It is absently true in fact that product safety products meet acceptable levels of safety and will not cause harm when used as intended which plays vital role. It has an array of amenities with couple of inconvenience.At the very outset customer also giving training on product safety as well as top factories also giving training to heir concern.
Product safety in the UK is governed by a wide regulatory framework consisting of both national and European-derived legislation. The laws apply to any business involved in the import, manufacture and supply of goods to consumers.
If we want to business with UK & EU, We have to maintain minimum standard of product safety requirement exemplified as EN-71,EN]14682.Otherwise they will not continue business with them.In this regards, We are following all types of rules & regulation of product safety as per customer standard as well as our internal standard. Before giving shipment of any goods, we must ensure some quality terms as save,legal & quality which is very much important for any producer. If the customer gets any kinds of nonlegal,unsafe product,they claim us huge amount of money/dollar.If we get any kinds of claim , we have to follow customer withdrawal & recalled procedure.If we follow this statement we will be benefited a lot.
REQUIREMENTS FOR SHARP TOOLS & NEEDLE
REPLACEMENT POLICY AND METAL CONTAMINATION
Babylon Group have a written
policies that are clearly communicated, understood, implemented, displayed in
the relevant language and kept up for the following:
A.
Sharp Tools
B.
Needle Replacement
C.
Metal Detection
D.
Glass and Hard Plastic Breakages
PREVENTION OF METAL AND OTHER
SHARP OBJECTS CONTAMINATION:
Babylon Group is fully
responsible to ensure that effective measures are in place to prevent any metal
contamination such as:
- Needle
parts
-
Machine sewing needles
-
Hand sewing needles
-
Tag gun needles
-
Staples
-
Pins
-
Gimlet
-
stray clippers
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Scissors
-
Cutters
-
Knife
-
Vertical Knife
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Handy cutter
-
Bundling wire
-
Mechanic tools such as screwdrivers, hammers etc.
-
Broken glass
-
prong snaps
-
rivets
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Hardware from machinery, such as nuts, bolts, screws
etc.
-
personal effects or jewellery parts
If any of the above are found in
a garment, they can cause serious injury or a potential hazard to the ultimate
customer, result in customer complaints as well as a possible serious fine,
which can amount to thousands of money.
Prevention – means taking
all reasonable steps to avoid any metal contamination in the first place.
This includes:
-
In sample room and any manufacturing operation pins and
wires are not being used. This includes securing, bundling, tacking components
or packing of any products.
-
No pins may be used for bulletin/notice boards in the
sewing plant.
-
In cases where metal components need to be to be used
such as check fabric laying, the control of the use is ensured maintaining
record.
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Scissors/clippers and any other sharp tools is securely
fastened to the sewing machines and inspection tables/workstations.
-
It is ensured that the production plant is free of
dangerous items such as broken glass, splinters etc., since these cannot be
detected by the needle detection unit.
-
Maintaining a metal free environment.
-
To avoid stray metal and other components, small
components (such as loose poppers, studs, rivets, zips etc.) are kept in
appropriate containers.
-
Workers and mechanics are complying with the policy and
products are being removed from an area if risk of contamination exists.
-
Any goods entering the factory are ensured as contaminant-free.
It is therefore ensuring that the policy is passed up the supply chain to other
suppliers. Trims and components are often secured with pins and suppliers of
those raw materials are being asked to use an alternative such as tape.
-
Check that bulk trims ‘pass’ through the metal detector
prior to use in production.
-
Any packaging is removing from outer packaging outside
production areas to eliminate risks of product contamination.
As part of the monitoring
process, the following questions are being asked periodically:
1.
The number of needles purchased?
2.
The number of needles distributed?
3.
The number of worn needles returned?
4.
The number of broken needles returned?
5.
The number of needle fragments found by the detector?
6.
The number of missing needle fragments?
7.
Number of needle ‘incidents’ or claims
The
figures 2, 3, and 4 above should sum to be the same as in 1, and the answer to
questions 6 and 7 would be zero!
Detection – means to put
additional checks in place to ensure the products are safe when shipped.
This includes:
-
At final inspection garments are being turned inside
out and pockets checked to avoid any loose components being trapped in them.
-
We require metal detection for all our products and it
is mandatory for all children’s or kids wear orders, any nightwear, underwear
or lingerie.
