Professional Documents
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Sewing-Sop
Sewing-Sop
Sewing-Sop
3 Objective:
Producing an optimum quality product, setting the process as a benchmark for the whole garment
manufacturing industry.
To achieve the desired level of productivity, processes should be set as per the following guidelines
given by Industrial Engineering Department
In any case production must not be started without the PP sample, style file and production hand over
meeting.
All the template used in production line should be duly signed by the technical dept. +
QC
Template:
a. Collar run stitch marking (Metal sheet) template example(metal sheet)
b.Collar assemble templete
c.Pocket marking
d.Button down marking
e.Pocket pressing
Each line should have two checkers for parts and one for assembly.
It is also very important that when new operators start, they are in fact trained properly on not only the
basic workings of the machine’s but daily care procedures as well. All machines must be cleaned at least
twice a day, needle change and broken needle procedures must be clearly understood. A daily routine
must be set up for all operators. Awareness through good training procedures is the key to ensuring
that a level of understanding exists. Operators need to react to such problems even if they do not know
how to fix them. At the end of the day, you can always deal with reaction. No reaction on the other hand
means that issues and problems will continue.
Pins that must be used in the laying-up of fabric must be controlled. No other uses of pins in cutting,
assembly, inspection or any other operation where garments or components are handled are allowed.
Pins must, not secure reels of elastic, lace, bindings etc. They must be eliminated and replaced by tape.
Neither pins nor staples must be used in any part of the factory for other uses such as securing
documents, tickets, pay packets or notice boards.
The procedure
No operator shall be in possession of any needles other than those in the machine being
operated, or that required for the hand operation being performed.
In some cases it may be necessary for a worker undertaking handwork to have more than one
needle in their possession. In these cases it should be recorded how many needles are issued to
each worker, these must be accounted for at the end of each shift.
All spare needles shall be held by a supervisor in a secure, locked location.
Only the supervisor shall issue needles to operators.
Mechanics must not leave spare needles with a machine after servicing.
If a needle needs replacing through wear the supervisor will issue a new needle and retain the
old one for safe disposal. Planned regular replacement is recommended.
Worn needles must be disposed of into sealed containers away from the factory floor and at
intervals securely disposed of to waste.
If a needle breaks all parts must be looked for. Broken needle fragments must be mounted with
clear adhesive tape on a chart and signed by the line/floor supervisor. Records (Annexure 40)
must be kept of needle breakages by machine type, needle size, operation etc. to establish
trends. All record sheets must be kept for a minimum of 18 months.
The following Label policy must be adhered to ensure that correctly labelled -products are being
manufactured. A system for rigid control and issuing of labels is essential.
The procedure
1. On receipt of the contract, check label information ensure fabric composition, care instructions
and all necessary safety instructions are correct. This must also includes legal responsibilities for
character merchandise.
2. All deliveries of labels must be quarantined and checked against the contract before being
released to trim stores. This inspection should include random checks for mixed labels within a
single box. It is vital to ensure that this responsibility is given to the trim store manager.
3. The quantity of labels issued to the production line must correspond with the cutting room
documents and be controlled by the trim stores supervisor.
4. Where labels are date coded, the oldest must be picked first.
5. Only the correct number of labels must be issued to the line. This must be no more than the
current bundle size.
6. Spare labels must not be kept by the operator. Any labels not required must be collected and
returned to the trim store.
7. Any additional label requirements must be authorised by the trim store supervisor e.g. re-makes
or repairs.
8. Label insertion must be an integral part of the product. If labels are required after dyeing, they
must be over-locked to the seam and not lock stitched.
10. At the final stage of garment inspection, prior to dispatch, all garment labels must be checked
against the UPC tickets and hanger/ box-end labels.
11. It is also necessary to check outer box labels against the actual contents prior to sealing of box.
Operation specifications (Annexure 41) play a key part in the successful implementation of new styles,
ensuring that we get quality levels right first time and not after three or four days of sewing. Each
operation that is set up must have a specification on the machine, which includes details such as;
Machine type.
Needle and Stitch size.
Seam width.
Thread size and quality.
A detailed description of the operation either by a detailed drawing or by attaching a mock ups (visual
standard).
They must be signed by the operator, QC, supervisor to confirm that they fully understand the
requirements. This may seem like a lot of additional work but the advantages gained from doing this are
evident and immediate.
A complete understanding of the requirements and standardization across additional machines doing
the same operation. Immediate understanding by new operators who have to step in the case of
absenteeism. The same would also apply to in line Q.C.’s.
A agreed and signed the Job Specification , each operator must be trained until the
supervisor/technician is satisfied with his/her out going quality.
There must be a visible and dedicated inline QC for all machines in a line.
Each operator must be checked 4 times a day using a simple, traffic light system and inspecting
no more than 10 pieces each time with fixed quantity.
In-line QC and Line supervisor must sign reports daily.
The monthly summary must be kept at the machine at all times until the end of the month.
After the month is over they can be put into the operator’s performance file.
It is not up to the Inline QC to fix the problem but to find the problem. Fixing the problem is the
responsibility of the operator, supervisor and technician. Not only does this act as a control tool
but it also acts as a database recording which operation the operator has been doing and which
one they are best at. Therefore in time it will build up a historic data of individual’s strong and
weak operations.
It is important for management to see first time quality as an essential cost factor. If operations
are not set up properly, and work produced continues to be bad then the additional costs
through repairs, seconds, and loss in productivity, short shipments and delays can be
substantial.
TWO defects mark card RED, THREE defects mark card BLACK, circle
Defect type# 1,2,3,4,5,6,7 or 8.
There must be an approved an approved PP sample that has been checked by the merchandiser.
Proper dedicated tables must be set up. It is unacceptable to have large tables with many
inspectors. This will only lead to people talking to each other and losing focus on what they are
supposed to be doing, or mixing up good and bad garments. One table one inspector.
Lighting must be a minimum of 100-foot candles.
Along with the approval sample, all relevant paperwork must be at the inspection table. This
must include clear copies of PP sample comments, and a list of Key points to be checked, during
the inspection.
Each inspector must have a predefined inspection method. If we determine the method then
through time the inspector will know what to inspect and in what sequence. That will allow
them to focus on the overall garment quality and not think about what she has checked and
what she hasn’t.
The inside as well as the outside of the garments must be thoroughly checked. The method of
inspection must be defined at the PP meeting
If there are excessive threads then these must be marked as repairs to ensure that the problem
is in fact rectified.
Proper bins must set up to ensure that we are segregating good garments and bad garments
(i.e. Sewing, stains and shading etc,).
Hourly records must be kept, using the END LINE DAILY INSPECTION REPORT (Annexure 42). A
repair in and out control is also included in the report, which will enable the supervisor to
ensure that repairs are being repaired and returned, straight away.
It is important for management to ensure that all reports are examined hourly to ensure that
the necessary corrective action has taken place.
Measurement methods must be established to ensure that all inspectors are in fact using the
same method.
Measurement sheets must be filed properly and must measure at least three pieces of every
size in full, every day across all colors, per auditor.
The only way to measure a garment is in fact with a tape measure. Under no circumstance must
templates be used nor there be any marks on the table. Inspectors will only pull or push
garments to meet specs in this case.