EXPRESS ASIA REGION TECHNICAL 2005

EXPRESS Standard Operating Procedures 标准操作流程

Best Practices 最佳做法
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EXPRESS ASIA REGION TECHNICAL 2005

•What are best practices? •何谓最佳做法?

Best Practices 最佳做法

•The practices that give the right result. •能取得正确结果的做法。 •What are the right results? •何谓正确结果? •FIRST TIME RIGHT 第一时 间正确 •NO REWORK 无返 工 •SHIP ON TIME 准时 出货
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices 最佳做法

•How do you achieve this miracle? •如何达到此奇迹? •Follow SOP’s. •跟 SOP 。 •Standard 标准 •Operating 操作 •Procedure 流程 This is a process not paperwork! 这是过程而非文字 工作

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices 最佳做法

Why? 为何 ? •Everyone knows their role and the expectations of them •每个人都知道他们的角色和期望 •Life at work becomes clearer and ordered •工作生活变得更清楚有序 •Profitability •收益性 •Business grows •交易增长 •Only path to Express tier one factory •成为 EXPRES 定单生产长厂的唯一途径 4

EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Fabric Storage 最佳做法—面料储存
•On clean shelves or pallets •于干净货架或托盘上 •By dye lot •分色缸 •No mixing of dye lots within shelf/pallet •于架 / 托盘内无混合色缸 •Covered at all times •始终有覆盖

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Fabric storage 最佳做法—面料储存
•Dye lot storage & identification •色缸储存和标识

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Trim storage 最佳做法—辅料储存

•Organized by brand,style,P.O. •分品牌,款,订单号

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Trim storage 最佳做法—辅料储存
•Trim inspection under right light condition(Min 100 FCL) on a clean and clear work surface. •于正确灯光下(至少 100FCL )的干 净整洁工作台上检验辅料 •Approved trim card displayed. •展示核可的辅料卡 •This is not just inventory control •此非仅对存货控制 •Trim quality issues are resolved before they reach the factory floor. •于辅料到达工厂层面之前解决其品质 8 问题

EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Fabric Inspection 最佳做法 - 面料检查
•Under proper light conditions(Min 100 FCL) •于适当灯光下(至少 100FCL ) •On clean ,smooth surface. •于洁净光滑台面上 •Back light and top light used properly for color /fabrication •查颜色 / 面料制作用正确的后背灯和顶灯 •Speed at maximum 15 yds per minute consistently. •始终用不超过 15 码 / 分钟的速度 •Inspection reports signed by management & action taken to resolve any issues. •检查报告有管理员签字并采取行动解决任何问题
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EXPRESS ASIA REGION TECHNICAL 2005

This is all about Risk Management. 关于风险管理。

Best Practices-Pre-production follow up 最佳做法—产前跟进

•Express Pre-production Meeting Record. 10 •Express 产前会议记录

EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Pre-production follow up 最佳做法—产前跟进
Here are some good examples of simple way to insure operator ownership to 1st time right quality: 确保操作 者第 一时间 掌握 正确品 质的 几 个简单好 方法 举例: •PP meeting instruction displayed & signed by sewing supervisors & operators. •产前 会议展 示指 导且有 车缝 主管和 操作 者签字 • Technical training provided for special operations before production begins •于产 前提供 特别 操作的 技术 培训
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Fabric relaxation 最佳做法—松布
•Fabric unrolled into bag with Velcro closure. •面料解开入袋加尼龙搭扣 • Fabric appropriately covered & shelved •面料适当覆盖和入架 •Relaxed a minimum of 24 hrs before spreading. •摊布前先松布至少 24 小时 • or Preshrunk with Steam shrinkage machine. 12 •或用蒸汽预缩机预缩

EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Fabric relaxation 最佳做法—松布
Bag ticket Information: 袋标签信息: •style number •款号 •PO number •订单号 •Dye lot/ roll number •色缸 / 卷号 •Quantity/Color •数量 / 颜色 •Width •门幅 •relaxing date/ time •松布日期 / 时间