SHARP TOOLS POLICY
Examples of sharp tools are:
Scissors, Clippers, Kimball/Tag guns, Knives, Drill hole spikes, Notch
punchers, Tweezers, Cutting pins (if used on stripes, plaids and checks).
1.
Control of sharp tools
The use of pins, staples, sharp
tools and other metal products is restricted in use in the factory.
All sharp tools are accounted for and issuing to the workforce by store
officer with a cross reference to stock levels of that particular tool to
ensure full traceability at all times.
1■ Factory is following A
‘One in, one out’ distribution system to
minimize the loss of tools, potential injury to employee’s and the risk of
tools being boxed in cartons and shipped and or lost in product presentation
boxes and or pockets or lining of product.
2■ all sharp tools are handing out to the workers by a nominated
person (store officer) at the beginning of each shift and are collecting at the
end of each shift. Counting and signed for by the store officer.
3■ Kimball/Tag guns are individually numbered and named per
worker.
4■ this distribution system is being recorded (s. attached daily
in/out log); detailing workers names, their signature and numbers of tool
issued/returned and records are keeping for a minimum of 03 years for
verification.
5■ all tools are being securely attached to the workstation
(machines, tables, benches and inspection areas) by cord or string as possible
to tool type, but holes are being drilled through wooden handles and location
and condition is being verified daily.
6■ Scissors and clippers are not being worn around the neck or
wrist as this is a safety hazard for the employee’s in case they trip and
injure themselves.
7■ we are following a documented control system for the issuing
and collecting of scissors and clippers.
8■ the employees will not remove their tools at break, lunch or
dinner times in order to avoid them becoming lost or leaving the factory
premises.
9■ the floor supervisors are checking at least twice a day that they have not been
removed without permission and keep a record of how many pairs have been
issued, as per the count in/out log process.
10■ any blades or other sharp cutting tools are using within the
factory floor maintaining proper sharp tools control policy. Snap blades are
not permitted as they can break easily, cause injury and get lost in product,
packaging and or cartons.
11■ Metal is not using as sewing guides and or templates for
pressing around to manage a shape, e.g. pockets. If guides are required thick
card and or plastic is using. Cut thin metal can cause injury, split and break
off into a small piece and become lost in product, packaging and or cartons,
which may damage a product: or injure employees at our customer’s warehouse,
stores or a customer.
12■ the use of pins is not acceptable in any products of Babylon
Group and it is being avoided throughout the factory (incl. sample room,
cutting, sewing, inspection, metal free zone, packaging or any other areas
where garments/components are being handled).
13■ where pins are being using in packaging for meet up the
requirement of a customer this is done in a separate area quarantined from any
other production and the issue of pins is being controlled.
14■ Pins/staples are not being using to assemble cartons.
15■ the use of
staples and staplers is being avoided in the factory environment. This includes incoming goods area, cutting room,
sample room, metal free zone, and
packing and is not being using on any paperwork used on the factory
floor.
16■ threading wires are kept by the mechanic and if they are needed
by the worker again they are kept in a controlled environment and counted in
and out at the beginning and end of a working day by a nominated person.
17■ Machinists is not being allowed to keep screw drivers or any
other tool for altering machine settings in their machine draws, its are being kept at all times by the mechanic and
or supervisor in charge authorized to amend machine settings.
18■ Tools collected at the end of the day and spare parts (e.g.
cutting blades) are always being kept
away from the factory floor in a safe and secure environment, i.e. locked away
in designated cupboards which only the store officer has access to. The record
log of tool/spare part issue is being kept in the designated cup board.
19■ the management is ensuring this policy applied to embroidery,
appliqué, printing etc. operations whether in house or at another site.
A.
NEEDLE REPLACEMENT POLICY
All needles or parts of
damaged/broken needles are controlled effectively and accounted for during the
production process and throughout the whole manufacturing unit.
This means that when a new needle
is issued it is cross referenced with stock levels of the particular needle and
size to ensure full traceability at all times.
This includes sewing needles
(machine and hand sewing), and any ticketing or kimbal/tag gun needles and the
policy is covering all areas of manufacturing e.g. the sample room, embroidery
and appliqué machines, machines that are positioned out of the main flow of
manufacture and operations that are performed outside the factory premises of Babylon Group.
