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Cont en t s
START TO END PRECESS CHART ... .... ... .... ... .... ... .... .... ... .... ... .... .... ... .... ... .... .... ... .... ... .... ... .... .... ... .... ... .. 3
PRODUCT DEVELOPM ENT (SAM PLE ROOM ) .. .... ... .... ... .... ... .... .... . .. .... ... .... ... .... .... ... .... . .. .... .... ... .... ... .. 4
M ERCHANDISING DEPARTM ENT .. .... ... .... ... .... .... ... .... . .. .... .... ... .... ... .... ... .... . .. .... .... ... .... ... .... ... .... . ... ... .. 6
PATTERN M AKING DEPARTM ENT/ CAD depar t ment . ... .... .... ... .... ... .... ... ... . ... .... .... ... .... ... .... ... ... . .... ... .. 7
Job Rol e of Pat t er n M aker .... ... .... ... .... ... .... .... ... .... ... .... ... .... .... ... .... ... .... .... ... .... ... .... ... .... ... .... .... ... .. 7
PLANING DEPARTM ENT . ... .... .... ... .... ... .... ... ... . .... ... .... ... .... ... .... .... .. . .... ... .... .... ... .... ... .... .. . .... ... .... .... ... .. 9
WORK-STUDY DEPARTM ENT .... ... .... ... .... ... .... .... ... .... ... .... ... .... .... ... .... ... .... .... ... .... ... .... ... .... ... .... .... ... 10
Job Rol e of I .E Of f i cer . ... .... .... ... .... ... .... ... ... . .... ... .... ... .... ... .... .... .. . .... ... .... .... ... .... ... .... .. . .... ... .... .... ... 10
Ef f i ci ency and Per f or mance Cal cul at i ons .... .... ... .... ... .... ... .... ... . ... .... ... .... ... .... .... ... ... . ... .... .... ... .... ... 12
HOW TRIM S ARE IN-HOUSED, STORED AND ISSUED FROM THE FACTORY . ... .... .... ... .... ... .... ... ... . .... ... 15
GRN r ai si ng .. ... .... ... .... ... .... .... ... .. .. ... .... ... .... .... ... .... ... .. .. .... ... .... ... .... ... .... .... . .. .... ... .... ... .... ... .... .... . .. 15
TRIM INSPECTION .. .... .... ... .... ... .... ... .... . .. .... .... ... .... ... .... ... .... . ... ... .... ... .... ... .... .... ... . ... ... .... .... ... .... ... 16
I SSUE NOTE . ... .... ... .... ... .... .... ... ... . ... .... .... ... .... ... .... ... ... . ... .... .... ... .... ... .... ... ... . .... ... .... ... .... ... .... .... .. . 18
HOW FABRICS ARE I N-HOUSED, STORED AND ISSUED FROM THE FACTORY .. ... .... ... .... ... .... .... ... .. .. ... 19
Fabr i c i nspect i on ... .... ... .... .... ... .... ... .... .... ... .... ... .... ... .... .... ... .... ... .... ... .... ... .... .... ... .... ... .... ... .... .... ... 19
Vi sual Inspect i on f or def ect s .... ... .... ... .... .... ... .... ... .... .... ... .... ... .... ... .... ... .... .... ... .... ... .... ... .... ... . ... 19
Shr i nkage t est . ... .... .... ... .... ... .... ... ... . ... .... .... ... .... ... .... ... ... . .... ... .... ... .... ... .... .... .. . .... ... .... .... ... .... ... 22
Shade band pr ocess .. .... .... ... .... ... .... ... .... . ... ... .... ... .... ... .... .... ... . ... ... .... .... ... .... ... .... ... . ... ... .... .... ... 22
QUALITY CHECKI NG PROCESS ... ... .... ... .... ... .... .... ... . ... ... .... .... ... .... ... .... ... . ... ... .... .... ... .... ... .... ... . ... .... ... 26
Job Rol l of Qual i t y Super vi sor .. .... ... .... ... .... .... ... .... . .. .... .... ... .... ... .... ... .... . .. .... .... ... .... ... .... ... .... . ... ... 26
Job Rol l of Qual i t y Checker ... ... .... ... .... ... .... .... ... . ... ... .... .... ... .... ... .... ... . ... ... .... .... ... .... ... .... ... . ... .... ... 29
Job Rol l of Qual i t y I n char ge.. ... .... ... .... ... .... .... ... .. .. ... .... ... .... .... ... .... ... .. .. .... ... .... ... .... ... .... .... . .. .... ... 30
FINI SHING ... .... ... .... ... .... ... .... .... ... .... ... .... ... .... ... .... .... ... .... ... .... .... ... .... ... .... .... ... .... ... .... ... .... .... ... .... ... 31
Washi ng r ecei vi ng . .... ... .... .... ... .... ... .... .. .. ... .... ... .... ... .... .... ... .. .. ... .... ... .... ... .... .... ... .. .. ... .... ... .... .... ... 31
Fi ni shi ng & Pol y bag Packi ng . ... .... ... .... ... .... .... ... ... . ... .... .... ... .... ... .... ... ... . ... .... .... ... .... ... .... ... ... . .... ... 31
Car t on pr ocess ... ... .... .... ... .... ... .... ... . ... ... .... .... ... .... ... .... ... . ... .... ... .... ... .... ... .... .... ... .... ... .... ... .... ... .... 32
Doi ng FA (Fact or y Audi t ) ... .... ... .... ... .... ... .... .... ... .... ... .... ... .... ... .... .... ... .... ... .... .... ... .... ... .... .... ... .... ... 33
WARE HOUSE .. ... .... ... .... ... .... .... ... .. .. ... .... ... .... .... ... .... ... .. .. .... ... .... ... .... ... .... .... . .. .... ... .... ... .... ... .... .... . .. 33
Car t on .. ... .... ... .... ... .... .... ... .. .. ... .... ... .... ... .... .... ... .. .. ... .... ... .... .... ... .... ... .. .. .... ... .... ... .... ... .... .... . .. .... ... 33
CIF (Cent r al Inspect i on Faci l i t y) .... ... .... ... .... .... ... .... ... .... .... ... .... ... .... ... .... ... .... .... ... .... ... .... ... .... ... . ... 33
Loadi ng.... .... ... .... ... .... ... .... ... . ... .... ... .... ... .... .... ... ... . ... .... .... ... .... ... .... ... ... . ... .... .... ... .... ... .... ... ... . .... ... 33
Syst em char t pr ocess map .... .... ... .... ... .... ... .... ... . ... .... ... .... ... .... .... ... ... . ... .... .... ... .... ... .... ... ... . ... .... .... ... 34
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WASH RECEIVE ... ... .... .... ... .... ... .... ... . ... ... .... .... ... .... ... .... ... . ... .... ... .... ... .... ... .... .... ... .... ... .... ... .... ... .... 34
FINISHING/ POLY BAG PACKI NG ... ... .... .... ... .... ... .... ... . ... ... .... .... ... .... ... .... ... . ... .... ... .... ... .... ... .... .... ... 35
FINI SHING / CARTON PAKING .. .... ... .... ... .... .... ... .... . .. .... .... ... .... ... .... ... .... . .. .... .... ... .... ... .... ... .... . ... ... 35
FACTORY AUDI T .. ... .... ... .... .... ... .... ... .. .. .... ... .... ... .... ... .... .... . .. .... ... .... ... .... ... .... .... . .. .... ... .... ... .... .... ... 35
WARE HOUSE/ LOADING ... .... ... .... ... .... ... .... .... ... .... ... .... ... .... ... .... .... ... .... ... .... .... ... .... ... .... .... ... .... ... 35


