
Md. Nazmul Huda
BSc in textile (CU)
MSc in environmental engineering & HRM (JU)
|
|
|
|
No comments:
Post a Comment