After discussion with customer - product specification is finalized with the help

Customer PO and of Sampling Department. Final specs sheet prepared for pricing and
Sampling production and handed over to marketing department and than to PPC
department for issuance of order number

Material purchased from approved Supplier. When goods arrive on main gate,
Incoming Material IGP is prepared and entered in system. After that auditor verifies quantity as
per challan and places these materials in under inspection area.

Quality Auditors inspect the material as per given standards. They verify all the
Incoming Material parameters as per given SOP. Sample size for inspection is AQL of total quantity
received and below 50pcs quantity 100% inspection. If faults occur more than
Inspection tolerance level, they reject the material and enter rejected material in system which
is returned to supplier.

Knitting Department receive program from R&D Department and feed it into
machines. As per planning Knitting Department put style on the machines,
Knitting of Sock
yarn requirements fulfilled as per PO sheets / Specs Sheets. After all this
process yarn is converted into socks.

During Inspection, Quality Officer verify trim card, yarn, style, specs and
Knitted Socks production inspection to find faults to determine how much ratio of faults is
Inspection produced in production. Every Quality Checker inspects his unit twice in each
shift .

Knitting Removal team makes 02 round in each shift of 08 hours and collect the
Knitting Removal kniited goods in bags from planned machines according to specific bag quantity and
enter the data in production system.

Stock Keeping Knitting removal teams provide the bag to stock keeping supervisor where he keeps
the goods in the racks and responsible to feed linking department.

This section stitches the socks when receive from stock keeping supervisor.
Linking / Toe Closing Stitching is carried out as per requirements of buyer either it is stitched on
Over Lock machine or Rosso machine. Type of stitching yarn is always
considered most important in this process.

Quality Inspectors inspect the socks to ensure the quality of stitching.

Toe Closing Inspection Inspection is carried out on AQL based on production

Final Bag Audit Quality Inspectors receive bag from knitting removal department after linking and
inspection is carried out on AQL based on production. If the bag will fail then it should
rework by the respective department until clear by Quality.

Batching Section will receive the pass bags from final bag audit and makes the
Batching of Socks batches of socks as per capacity of processing machines. During this process
Batch Officer always considers that style, size of the socks should not be mixed
 Grey Store supervisor receive the full batches from batching department and
Grey Store Stock maintain the stock and als oon the demand of processing planning department issue
to processing department. Grey store supervisor should consider the quantity and
location of the batch must be accurate.

Turning of Socks In this section, batches are received from grey store stock and turned according to
requirement before processing.

This Section processes the socks as per PO instructions. Three types of

Dye / Washing of processes are carried out in this department. They are Washing, Bleaching and
Socks
Dyeing. As per MTA all recipe prepared and feeded in the system.

Each batch is inspected before forward to next section from Processing.

Socks Inspection after Inspection Parameters are; shade standard, whiteness standard, color fastness
dye / washing standard etc. Inspection is conducted on AQL based on production or as per
buyer’s AQL.

In this section, batches are received after processing and turned according to
Turning of Socks requirement before processing. This batches were not turned previously due to
dye/wash requirement

Processored Store This section is the WIP stock area between processing and pressing

Boarding Department press or board the socks on trolleys to move to Ready

Boarding of Socks for Pack Section or direct inline packing. Frame requirements and size
requirements are confirmed as per PO sheet & specs sheets.

Socks inspection Inline inspection always remains in operation to make sure that all the
during Pressing parameters are as per requirements. Audit of each batch is also conducted on
according SOP and according AQL in press dept

This Department packs the socks as per packing instruction provided by PPC
Packing of Socks
Department. Packing type and packing style are confirmed as per PO sheet.

Quality Inspector assures the packing type, packing style, packing accessories
and packing quality (balancing, uncut thread, shoot pins, pairing, stickers
Packing Inspection pasting, poly bag closing and Carton filling). Audit of each batch is conducted
before forward to final audit.

Final Audit Department inspects the product to make sure that all the
requirements of buyer regarding to packaging and socks are fulfilled. AQL 1.5,
Final Audit of Socks 2.5 & 4.0 are followed at final audit for the inspection of packed socks. This
Section also scans all barcodes with the Digital Scanner to make sure that all
UPC codes are as per requirements.

FGS received goods from Final Audit Department and stacks it buyer wise, PO
Finished Goods Store and style wise in specified locations of FGS. FGS loads container as per
and Dispatch Shipment Schedule provided by PPC Department. Seven Point Container
Inspection Procedure adopted before loading the shipment.