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ST ART T O END PRECESS CHART


Obt ai n t ech
pack f r om
Cost i ng Sampl i ng
Cost sheet sampl e send t o
buyer f or appr oval
Anal yze cost of t r i m
and f abr i c
Obt ai n gener al sew i ng
dat a f r om IED
Devel op
sampl e as per
Devel op
pr ot o sampl e
Conf i r mat i on
of or der
Sour ce t r i ms and f abr i c
f r om concer n ed dept .
Book w ashi ng and embr oi der
capaci t y i f r equi r ed
Obt ai n PCD det ai l s
f r om pr oduct i on
uni t s
Hol d pr e-pr oduct i on meet i ng
w i t h pr oduct i on uni t
Obt ai n GSD f r om I ED
Execu t i on of or der by ent er i ng det ai l s i n ERP
Anal yze f abr i c
consump t i on f r om
CAD
Pr epar e cost sheet f r om sampl e

Cost sheet
r ew or ked
Execu t e
bul k or der
Fol l ow up w i t h
pr oduct i on depar t ment
& updat e t h e buyer
Submi t r equi r ed
documen t s t o
documen t at i on dept .
Of f er gar men t s f or
f i nal i nspect i on.
Tr uck out
Appr oval
Pr epar e sampl e as per buyer r equi r ement s
For w ar d t he sampl e t o buyer f or appr oval
Appr oval Comment s r ecei vi ng f r om buyer shoul d be
i ncor por at ed and f i t sampl e r ew or ked
Fol l ow up on
t he payment s
f or goods
YES NO
YES NO
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PRODUCT DEVELOPM ENT ( SAM PLE ROOM )
When t he mer chant r ecei ved t he Tech-pack f r om t he he ar r ange a pr oduct scr eeni ng meet i ng w hi ch
i s a 15mi n. di scussi on bet w een mer chant and seni or t echni ci ans. At t hi s t i me t hey consi der f i ve
maj or poi nt s
Cycl e t i me t he t i me t aken t o compl et e 01 gar ment
(i f i t is nor mal w ash most pr obabl y 5days)
Fabr i c w het h er t he f abr i c i s sui t abl e f or our machi ner i es
(as an exampl e kni t t ed f abr i cs and t hi n w oven f abr i cs ar e not f easi bl e w i t h t he
machi nes i n Br andi x casual w ear )
Wash have consi der about f abr i c gauge
coz t hi n f abr i cs cannot use har d w ash
M achi ner i es have t o check w het her w e have enough Saw i ng machi ne t yp es t o devel op i t
Const r uct i on somet i mes w e ar e not abl e w i t h t he desi gn pr act i cal l y.
If i t can devel op pat t er n maker dr aw t he pat t er n usi ng spec and make a mar ker t o cal cul at e t h e YY
(yar ds per yi el d) and next mar ket i n g depar t ment consi der l abor cost , machi ne cost , YY val ue and all
t he ot h er cost and addi ng some buf f er and gi vi ng t o t h e buyer t he cost . I f buyer i s OK w i t h t he cost
t hen st yl e hand over meet i ng i s bei ng hel d.
The key t eam i n t hi s meet i ng i s : -M er chant
Pat t er n M aker
Techni cal Of f i cer
Wor k-st udy Of f i cer
i f t he st yl e i s f easi bl e t he mi nut es of t he meet i ng (const r uct i on det ai l r ecor di ng sheet ) i s handover
t o ever yon e t o devel op t he sampl e. But t h e mer chan t has t o book a pl an f r om t he pl anni ng
depar t ment 03 days bef or e maki ng t he sampl e. Af t er t hat syst emat i cal l y devel opi ng t he sampl e