The sample room is keeping a
separate needle record, rather than having the record amalgamated with the
production area.
All records are keeping away from
the production floor to avoid contamination. Old records are being destroyed
safely and off the factory premises.
For guidelines on how long to
keep certain records please see individual sections below.
1. Control of needle supplies
■ a person is nominated to hold a restricted supply of a
pre-determined number of needles in a permanently locked & clearly marked
facility. This facility is only be accessed by the nominated person responsible
for managing the total process.
■ Replacement is only be issued if the store officer returns
the equivalent number of used needles to the relevant manager/section (e.g.
store).
■ stock of needles is being controlled by
a designated member of the management (e.g. production manager, warehouse manager
etc.). The good needle releasing quantity is fully traceable according to the
‘One in/one out’ policy in the sewing workshop, i.e. needle stock match needle
balance record.
■ Spare needles are being stored in a secure and locked
position away from the production floor.
■ There is a recorded needle inventory, so that the amount of
needles coming into the factory is accounted for with the records kept for
needle distribution and broken needle records.
2. Control of
sewing needles in use
■ Workers
are not being allowed to have any spare needles in their possession.
■ A person nominated as safety officer e.g. responsible for
health & safety and internal auditing is checking compliance to this policy
on a regular basis by carrying out audits and random checks.
■ New needles are being distributed by a store officer.
■ The nominated person to exchange needles, is ensuring that
they receive all parts of the old needle before issuing a new one. A new needle
can only be issued if all parts of the old one have been returned.
■ New needles are keeping in a secure, locked, clearly marked
and safe environment with restricted access. The key to the storage place is
held by the authorized person at all times and are not being available to
machine operators.
■ The needle record is kept for all types of needles and are
include the bend or broken needle fragments taped to the record.
■ To
identify trends of breakage the broken needle record is reviewed on a daily
basis which will lead the factory to be proactive in preventing excessive
Needle breakage. Worn out, out of alignment machine
parts or operator handling may cause breakage.
3. Change of a needle during production
■ To avoid needle breakage, damaged or worn points, needles
& their points is being checked on a daily basis. The checks and any needle
changes are recorded mentioning the needle ref. that needle got exchanged.
■ Whenever the nature of the fabric, the operation or type of
needle changes, needles are changed according to needle size and point
required.
■ Machines including their needles are checked on a daily
basis in the morning prior to work commencing by the worker.
Any damage to the needles and changes are recorded on a
Replacement Needle Record.
■ If any inline or final QC inspectors find any needle
damage, the relevant machine is checked immediately and needles changed.
■ All broken or bent needles are securely attached to the
needle replacement form with a clear adhesive tape and all parts need to be
accounted for. Store officer is responsible for the record keeping.
■ Any old/blunt needles are collected by the mechanic/s,
recorded, kept in a sealed container in a separate area from the sewing floor
and sent externally for recycling.
■ Broken needle/calibration records is keeping for a minimum
of 06 years from shipment date for auditing purposes and disposed off safely
thereafter.
At no times are records being stored near the factory
floor as this can be cause possible contamination.
■ A broken or damaged needle are being always be replaced
with a brand new needle and all parts of the old one is accounted for. So the
exchange is on a one for one basis.
■ Mechanics are ensuring that no needles are left behind on
the machines after any maintenance work carried out.
■ Unused/spare machines are having the needles removed.
4. Requirements
for broken needle control
■ When a needle breaks the worker call the line supervisor
for the process and find all fragments of the broken needle and handover them
to the store officer.
■ the needle
or needle pieces are being placed in a small sealed container, in order to reduce risk of loss and taken to the needle control area where the new
needles are being issued.
■ ideally
this is a small self contained sub store on the production floor one full time employee situated
inside, who only has access.
■ Store officer is
keeping the needle log is check that all pieces have been submitted, by
aligning the pieces and comparing them to an intact needle of the sample chart with the following columns:
■ All pieces
of the broken/bent needle are then be taped to the needle replacement form by sticky tape ensuring that all parts
are securely kept in place. Broken needles are
not be disposed of in any other manner.
■ This
record are kept for a minimum of 06 years as proof of due diligence in case of any legal claims.