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Cutting 最佳做法—裁剪
•Cutting operation procedures set & posted. •裁剪操作流程设立并张贴

•Provide information to cutting room of faults found during fabric inspection.This is a very simple way. •向裁剪室提供面料检查时发现的布疵 信息。这很简单。

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Cutting 最佳做法—裁剪

•Acceptable & unacceptable zoning area applied. •采用可接受和不可接受分区制

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Cutting 最佳做法—裁剪
•Good housekeeping •良好的车间管理 •End cut control. •尾裁剪控制

•Use only computer generated markers. •只用电脑排料图

•Pile height appropriate for fabric & style,but no higher than 2 1/2”. •据面料和款式,合理摊布高度,但勿 高于 2 ½” 16

EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Cutting 最佳做法 - 裁剪
•Use band knife & block fusing for small parts to maintain consistent shape. •用整体 烫衬 和龙门 刀裁 剪来保 证小 裁片的 精度 和连 续性

•Band knife operation procedures & protection device in place. •龙门 刀操作 程序 与保护 装置 须就绪

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Panel Inspection 最佳做法 - 验片

• One of the most important steps in 1st time right quality. •第一时间正确品质最关键的一步 • Seeing faults on some fabrics is difficult. We will show you several types of light boxes constructed very simply to enable the cut panel inspectors to work efficiently. •某些面料上的疵点不易察觉。下面将演示几款构造很简 单的灯箱来实现有效率的验片。 • Remember this process is not for color, only fabric faults. 18 •请注意此步骤不适用于颜色,仅为面料疵点。

EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Panel Inspection 最佳做法—验片
Light box type 1 – table top 灯箱 型 1— 桌顶

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Panel Inspection 最佳做法—验片

Light box type 2 – Floor standing. (On wheels) 灯箱 型 2— 立地(有轮)

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Panel Inspection 最佳做法—验片

Light box type 3-separate work station with slanted surface for ease of viewing. 灯箱 型 3— 单独的工作岗位有便于观察的倾斜工作台

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practice-Panel Inspection 最佳做法—验片
•Inspection procedure & defect standards displayed. •展示检验程序和疵点标准 •Standards include accept/reject criteria •标准含可接受 / 拒收标准
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Panel Inspection 标准做法—验片
• Table top without under light •无背灯的桌顶 •Panel defects guideline/standard (AC/RE) •裁片疵点指南 / 标准(接受 / 拒收 ) • 100% cutting panel inspection • 100% 裁片检验
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Cutting Department 最佳做法—裁剪部门

•Fusing In-process controls •烫衬操作过程控制

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EXPRESS ASIA REGION TECHNICAL 2005

Cutting Department-Cut panel storage on shelves 裁剪部门—裁片存放于架上

Identify: 标注
•Style number/P.O. •款号 / 订单号 •Quantity •数量 •Size •尺码 •Cut lot number •裁剪批次号

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Sewing Line 最佳做法—车缝线
•Clean ,clear aisles & work stations •干净整洁的过道和工作场地 •Covered bins •有布衬的箱柜 •Lighting Min 100 FCL •灯光至少 100FCL

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Sewing Line 最佳做法—车缝线
•Individual lights on machines for critical operations •为标准操作,机上有各自的灯 •Operator standards (SOP) •操作标准( SOP ) •Job specification for sewing operator. •车工工作说明
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Sewing Line 最佳做法—车缝线
•Standard signed off by operator and supervisor & in line QC. •操作者、主管和中查 QC 签发的 标准 •Ownership to 1st time right quality. •第一时间正确品质的主导 •Small parts pressing on clean, clear surface. •于干净整洁台面上小片烫 •Pressing SOP. •整烫标准操作程序
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Sewing Line Operator/Responsibilities 最佳做法—车缝线操作员 / 职责
Responsibility of operators need to be identified clearly. 须明晰操作者的职责。 •Production Q.C. •生产线 QC