Pl ani ng
Sect i on
Package
Recer vi ng
Sect i on
Pat t er n
Sect i on
Cut t i ng sect i on
Pr i nt &
Embroi der
Sect i on
Sew i ng sect i on i n l i ne QC
Washi ng
sect i on
Fi nal QC
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Somet imes more samples have t o send t o t he buyer . They are,
• Sal esmen sampl es or pr omot i onal sampl es
• Pr ot o sampl es or f i t sampl es
• Count er sampl es or r ef er ence sampl es or appr oval sampl es
• Wash t est sampl es
• Phot o sampl es
• Fashi on show sampl es
• Pr e-pr oduct i on sampl es
• Pr oduct i on sampl es
• Shi pment sampl es

- Salesmen samples or pr om ot i onal samples
Some buyer needs t hese sampl es f or get t i ng t he or der s f r om t hei r cust omer s. If t he buyer i s havi ng 7
sal esmen i n his of f i ce, t hen t he bu yer w i l l ask us t o make 7 sampl es i n each st yl e. The sal esmen w i ll
book t he or der s f r om t hei r cust omer s, by show i ng t hese sampl es. Buyer w i l l pl ace t he or der t o us
accumul at i ng t he quant i t i es.

- Phot o samples or f it samples
These sampl es ar e t o be made af t er get t i ng t h e or der sheet s. These sampl es ar e needed t o check
t he measur emen t s, st yl e and f i t . So t hey can be made i n avai l abl e si mi l ar f abr i cs but i n t he act ual
measur ement s and speci f i cat i ons.
Some buyer s may need t h ese sampl es i f t hey w ant t o pr i nt t he phot os of gar ment s on phot o i nl ays,
packi ng box, hang t ag, et c. These sampl es may be needed f or l ocal adver t i semen t or buyer ’ s
pr omot i onal occasi ons.

- Count er sam ples or ref erence samples or approval sampl es
These sampl es ar e t o be made i n act ual f abri cs wi t h act ual t r i ms. If t he or der i s f or 3 col or s, buyer
may need sampl es i n any one col our and sw at ches (f abr i c bi t s) i n ot her col or s. These sampl es shoul d
be st r i ct l y as per t he speci f i cat i ons i n t he or der sheet s. We have t o get t he appr o val f or t hese
sampl es f r om t he bu yer bef or e st ar t i ng pr oduct i on.
Af t er get t i ng t h e appr oval , t he appr oved sampl es shou l d be f ol l ow ed i n pr oduct i on. Somet i mes,
buyer may co mmen t on f abr i c, measur ement s, maki ng, et c. We have t o f ol l ow hi s comment s
car ef ul l y i n pr oduct i on.

- Wash t est sam pl es
If t hese sampl es ar e sent bef or e st ar t i ng pr oduct i on and i f w e get some r emar ks or comment s on
t hese sampl es, w e can cor r ect t hem i n pr oduct i on. But some buyer s w i ll need us t o send t hese
sampl es f r om pr oduct i on bef or e shi pment . I n t hi s case, t hese sampl es may be consi der ed as
‘ shi pment sampl es’ .

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M ERCHANDI SI NG DEPARTM ENT
M er chandi ser has t o do a maj or r ol e i n gar ment i ndust r y. When buyer sends t he t ech-pack he have
t o t ake t he r esponse t o or der t r i ms and f abr i cs, make t he sampl e and sent t o buyer s, and cost t he
sampl e and negot i at e t h e Best Deal . M er chant have t he r esponsi bi l i t y t o del i ver t h e goods on t i me.
To do t hi s j ob easi l y and neat l y M er chandi si ng has di vided i nt o t o sever al cat egor i es.
Devel op ment M er chant : Fr om t he begi nni ng t o PP appr oval Devel op men t mer chant has t o deal
w i t h Buyer s and make t he busi ness. And al so he has t o do an i ni t i al booki ng t o devel op sampl es
Oper at i on M er chant : accor di ng t o t he or der op er at i o n mer chan t has t o pr epar e cut l et t er s. Thi s cut
l et t er s ar e ver y usef ul t o i dent i f y t he st yl es unt i l t he end of t he pr ocess
Pr ocur ement M er chant : has t o or der t he t r i ms and f abr i cs accor di ng t o t he buyer s r equi r ement s
and bui l t PO number s t o t h e st yl e.
M ost pr obabl y gar ment f act or i es pur chase t he or der s f r om nomi nat e suppl i er s.
Ther e ar e man y advant ages and f ew di sadvant ages of deal i ng onl y w i t h nomi nat e suppl i er s.
Advant ages
 They al w ays t r y t o mai nt ai n t hei r goodw i l l.
 Wor k accur at el y i n t o deadl i nes.
 Easy t o i dent i f y t h e goods f r om Tr ademar ks.

Di sadvant ages
 Nomi nat e suppl i er s may l i t t l e bi t expensi ve t han ot her s.

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PAT T ERN M AKI NG DEPART M ENT / CAD depar t ment

Comput er -ai ded desi gn (CAD) i s used by t he t ext i l e i ndust r y t o i mpr ove desi gn capabi l i t i es and t o
documen t t he desi gn pr ocess. CAD sof t w ar e f or t ext i l es i s desi gned t o st r eaml i ne t he desi gn si de of
t he busi ness and of t en of f er s cost -savi ng benef i t s
Job Rol e of Patt er n M ak er
Have t o dr aw t he pat t er n accor di ng t o t ech-pack and t hey have t o make changes accor di n g t o
cust o mer ’ s comment s. When t hey dr aw a pat t er n t hey have t o add t he saw i ng l ost and shr i nkage
per cent age al so. (M ockup and shr i nkage sampl e i s done f or f i nd t hi s) af t er t hat t hey dr aw a mar ker
f or t he f i r st sampl e t hat sends t o buyer i t s cal l 1
st
f i t and i t made of avai l abl e t r i ms & f abri c.
Accor di ng t o buyer s comment s most pr obabl y have t o go f or 2
nd
3
r d
t i l l buyer sat i sf i es w i t h t he st yl e.
Then af t er buyer ok w i t h t he f i t he ask t o send t he PP sampl e i t i s t he f i nal sampl e w hi ch made of
act ual t r i ms and f abri cs.