■ If any parts of the broken needle cannot be found, the
machine operator with the supervisor
present search the area around the machine, including looking in the oil bed
inside the machine throat plate, feed dogs and bobbin case.
The bundles that the worker was working on as well as any
bundles in surrounding areas of the workstation (within 2 metres) is being
isolated, moved to a separate location in a
wooden container clearly labeled
and checked with a metal detector (conveyor belt).
■ Any found fragments are being added to the needle
replacement form.
■ If any parts of the broken needle still cannot be found,
then these bundles are placed in a locked container and later on destroyed
after authorization has been obtained by the production or factory manager.
Records of the complete procedure are being kept for a
minimum of 06 years after production to be available for auditing purposes.
■ Under NO circumstances the product being returned to stock.
■ If all parts have been found the components/garments are
being returned to the workstation.
■ Only once the needle replacement form has been fully
completed the machinist is being issued with a new needle.
6. Kimbal/Tag
gun needle control policy
All
needles are being accounted for in each factory of Babylon Group: this means
when a new needle is issued it cross references with stock levels of the
particular needle and size is ensuring full traceability at all times.
■ Kimbal/tag gun needles are holding by the nominated person
in a locked cupboard, which is only accessible by the person responsible for
issuing new needles.
■ ‘One in, one out’ distribution system - All kimbal/tag guns
are being handed out to the workers by a nominated person at the beginning of
each shift and are being collected at the end of each shift.
■ This distribution system is being recorded (s. attached
daily in/out log), detailing workers names and numbers of kimbal/tag guns
issued/returned and records are being kept for a minimum of 3 years from
shipment date in case of a legal claim.
■ The number of workers with access to kimbal/tag guns are
limited.
■ All kimbal/tag guns are being kept on cord secured to the
workstation table.
■ The procedure as well as record keeping for any
broken/bend/lost kimbal/tag gun needles is the same as described above for
machine sewing needles.
■ Kimbal/ Tag gun logs as well as kimbal/tag gun needle
control logs are fully completed each time before a new needle is issued and
records are being kept for 03 year as proof of due diligence in case they are
required for any legal claims.
■ Product are not being kimballed in the metal free zone,
after passing through the tunnel conveyor belt detector.
C. METAL DETECTION
Babylon
Group is doing all products to be checked 100% with a metal detector prior to
shipment after all manufacturing operations have been completed. This check is
being carried out after the final examination and packaging of the garment
(incl. attachment of swing tickets) but before packing/boxing the goods in the
metal free zone and are being the part of the final quality control procedure.
Metal detectors are an aid to prevent metal contamination
and are the best way to ensure that needle control procedures are effective,
but are not to being used to replace an effective needle replacement policy.
Metal detection are being implemented within the production process and used in
conjunction with the broken needle procedure.
1. Calibration procedure:
■ Machines are being calibrated every working day with this
test card, at the beginning and at the end of each inspection lot, as well as
when the machine is started up, then every hour and at the end of a working day
as well as after any electricity cuts.
If an issue is found with the machine at the next
calibration, the goods that were done since the last successful calibration
need re-checking, so the smaller the gap between calibrations checks the
smaller the quantity of goods that are being re-checked.
■ If the machine is to be found out
of order after a check, it is being arranged for urgent repair and a
replacement to cover for the time the machine will be out of order. This is
being done through a static metal detector. It is being ensured though, that no
orders leave the factory, that is not been checked, especially in case of
children swears.
■ The following procedure are being adhered to when
checking the machine.
Please see below diagram for the width across the belt of
the metal detector and where the test card should sit when tested at the
bottom, center and top position:
CROSS
SECTION TUNNEL NEEDLE DETECTOR
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TOP
|
CENTRE
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BOTTOM
Calibration
procedure:
1. Switch
on the machine and set the sensitivity level to less than 1.2mm sphere.
2. Position
the test card directly onto the conveyor belt at position A1.
3. Let
the card pass through the search head.
4. The
metal detector is being activated and the alarm is sound.
5. Repeat
the above steps 1-3 with the test card in positions A2 and A3.
Again the detector is being activated and the alarm
is sound.
The test card is putting through on its own, we are
not put it on a paper or put it through with a garment.