•Green line leader •绿衣流 水线组 长

•Red supervisor •红衣主 管

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Sewing Line 最佳做法—车缝线
•Traffic light system • 交通灯系统
•Again, this reinforces operator ownership to 1st time right quality. •再次 ,此增 强车 工对第 一时 间正确 品质的掌 握。 •Operator quality performance sheet. •车工 质量表 现表 •Process & results not paperwork. •是过 程与结 果, 而非文 字工 作
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-End Line QC 最佳做法—尾线 QC
•Clutter free area. •无混乱区 •QA should not be trimming. Trimming is separate function & location. QA 不该是剪线。剪线是单独的 职责和区域。 •Specific, clearly marked area for good, repair and rejected garments. •专门的清楚标记的区域用来放良好 31 、回修和拒收的成衣。

EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-End Line QC 最佳做法—下线尾查 QC

•Q.C. information & inspection process. •QC 信息和检验步骤

•Inspection method standard •检验方 法标准

•Measurements documented 32 •尺寸度 量记录

EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-End Line QC 最佳做法—尾线 QC
•Key checkpoint for end line inspector. •下线尾查检验员关键检查点

•Accurate fault repair record. •精确的返修记录

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Pressing 最佳做法—整烫

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Pressing 最佳做法—整烫
•Pressing pattern/Size boards for bias & knit garments.Fit /spec consistency. •斜裁和针织衣服须有整烫纸 样 / 尺码板。试身 / 尺寸一致 。 •Regular changing of covers,boards & markings. 35 •覆盖布、板和标记的经常更

EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Pressing 最佳做法—整烫
•Pressing procedure instruction. •整烫程 序指示 •Pressing standards displayed. •显示整烫标准
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Pressing 最佳做法—整烫
Some factories have taken the traffic light system a step further. •某些工厂已进一步实施了交通灯系 统。 •Presser controls-traffic light system •整烫控制—交通灯系统 •Pressing operator numbers assigned •指派整烫工编号
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Pressing 最佳做法—整烫
Presser operator numbers on stickers,applied to back of factory ID label. 整烫工编号纸贴于厂商唛背后 •Pressing operator performance documented with follow up action. •由后续工序记录整烫工表现
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Fitting 最佳做法—试身
•In-line fitting (woven) •中期试身(梭织) •Fitting after pressing(knits) •烫后试身(针织)
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Fitting 最佳做法—试身

•Fitting standards, acceptable/not acceptable •试身标准,可接受 / 不可接 受

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Finishing 最佳做法—后道

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Finishing 最佳做法 - 后道

•100% measurement check •100% 尺寸度量检验

•Blind measurements •无标准 尺寸 参照的 度量
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Finishing 最佳做法—后道

•Folding instruction /standard •折叠指示 / 标准

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Finishing
最佳做法—后道 •Folding ,standard posted •折叠, 张贴 标准 •Metal detect machine •金属探 测机 •All garments with hand work should be passed through mental detector before packing. •所有用 到手 工的成 衣须于 包装 前通 过金 属探测 机 44

EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Final Q.A. 最佳做法—尾期 QA

•Inspectors identified •检验员有标识

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Final Inspection 最佳做法—尾查

•Top garments compared to Red Tag. •TOP 与红牌版对比

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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Final Inspection 最佳做法—尾查
•Q.C. information & inspection process. •QC 信息与检验步骤

•Inspection method standard •检验方 法标准

•Measurements documented 47 •尺寸度 量记 录

EXPRESS ASIA REGION TECHNICAL 2005

Best Practices-Results and Rewards 最佳做法
First Time Right Quality 第一时间正确质量 STR inspections are no longer necessary 不再需要 STR 查货 FCA certified/Self Auditing factory 有资格的工厂查货员 Order ships on time 准时出货 Satisfied store customers 顾客满意 Good Sales 好的销售业绩 More business…..and everyone is satisfied! 更多生意…所有人都满意 !
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EXPRESS ASIA REGION TECHNICAL 2005

Best Practices

lAny Questions ? l有问题吗 ? lAny Idea? l有意見吗 ?
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EXPRESS ASIA REGION TECHNICAL 2005

THANK YOU

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