Di f f er ent t ypes of CAD sof t w ar e can be used t o desi gn cur ves and f i gur es i n ei t her 2D, 3D or bot h.
Gerber' s Text ile CAD Sof t w are
US-based Ger ber Technol ogy r ecent l y i nt r oduced a new ver si on of i t s AccuM ar k CAD sof t w ar e cal l ed
AccuM ar k 8.4.1. The new t echnol ogy can be used f or pat t er n desi gn, mar ker maki ng, gr adi ng and
nest i ng. Accor di ng t o t he co mpany i t can pr ot ect agai n st l ost w or k i n t he event of pow er f ai l ur es and
hel ps t ext i l e f i r ms t o mi ni mi ze f abr i c w ast e.
CAD Sof t w are f rom Lect r a
Fr ench compan y Lect r a al so speci al i zes i n pr oduci ng CAD sof t w ar e f or t ext i l es. It s l at est i nnovat i ons
i ncl ude: Kal edo (V2R1) t o hel p f i r ms i mpr ove br andi ng and pr oduct desi gn t o st r eaml i ne t he desi gn
devel opment pr ocess; M odar i s (V6R1), w hi ch speeds up t he pat t er nmaki ng pr ocess; and M osaïc, a
syst em f or pr ocessi ng pat t er ned f abr i cs.

Tuka CAD
The l at est CAD sof t w ar e t hat br andi x use i s TUKA Cad
W hy Choose TUKAcad
TUKAcad i s t he f ashi on i ndust r y' s most advanced CAD sof t w ar e syst em. Devel oped by pr ogr ammer s
w i t h exper i ence i n t he gar ment i ndust r y, TUKAcad i s t he w or l dw i de st andar d i n CAD syst ems.
Tukat ech of f er s ext ensi ve t r ai ni ng and unpar al l el ed cust omer suppor t t o ensur e t hat each cust omer
f ul l y ut i li zes all of TUKAcad' s many t i me-savi ng f eat ur es.




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Com parison bet w een CAD marker making & manual marke r making:

1. I n manual syst em t h e syst em i s used t o make maker f or gar ment maki ng i s t r adi t i onal .
But i n CAD syst em mar ker maki ng i s done i n moder n syst em.
2. M ar ker ef f i ci enci es i s not vi si bl e i n manual syst em. Ot h er hand, mar ker ef f i ci ency i s vi si bl e i n CAD
syst em.
3. M arker l engt h i s not vi si bl e i n manual syst em. M ar ker l engt h i s vi si bl e i n moni t or scr een at CAD
syst em.
4. In manual , once mar ker i s made, not possi bl e t o i ncr ease i t s ef f i ci ency. But i n CAD i t i s possi bl e t o
i ncr ease t h e ef f i ci ency at any t i me.
5. M arker copyi ng i s not possi bl e manual l y. I n CAD, by usi ng Pl ot t er as much as possi bl e copy can be
done.
6. M anual mar ker maki ng is ver y t i me consumi ng met hod w her eas, CAD i s a f ast er met hod.
7. In manual syst em qual i t y cannot be assur ed. I t has qual i t y assur ance.
8. M anual syst em cost i ng i s l ow but CAD i s expensi ve.

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PLANI NG DEPARTM ENT
Af t er t he mer chan t s book a dat e pl anni ng depar t ment makes a r uf f pl ans t o cut t i ng sect i on, t r i m
sect i on t o ch eck w het her t h e t r i ms and f abr i cs have i n-house t o t h e sampl e st or es i f t hat so cut t i ng
sect i on and t r i m sect i on pr epar e def er ent packages accor di ng t o di f f er en t booki ngs and mar k t he
compl et e packages and gi ve back t he r uf f pl ans t o t he pl anni ng depar t ment . Then t he pl anni ng
depar t ment pr epar es t he f i nal pl an t o devel op t he sampl e and gi ve i t t o w or k-st udy of f i cer s t o dr aw
l i ne w i se l ayout s t o t he pr oduct i on f l ow

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WORK- ST UDY DEPARTM ENT

Job Rol e of I .E Offi cer
M ont hl y Rou t i ng:
1. Li st t he machin e r equ i r ement by cal cu l at i ng & send i t t o t h e w o r k st ud y o f f i cer i n
pl annin g.
 Shoul d do f o r al l st yl es of next mont h pl an at 25
t h
o f t he mont h.
2. End of t he 2
nd
w eek; pr ep ar e t h e machine r equ i r ement o f t he n ext 2 w eeks by
con si der i ng t h e r evi si on o f t he pl an& gi ve i t t o t he wo r k st u dy o f f i cer in pl anni ng.
3. Do gradi ng f o r op er at or s & f or h el pers.
 Do i t f or af t er 6 mont hs.
 For n ew oper at o r s – af t er 3 mont h s.

Dai l y Rou t i ng:
1. Ch eck t he ab sen t eei sm o f t he li n e & b al an ce t he l i ne f or act u al cadr e w i t h r unn in g
ef f i ci ency l evel .
 It sh ou ld be f i l l in g f or agr eed l ayou t of cadr e.
2. Pr epar e i ncent i ves of t he l in e & show i t t o t he l ine.
3. Fi ll t he r eason & t r ansf er r i ng f o r m of pr evi o us d ay.
 Need t o hi ghl i ght f act or y lo ss hour s & accu r acy.
4. Par t i cip at e t o dai l y f or ecast meet i ng at 9. 00 A.M .
5. Do capaci t y st udy f or r ep l aced op er at or s, i f t h ey ar e no t p er f o r mi ng t o meet t h e
t ar get .
6. Do t he p r odu ct i on st ud y f or bot t l e n eck op er at i ons.
 Ar r ange t he handl in g.
 Redu ce t h e unn ecessar y mo t ion s.
 Do t he p r odu ct i on st ud y f or 30 mi nut es.
 Fi ll t he p r odu ct i on / t i me st ud y sheet .
 End of t he st udy, show i t t o t he o per at or & si gn i t .
7. Int er vi ew t he n ew r ecr ui t men t s.
8. Impr o ve t h e met h od s of op er at i on s accor ding t o t he GSD pat t er n.