6. Repeat
steps 1-3 with the test card positioned in the middle of a stand (7-8cm high)
or on top of a stand that is around 3-4cm high (depending on the height of the
gap between conveyor belt and top of machine) at positions A4, A5, A6.
Again the metal detector is being activated and the
alarm is in sound.
The stand are being a non-detectable block made of
plastic material.
7. Repeat
steps 1-3 with the test card on the top of a stand (7-8cm high or as high as
the gap allows for) at positions A7, A8, A9 and again the metal detector are
being activated and the alarm are in sound.
Records are being kept of all of these checks by using
the prescribe form.
■ In case the machine fails to pass the calibration test, it
is immediately being turned off and re-calibrated by an authorized technician.
All goods checked after the last calibration is being re-checked once normal
operations of the detector have been re-established.
■ Machines are being calibrated at least every 6 months by
the manufacturer.
■ Calibration certificates are being obtained and being kept
for auditing purposes.
■ If for any reason the detector are being relocated, it is
being re-calibrated by the supplier’s authorized technical service.
■ Regular
maintenance (at least annually) of the detector is being carried out by the
supplier’s authorized technical service based on the periods set up by them.
Records for maintenance and any re-calibration made by the supplier are being
kept, in case these need to be provided during any audits.
2. Metal detection:
■ When performing the metal detection it is being ensured
that products are placed on the moving conveyor belt one by one with sufficient
space in between products, so that there is no overlap.
■ If goods are being shipped e.g. on
hangers that are ferrous and cannot be passed through the metal detector, the
goods are being taken off the hanger, passed through the metal detector and
then re-hung. It is permitted for the hangers to be moved through the metal via
a door. This process are controlling by the authorized person and only the
correct amount of hangers per order are to be held at any one time, no spare
hangers to be stored.
■ As a general guideline though garments be metal detected as
last as possible in the production process and any ferrous metal items are
being attached in the metal free zone, such as security tags, hangers etc.
■ The
metal free zone are not being used for general storage and are being tidy. Once
product is boxed or hung is to
be taken to dispatch.
■ In case of stone washing the garments are being metal
checked prior to washing as the pumice dust contains small metal particles that
have an adverse effect to metal detection.
■ Any garments or part of a garment that are being outsourced
for the application of a print, embroidery or any other process are being metal
detected upon receipt back into the factory, prior to continuing production.
This is to ensure that no whole or broken needle pieces, staples, other stray
metals or sharp objects are in the returned pieces.
■ The factory are making sure that procedures are in place to
ensure that all garments including repaired and re-inspected do not go to packing
without being checked by the detector.
■ Clear separation and identification of the garments that
are waiting to be checked and that are being checked to be strictly
made.
■ Records are being kept for all garments that are passing
through the metal detector and are being completed as product passes through
the machine to verify compliance with this requirement.
■ If the alarm sounds, all garments on the halted conveyor
belt are being put into a sealed bag, segregated and locked in a secure
rejection box, to be located near the metal detector.
■ The rejection bin are being taken to a clearly marked area
and thoroughly checked for contamination by the assigned person.
■ If the metal parts are found and the garment passes through
the conveyor metal detector successfully, the garment can be returned to the
bulk.
■ If the metal part cannot be found, the contaminated product
are being put into a polybag with details clearly marked on it and then placed
inside the rejection bin (s. photo) locked away from the factory floor and THE
GARMENT ARE BEING DESTROYED after authorized sign off by the factory manager.
Under NO circumstances can it be returned to stock for shipment.
■ If a product is metal detected in its packaging, remove the
packaging and detect the product and packaging separately as some packaging can
contain traces of metal, especially if recycled, e.g. card, therefore may
prevent the product being rejected.
■ The rejection bin are being locked with a designated person
holding the key. The bin is having a slit at the top through which the garment
can be passed through. The slit is being big enough to let the garment fit
through, but small enough to avoid a hand fitting through it.
■ Any action is being recorded accordingly and any found metal
parts are being taped securely to the metal detection failure record by sticky
tape confirming source of contaminant and action taken to prevent future
contamination.
■ Records of garment destruction are being kept for a minimum
of 5 years for auditing purposes.
■ After the tested products are packed in a carton, the
carton are being marked with a stamp stating date and ‘tested’.
