PT RAPI TEXPRO PRATAMA

STANDARD OPERATION PROCEDURE

1. FUNCTION OF WASHING ROOM

To supply a quality wash garment on time that complies with all the
buyer's requirements and at the most cost effective way. To achieve
the finish required by the customer as per their approved wash
standard.

2. PROCEDURE
2.1 BEFORE Bulk WASHING

For a new style wash development must start on leg panels before
washing bulk.

Sewing factory must give a set of leg panels to the washing room,
with the approved standard from the buyer.

Washing room must do the dry process and washing according to

the standard and record the washing formula.

Factory must make a blanket before cutting process. Take A4 size

pieces of fabric that are taken from each roll & a blanket made.

Blanket must be washed according to the approved standard.

If washing room finds too many shades on this blanket they should
inform Sewing factory immediately.

Style & cut lots should be kept separately when receiving from
sewing factory.

Check the production sheet (tech pack) for wash effect before
starting bulk.

Wash first test wash / first bulk load for approval using one sticker (color)
shade.

Friday, June 5, 2015

PT RAPI TEXPRO PRATAMA

STANDARD OPERATION PROCEDURE

If the first load color is achieved as per approved shade band, show to
buyer QA for approval. Make internal plan to complete washing style at
least 3 days before loading. If the buyer QA approved washing color, the
washing in charge must ensure that operators follow the same washing
formula.

After making washing formula, washing in-charge must approve the

formula then issue the washing formula to washing room & chemical
room.

Ensure that operators understand & are given the right formula &
instructions.

For the styles that are running in washing room, the washing manager
must prepare a sample for the QC to check production. The sample should
be the same as the approved shade band.

In checking area, shades must be separated, then sent to dispatch with

the right color in accordance with the approved shade band

2.2 SAMPLE WASHING

Receive sample requisition from merchandising dept.

Receive the correct washing standard and place in a polybag and

keep out of direct light.

Any instructions from buyer must be clearly communicated verbally

or put in writing before giving to washing technician.

Washing set of leg panel according to buyer standard.

Ensure that the wash formula in leg panel is recorded.

Wash the sample according to the buyer standard and ensure that
the washing formula is recorded properly.

Send back the sample to the factory according to the sample

schedule.

Ensure that the washing formula must be recorded properly and

updated.
Friday, June 5, 2015

PT RAPI TEXPRO PRATAMA

STANDARD OPERATION PROCEDURE

2.3

Keeps a leg panel from every process of the wash process for bulk
washing process.

BULK PRODUCTION

Make1st test wash / 1st bulk load according to the shade band
approved by the buyer.

For first load follow the leg panels from the 1st test wash / sample
wash to approve every process.

First load must be submitted to buyer for approval within 2 days of

garment receipt.

Wash sticker by sticker (Dye lot by dye lot).

Separation of shading before washing.

Sometimes we need preparation before wash like, put tie, remove

sticker, sewing the flaps.

Remove the plastic & stone before drying.

Ensure daily production out-put is as per the required target

planned.

2.4 COST CONTROL

Chemical budget making according to formula in 3 months

production.

Ensure the chemical must be recorded properly upon issuing to

washing room.

Ensure that the valve of water line be closed when not using.

2.5 QUALITY CONTROL

Friday, June 5, 2015

PT RAPI TEXPRO PRATAMA

STANDARD OPERATION PROCEDURE
Always check minimum 10% of before wash garments before bulk
washing and if any rejection found must be communicated with
factory.

After Each and every dry process garment must be 100 % checked

After drying the QC must check the garments according to the

approved sample.

Ensure that the right color send to Sewing factory for finishing.

Ensure 100% check the quality of washing and dry process.

During checking if encounter the dark color must be separated or

back to the washing area. Inform supervisor & line manager.

If encounter-washing problem must be inform washing in-charge,

line manager, and supervisor.

2.6 SAFETY CONTROL

Provide the following safety gadgets to every operator to ensure
safety.

Gum boots

Gloves

Plastic apron

Masker

Eye goggles

3. PRODUCTION FLOW

3.1 : Sample Making

Analyzing the washing effect

Fabric analysis
Friday, June 5, 2015

PT RAPI TEXPRO PRATAMA

STANDARD OPERATION PROCEDURE

Checking the color shade and PP Spray washing effect

Making dry process

Intensity of pp spray analysis

Washing sample

Review of sample (color must checked in light box)

Washing formula recording

Submit for buyers approval

3.2 : Blanket washing

Preparation of Blanket sample (A4 size from each fabric roll and
stitch in one blanket)

PP Spray and Washing according to the sample washing process.