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Fo r new st yl e:
1. Af t er r ecei ve t he pr od uct io n pl an, get t he st yl e f i l e & ch eck i t wi t h t he ap pr o ved
sampl e.
 Revi se t h e oper at i on s of st yl e f i l e i f need , i nf o r m i t t o GSD cel l & get t h e f inal
st yl e f i l e.
2. Par t i cip at e t o PP meet i ng.
3. Par t i cip at e t o t ech ni cal meet i n g.
 Di scuss t echni cal i ssues & met hods of sew i ng
4. Pr epar e t he machi ne l ayout .
 Consi d er t he det ai l s whi ch w er e d i scussed at t he t ech ni cal meet i n g.
 That should pr epar e t o achi eve t h e 100% ef f i ci ency.
5. Ar r ange t he l ayo ut meet i n g.
 Di scuss t he op er at i ons & op er at or s w h o ar e sui t abl e f or t he o per at i ons
accor d in g t o t h e machin e l ayou t .
6. 1 1/2 days b ef or e o f t he l i ne f eedi ng shou ld p r ep ar e t he f eedi n g p l an & gi ve i t t o
t ech ni cal d ep ar t men t & t o pr odu ct i on sup er vi sor .
 For p r ep ar e t hat n eed t h e WIP of pr evi ou s day.
7. Ar r ange t he machin es accor di ng t o t he machi ne l ayo ut .
8. Ch eck t he t h r ead co nsumpt i on of t he bul k out put o f 1
st
day.
 Ch eck t he t h r eads w hi ch r el evant t o t h e oper at i on w i t h t he t hr ead sheet .
 Wh en t her e i s r evi si ng of t hr ead s should in f or m t o t he GSD cel l .
9. At t he 4t h d ay of af t er l in e f eed i ng, do capaci t y checks f or each op er at or & f or
hel p er .
 Fi ll & i ssue t he l ine b ar ch ar t sh eet .
 Shoul d ach i eve t he pl anni ng peak ef f i ci ency l evel .
 Id en t i f y t he cr i t i cal oper at i ons & bal ance i t w i t h t he oper at o r s & h el p er s.
10. Do t he p r odu ct i on st ud y, i f necessar y & p r ove t h e capaci t y.
11. If t h er e i s a cr i t i cal op er at i on w hi ch has not been ach i eved t h e SM V, it sh ou ld b r in g
t he mot i ons of t h e oper at i on f r om GSD cel l .
 If it i s need t o r evi se t he mot ions, inf o r m i t t o t he GSD cel l.
KPI`S
1. Achi eve t he pl an ef f i ci ency.
2. Achi eve t he pl an SAH (St andard Act ual Hour s).
3. Achi eve t he pl anni n g pi eces.
4. Inno vat i on s- savi n g of SM V


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Effi ci ency and Per for mance Cal cul at i ons

F¡¡|c|ency ( u¡ |nd|u|dua|)

=
nu. u¡ pruduced p|ecex × SMF u¡ that act|u|ty.
wurk|ng m|nutex
× 1ûû



L|ne e¡¡|c|ency

=
nu. u¡ pruduced 6mtx × SMF u¡ that 6mt.
nu u¡ uperaturx × wurk|ng m|nutex
× 1ûû

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SM V
SM V – t i me t h at i s allo w ed t o per f or m t he jo b sat isf act or y.
SM V = Basi c t i me + Al lo wances
St andar d M i nut e Value



Basic Time
The basi c t ime f or t he oper at ion is f ound by appl yi ng concept of rat i ng t o relat e t he obser ved t o
t hat of a st andard place of w orking.
Cal culat ed as f oll ow s:
Basic t ime = obser ve d t ime * obser ved r at i ng
100
(BT = Obser ved t i me * Obser ve d Rat ing = A const ant )
100













Types of allow ance
1. relaxat ion allow ance
Per sonal needs (f r om 5 t o 7% of basi c t i me)
Basi c f at i gue (4 % of basi c t i me)
2. Cont ingency All ow ances
(l ess t han 5 per cent )
3. M achine at t ent ion All ow ance s
Si ngl e needl e l ockst i t ch – 9% - 12%
Doubl e needl e l ockst i t ch – 14% - 17%
Thr ee t hr ead over l ock - 7%
Four t hr ead over l ock - 9%
Fi ve t hr ead over l ock -11%

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SM V calculat ion














Tot al basic t ime/ garment (brought f orw ard) 1 . 416
Add machi ne at t ent i on al l ow ances 7%
7% f or (0.480 + 0.504) = 0.07 x 0.984 = 0.069 0.069
Basic t ime + M AA (1. 416 + 0. 069) 1 . 485
Add per sonal n eeds and r el axat i o n al l owances 14%
14% of 1.485 = 0. 14 x 1.485 = 0.208 0.028
St andard minut e Value (SM V) = Basi c t ime + all allow ances 1 . 693

GSD – General Sawi ng Dat a
Accor d ing t o ISO Pr odu ct i vi t y, GSD (Corp or at e) Lt d . Have gi ven st andard mi nut e val ues f or
each of ever y Gar ment s Op er at i ons, u sing t h ese SM V val ues can get a idea about t he cost o f
t he gar ment .