■ Any products that are being returned from the storage area
/ warehouse to the sewing/finishing floor are being checked again with the
metal detector and the cartons must be re-stamped with date and ‘tested’.
■ In summary, records that are being kept to support the
operation of the metal detector are:
- Calibration checks of metal detector
- Style number, date and time of products
metal detected
- Contaminants detected and follow-up action
taken
These records are being retained for 03 years after
shipment in case of any legal claims.
■ Furthermore Personnel Training Records are being kept,
listing the responsible people who have received training in needle control and
metal detection procedures.
■ All records are fully completed at all times.
D. GLASS AND HARD PLASTIC
BREAKAGES
If in the case of a breakage of
glass or hard plastic in an area of production, the following procedure is
being managed;
- Stop production
- Restrict movement through the
area
- Quarantine product in the
affected area
- Report to Management and
responsible personnel
- Clean up and remove glass
- Check all products in affected
area
- Record in issue log
- Investigation to be conducted
as to how to prevent the same occurrence going forwards
Moreover we are also maintaining
pull test, minimum neck,
Choking &
Ingestion hazard
Sharp Edges and
Points hazards
Pathalates free
Nickel test
Chemical Toxicity hazards
Applique, Badges,
Embroidery
Bows, Fabric
Loops, Decorative and 3D Motif Buttons
Diamante, Glued
& Heat-sealed Decorations
Packaging
Zips - Slide
Fasteners & Pullers
Product
Safety & legality CHECK SHEET
BUYER: ……………………… STYLE: ………………….. COLOUR: ………………..……. DATE………………………
ORDER NO:…………………. FAB. COM:………………. TYPE OF SAMPLE ……………..
Product legality
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Special
Attention:
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Fabric
col./Quality as per
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Product Features
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Buttons :
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Diamantes, Glued & Heat-sealed Decorations
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Drawstrings, Functional Ties, Decorative Ties
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Metal Trims, Buckles, Rivets & Snap:
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Packaging:
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Sequins:
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Zips - Slide Fasteners & Pullers:
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Pull test
Procedure
46.0 Purpose & Scope : Pull test is very
important for garments components attachment
like button, eyelet, rivet, snap, shank button and all kind of stud
attachments. It’s the test for pulling strength and attaching security, pulling
strength must be need to meet required strength, otherwise it may be issue for
children safety and hampering human prestige .Improper pull strength is a
critical issue for garments buying sealing and wearing period.
46.2 Responsibility: Quality supervisor will perform the
report two times in a day .Quality in-charge in the main concern of
implementing the procedure effectively.
46.3 Procedure: PULL TEST PROCEDURE:
For pull test always
need to follow the buyer requirement
pulling strength, if any buyer have no requirement than should be follow the Babylon won procedure.
46.3 Procedure:
At first make a mock up as per bulk condition. And attached
button on mock up . Then test pulling strength as per requirement if it pass
then we attach with garments. We also check pull strength random basis two
hourly. If any machine fail as required pull strength than we stop that machine
production and re-checked all garments.
For pull test holding
time 10 (seconds) in 90N force for all attaching components like button, rivet,
eyelet, snap etc. If any item fail the above test shall to be removed from
production and segregated as reject.
Pull test should be
done three (03) pieces from each style 3
times everyday in ten hour shift- at beginning of the shift, after lunch and
again end of the day. Keep record and documents for every test as long as buyer
requirements.
WEIGHT CONVERTING :
|
Newton
|
Kg
|
L.B.S
|
|
40 N
|
4.7 Kgs
|
10.36 L.B.S
|
|
50 N
|
5.10 kgs
|
11.24 L.B.S
|
|
60 N
|
5.39 kgs
|
11.88 L.B.S
|
|
70 N
|
7.13 kgs
|
15.71 L.B.S
|
|
80 N
|
8.15 kgs
|
17.96 L.B.S
|
|
90 N
|
9.17 kgs
|
20.21 L.B.S
|
|
100 N
|
10.19 kgs
|
22.46 L.B.S
|
46.4 Reference: Pull test report
Taking every thing into account, i would prefer in order to depict that i am in favor in this topic. I ponder that i have illustrated with the help of this statement emphasizes this entire.
Nazmul Huda -B Sc in textile -CU,M.Sc in Environmental science in JU.
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