Separation according to the Shade lot

Recording and inform factory to separate garment According to the

shade lots and shrinkage.

3.3 : Dry process control

Shade lot wise separation Before Dry process

After Separating shade lot the garment send to the Dry process

100% QC checking after Dry processes

Prepare washing load.

3.4 : First Load( Pilot run) Analysis

Making the first load in bulk production (Try to include all shade lot
in pilot run)

Analyze the color shade, tone, dry process effect and washing
effect.
Friday, June 5, 2015

PT RAPI TEXPRO PRATAMA

STANDARD OPERATION PROCEDURE

Take first load approval from buyer washing technologist/buyer QC.

3.5 : Preparation

Receiving the garment from factory and separating shade lot wise.

Tying the identification before washing

Load making for washing machine according to first load washing

process ( Must be scale)

3.6: Wet processing

During washing, garment must be checked after each step with

keeping step sample/panel.

Chemical weighing and addition of chemical.

PH value checking in each required step.

3.7: Hydro extraction

During the extraction Supervisor must check the extraction time &
speed to achieve
proper color & consistency.

3.8: Drying

At the time of drying supervisor must ensure the time and

temperature as per requirement.

3.9: Final QC Inspection

All garment must checked 100% with duplicate shade band from
first load

If color or washing quality is not up to Standard send for rewash.

3.10: Delivery to packing dept.

Garment must be separated according to the shade

4. NEW DEVELOPMENT
Friday, June 5, 2015

PT RAPI TEXPRO PRATAMA

STANDARD OPERATION PROCEDURE

WASHING PROCESS FOR MAKING SAMPLE

4.1 : RECEIVED SAMPLES

At the time of receiving the sample, washing room must record the
Progressive sample no. with all detail such as Buyer name/fabric
type/receiving date/Contact person buyer end/Approx. submission
date

4.2 : QC Checking & Recording

QC must check all the sample thoroughly and record in the QC

recording book with QC progressive no. and suggest to sample
washing room if any suggestion.

4.3 : Analyze Washing Method

Washing technician must analyze the washing method according to

the Fabric type such as :

Woven

Denim- Oz./Sq.Yd./Type of yarn used in sample/color/Required

washing effect/softness/feel/pH value etc.

Non denim- color/Required washing

effect/softness/Brightness/feel/pH value etc.

Non woven/knitted color/Required washing

effect/softness/Brightness/feel/pH value etc.

4.4 : Before washing process

Washing technician must ensure the position and intensity with

marking such as: - PP spray/Color
Spray/Tacking/Scrapping/damaging/grinding /Nicking etc.

4.5 : QC Checking Panels (Dry Process)

Friday, June 5, 2015

PT RAPI TEXPRO PRATAMA

STANDARD OPERATION PROCEDURE

After dry process QC must check properly the panel/ mock before
washing and if it is not up to the std. Sample, send back to concern
person for improvement, and keep one panel before washing to
compare after washing. If it is good then send for washing.

4.6 : Washing Panels

If all process is up to the Std. sample, then wash the panel/mock

and record the washing method. And washing technician must take
one panel after each washing step such as: - after enzyme / after
bleaching etc. for washing sample garment and Bulk production.

4.7 : QC Checking (Wet Process)

QC must check properly the panel/ mock after washing and if it is

not up to the std. Sample send back to concern person for
improvement, and keeps one panel to compare after sample
garment washing.

4.8 : Washing sample garment

If Panels/ mock are up to the Std. Target sample then follow the
same washing method and start washing the sample garment and
check after each step with keeping panel during panel washing. And
record the washing method

4.9 : QC checking sample garment

QC must check properly the Sample Garment after washing and if it

is not up to the std. Sample send back to concern person for
improvement.

4.10 : Submit for buyers approval

If sample Garments are up to the Std. Target Sample then sent to

the buyer for Approval with proper documentation.

5. Necessity of Development in washing

Friday, June 5, 2015

PT RAPI TEXPRO PRATAMA

STANDARD OPERATION PROCEDURE

Being successful in business or in Personal life requires much more

than hard work and good ideas. You have to be persistent, tough,
confident, curious, flexible, passionate, patient, and in love with
what you are doing. You were probably born with some of above
qualities but Rest you can and must develop.
To break the monotony of human eyes the continual development is
most important thing in Garment business.

Friday, June 5, 2015