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HOW T RI M S ARE I N- HOUSED, ST ORED AND I SSUED FROM T HE FACTORY
Suppl i er s suppl i es t he goods w i t h a “PACKING LI ST” and “INVOICE”, Co mpar e t h e goods i n t h e
vehi cl e w i t h t he PACKI NG LI ST b y STORE KEEPER and in-house t h e Goods. Onl y t he l abel s and boxes
ar e checked b y t he St or e keeper accor di ng t o t he “PACKI NG LI ST” and “INVOICE”.






 If t her e i s,
Excessi ve suppl y,
Not enough Goods,
Not i n Good condi t i ons, have t o i nf or m t o M ERCHANT i mmedi at el y.
Then STORE KEEPER gi ves t he i nvoi ce + ad vi ce not e + packi ng l i st t o GRN Rai si ng t eam an d
same t i me t he copy of t hose d et ai l sheet s gi ves t o Locat i on ow ner s i n t he St or es. Col l ect s hi s goods
and he st or e i n a sui t abl e l ocat i on. Locat i ons ar e cat egor i zed as It em w i se and sub cat egor i zed as
buyer w i se.







Then he co mpar es t he goods w i t h i n voi ce and a coun t i s t aken af t er checki ng t he cont ent s i nsi de. If
t he quant i t y i s equal t hr ough STORE KEEPER he t el l s t o GRN Rai si ng t eam t o r ai se a GRN.
GRN r ai si ng
In t hi s st ep al l t he goods w e r ecei ved i s ent er ed t o t he i NCITO Syst em and t i l l t he quali t y
i nspect i on i s passed i t i s aut omat i cal l y l ocked t hr ough t he syst em t o i ssue Del i ver y Advi ce Not e
(DAN) or Fact or y I ssue Not e (FIN)


TEL :
PO # :
DESIGN :
QTY : WGT:
BOXES __OF___
C/ N :
PACKING LIST

I NVOI CE



Label St i cker Zi pper
Pol y
bags
Tags But t on
M & S
GAP
M & S
GAP
M & S
GAP
M &S
GAP
M & S
GAP
M & S
GAP
Locat i on ow ner s’
(Hel per )
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Af t er GRN i s r ai sed St or ekeep er gi ves t he GRN copi es t o Rack l ocat i on ow ner and t o t rim inspect i on
t eam.
TRI M I NSPECT I ON
Tr i m i nspect i on t eam have t o t ake a r andom st ock accor di ng t o Gener al I nspect i on Level t o check
t he qual i t y. Ther e ar e def er ent sampl e si zes f or Sew i ng t r i ms and Packi ng t r i ms and sampl e si ze
dep ends on t he bat ch si ze t oo.
GENERAL I NSPECTION LEVEL
(SI NGLE NORM AL -03)
LOT OF BATCH SIZE SAM PLE SIZE ACCEPTABLE LEVEL ACCEPTABLE LEVEL
(SEWING -1. 5) (PACKI NG – 2.5)
8-5 5 0 0
16-25 8 0 0
26-50 13 0 0
51-90 20 0 1
91-150 32 1 2
151-280 50 2 3
281-500 80 3 5
501-1200 125 5 7
1201-3200 200 7 10
3201-10, 000 315 10 14
10,001-35, 000 500 14 21
35,001-150,000 800 21 21
150, 000-500,000 1250 21 21

Sew i ng Trims and t heir i nspect ion point s












Tre ad TKT
FLY
DYE PATCH
Zipper SEAM ALLOW ENCE
Top
Bot t om
Si de

LOGO EM BOSE
FUNCTION
Label INSTRUCTI ON
SEAM ALLOW ENCE
WEAVING DEFECTS
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Packing Tri ms and t heir inspect ion poi nt s










Tape DYE PATCH
WEAVING DEFECTS
Vel cro DYE PATCH
SEAM ALLOW ENCE
Elast ic DYE PATCH
SEAM ALLOW ENCE
Hanger Loop DYE PATCH
WEAVING DEFECTS
SELVAGE DAM AGE
Buckle NORM AL
CROSS CHECKING
L-SI DE/ R- SIDE
But t on LINE
LOGO EM BOSE
Hook & bar / Revert s FIX IT
PROPERLY
HOOK HIGHT
Hanger ADJUSTABLI TY
Size t ab FI X ABI LI TY
Tag / st icker INSTRUCTI ON
BARCODE READING
Pol y bag INSTRUCTI ON
CLOSE ENDS
GAUGE
Cart ons FI X ABI LI TY
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Those t r i ms ar e checked w i t h an appr oved t r i m car d and pr epar e anot her f ew t r i m car ds.

And t he l ocat i on ow ner compar es t he goods quant i t y agai n w i t h t he GRN
 If not t al l y w i t h GRN t hr ough STOREKEEPER t h e Locat i on ow ner r epor t s t o GRN r ai si ng t eam.
<ver y r ar el y t hi s happens >
 If t all y t hen he w ai t s unt i l he r ecei ved I SSUE NOTE
I SSUE NOT E
ISSUE NOTE i s pr epar ed by t h e coor di nat or f r o m iNCI TO Syst em. Pl anni ng d epar t ment send t h e
Pl ans t o t h e coor di nat or . And t he PURCHACE ORDER + TRI M REQUIREM ENT SHEETS + o t h er
det ai l s ar e al r ead y updat ed i n t h e i NCI TO. Th e coor di nat or conceder t hose det ai l s and makes
t he I SSUE NOTES f or each of ever y TRIM Cat egor y and del i ver i t t o t h e sui t abl e Locat i on ow ner s’
accor di ng t o i ssue not es l ocat i on ow ner have t o i ssue t he exact amount of t r i ms t o t he cor r ect
pl ant .
 To but t on l ocat i on ow ner i t i s i mpossi bl e t o count t h e exact amount of but t ons i n i ssue
not e. So h e consi der s t he amoun t s have l abel ed i n t he packages and f or t h e def i ci ency
t her e i s a scal i ng syst em.




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HOW FABRI CS ARE I N- HOUSED, ST ORED AND I SSUED FROM T HE FACT ORY
Accor di ng t o st yl e w hi ch buyer r equi r es, our w ashi ng pl ant pr epar es 3Lap-di ps and send i t t o buyer s


If buyer r equ est s t he col our B, w e sel ect a suppl i er avai l abl e t o suppl y B and r equest col our B f r om
hi m. Then he pr epar e a dye r eci pe dye a sampl e r ol e and suppl i er says he can suppl y us t he col our
w i t h ± Rongc


Then i t al so sends t o t he suppl i er and has t o t ake an appr oval . M ost pr obabl y happeni ng i s i f t he
r ange i s al r eady appr oved i n buyer s manual or i t i s i n range of 4-5 i n gr ay scal e w e al l ow t o suppl i er
t o suppl y t he f abr i cs
The STORE KEEPER ch ecks t h e f abr i cs w i t h t he PACKING LIST based on Rol l er s and Col or s
Then he i n-house t he r ol l er s, col or w i se. Af t er i nspect i ng al l t he r ol es t hose r ol es ar e l abel ed f r om a
st i cker w hi ch cr eat es f r om t he FOSS syst em, i t cont ai ns bar code and PO i nf o. As soon as t he f abr i cs
i s unl oaded t o pal l et s and st or ed i n t he quar ant i ne ar ea, dependi ng on w het her or not t he f act or y
has r ecei ved t he head- end(1/ 2yr d * f ul l wi dt h). It i s t he dut y of t he M ESURING TEAM t o t ake head-
end of each r ol e and measur e t he cut -abl e w i dt h. Then i t sends t o t he f abric i nspect i on depart me nt .
At t he same t i me t he f abr i c r ol es ar e pl aced i n r acks. Then a st i cker i s past ed on t he pal l et and t hen
i s shi f t ed on t o t he r ack ever y r ack consi st of a bar code, t hr ough a bar code r eader t h e bar cod es of
t he r ol es and t he pal l et s ar e l i nked wi t h t he bar code i n t he r ack t o t he FOSS Syst em.

Fabr i c i nspect i on
Vi sual I nspect i on for defect s
Sampl e sel ect i on
Except smal l quant i t y of bul k and If buyer haven’ t r equi r ed a speci al per cen t age or t h e
sampl i ng, M ost pr obabl y 10% sampl i ng i s done.
Fr om t he packi ng l i st and i nvoi ce w e can see t h e co mbi nat i on of dye l ot s accor di ng t o
r ol es. So w e consi der t he r at i o of t he r ol es i n di f f er ent dye l ot s and do t he 10% sampl i ng

STANDARD: 4 poi nt syst em







How t o gr ade t he sampl es accor di ng t o def ect s

Range poi nt s
Def ect l engt h l ess t han 3 i nches 1
bet w een 3 i nches-6 i nches 2
bet w een 3 i nches-6 i nches 3
mor e t han 9i nches 4
POINTS PER 100 yr d
2

A C
B B B B B
B
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Def ect s on yar n;
• Br oken end/ pi cks-w her e a f i ll i ng / end br eak l eaves a pi ck/ w r ap mi ssi ng f or a por t i on
of t he w i dt h/ end of t he f abr i c.
• Coar se en d/ pi cks- an end/ pi ck w hose di amet er i s not i ceabl y gr eat er t han t hat
nor mal t o t he f abr i c.
• Fi ne ends/ pi cks- an end/ pi ck w hose di amet er i s not i ceabl y smal l er t han t hat nor mal
t o t he f abr i c.
• Knot s- a pl ace w her e t w o ends of yar n ar e t i ed or ball ed t oget her .
• Neps - an excessi ve amoun t of t angl ed masses of f i ber (neps) appear i ng on t he
f abr i c.
• Sl ub- a shor t t hi ck pl aces i n a yar n usual l y symmet r i cal .

Def ect s on w eavi ng;
• St op mar k- a def ect r esul t i ng f r om t he w ar p yar n el ongat i ng under t ensi on w hi l e a
l oom i s st opped; w hen i t is st ar t ed agai n t he sl ackness i s t aken up by t he w eave,
l eavi ng a di st or t i on acr oss t he w i dt h of t he f abr i c.
• Thi ck pl ace- a l ace acr oss t he w i dt h cont ai ni ng mor e pi cks or heavi er f i l li ng t han t hat .
• Thi n pl ace- a l ace acr oss t he w i dt h cont ai ni ng l ess pi cks or l i ght er f i l l i ng yar n t han
t hat nor mal t o t he f abr i c.
• Fl oat - a t hr ead ext endi ng unbound over or under t hr ead of t he opposi t e yar n syst em
w i t h w hi ch i t shoul d have been i nt er l aced.
• Hol e- a br eak i n t he f abr i c i nvol vi ng a mi ni mum of t w o or mor e yar ns.
• M i ss-pi ck- an i ncor r ect sequ ence of w el t i nser t i on

Def ect s on f i ni shi ng;
• Skew - i n w oven, w her e t he f i l l i ng yar ns ar e of f squar e t o t he War p en ds, i n kni t s.
Wher e t he cour ses ar e of f squar e t o t he Wal es.
• Bow - i n w oven’ s, w her e t he f i l l i ng yar ns li e i n an ar ea acr oss t he w i dt h of t he f abr i c,
i n kni t s, w her e t he cour ses l i e i n ar e acr oss t he w i dt h of t he f abr i c.
• Cr ease mar k- a mar k l ef t i n a f abr i c af t er a cr ease has been r emoved. I t may be
caused by mechani cal damage t o t he f i ber s at t he f ol d, by var i at i on i n t r eat ment du e
t o t he const r uct i on al ong t he f ol d, or by di st ur bance of t he f abr i c st r uct ur e.
• M i spr i nt -ei t her mi ssed, or par t i al l y mi ssed of pr i nt pat t er n.
• Smash- t he br eakage of a l ar ge number of w ar p ends, usual l y as t he r esul t of a
shut t l e t r ap.
• St ai n- col or st ai n or oi l st ai n.

Iotol points pcr rolc =
11P× 100
w
36
× L

=
11P× 3600
w× L


Iotol points pcr Consumption =
11P× 3600
W× L

Tot al poi nt s per al l r ol es
M i ni mum wi dt h f r om al l r ol es
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Af t er gi vi ng poi nt s t o sampl e r ol es t hey cut and past t he def ect t ypes i n a def ect card

Wi t hi n r ol l er col or var i at i ons (shadi ng)
In suppl i er s one dye l ot t h er e can b e many nu mb er of shade l ot s. Because of t hi s w e
cat egor i zed t he r ol es t o sever al shadi ngs and ent er t h e r esul t s t o t he FOSS syst em.
 In i nspect i on st age Lengt h wi se and w i dt h wi se shadi ng i s checked.
 Si de t o si de shadi ng and si de t o cent er shadi ngs ar e checked f r om t he 1/ 2yr d head- end.
 Shedding i s i mport ant very import ant t o decide t he maker t ype
M arker t ypes
Si de t o si de maker
one gar ment one si de
--- ---- ---- ---- ----- ---- ---- ----- ---- ---- ---- ------------- ---- --------------------- ----- ---- ---

Skew i ng/ Bow i ng
Si nce t he w eavi ng st age w ef t yar ns shoul d be per pendi cul ar t o t he w ar p yar ns i n a
Per f ect f abr i c. If not t her e can be pr oduced a Skew ed or Bow ed f abr i cs.










Skew i ng Bow i ng








Wh y i t i s i mpor t ant t o measur e Skew i ng and Bow i ng
 Because of Skew i ng t he f i nal gar ment can be t w i st .
 Ther e can be r ep eat var i at i on Check f abr i cs.
d
d
1

Per f ect w oven f abr i c
Take a head- end (6” or 9” x f ul l wi dt h)
f r om each of ever y sampl e r ol es by
t ear i ng. Keep on edge t o ot her edge and
f ol d t he f abr i c ver t i cal l y t o wef t s, t hen i f
i t i s a skewed f abr i c t her e wi l l be a
di st ance bet w een ot her t wo edges,
t her e i s an equat i on t o cal cul at e t he
skew i ng per cent age………………………………
xkew|ng percentage =
d
w
× 1ûû%
t he di st ance wher e measur e as “ d”
w – cut - abl e wi dt h of t he f abr i c
Take a head-end (6” or 9” x f ul l w i dt h)
f r om each of ever y sampl e r ol es by
t ear i ng. Keep on edge t o ot her edge and
f ol d t he f abr i c ver t i cal l y t o w ef t s, t hen i f i t
i s a bowed f abr i c t her e wi l l be a cur ved
l i ne w i t h a di st ance bet w een t wo ends,
t her e i s an equat i on t o cal cul at e t he
skewi ng per cent age………………………………..
huw|ng percentage =
d
1
w
× 1ûû%
t he di st ance wher e measur e as “ d”
w – cut -abl e wi dt h of t he f abr i c
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Shr i nk age t est
Shr i nkage t est i s done t o each of ever y head-end w hi ch got f r om ever y r ol l er . Soon af t er
t hey ch ecked shadi ngs t hey cut t he head- ends t o 2peases, one keep as bef or e w ash
sampl es and ot her Sampl es measur e t h ei r di mensi ons at sever al pl aces i n l engt h an d
w i dt h di r ect i ons and mar k t hose di mensi ons and sends t o w ashi ng pl ant . Af t er w e
r ecei ved t h e w ashed sampl es measur e t h e per cent age of shr i nkage. Al l t hese det ai l s ar e
ent er ed t o t he FOSS syst em.
What i s t he pur pose of measur i ng i t
It i s ver y i mpor t ant t o dr aw t h e mar ker , w hen w e dr aw i ng t he pat t er n t o w ash gar ment s
w e have t o add t he shr i nkage p er cent age an d dr aw t he mar ker i f not t h e gar ment w i l l be
not i n t he r equi r ed si ze af t er w ash.

Shade b an d p r ocess
Fr om t h e same sampl es w e used t o shr i nkage t est w e have t o ch eck t he col or
var i at i ons bet w een Rol es (shade) and have t o pr epar e a shade band
How t o pr epar e a shade band
To pr epar e a shade band w e have t o consi der t he shade and have t o check w het h er
i t i s mat chi ng t o t he buyer ’ s manual w hen i n def er ent l i ght sour ces.

Fol l ow i ng l i ght s ar e used i n col or box;
TL84 –Col or of Amer i can dayl i ght and most of Amer i can show r ooms use t hese col or s i n shops.
D65- Thi s l i ght i s ver y much si mi l ar t o t he day l i ght i n Engl and.
UV ( ul t r a vi ol et )-Thi s l i ght speci al l y used t o check w hi t e f abr i c as w el l as t o check t he cont r ast
f abr i c. In cont r ast f abr i c i t i s used check t he t r anspar ency of under par t s near t he seams.

REF CUSTOM ER PRIM ARY SECONDARY
01 M & S TL84 D65
02 LAND’ S END D65 U35
03 OLD NAVY U35 INCA
04 EB D65
05 GAP U35 INCA
06 BR INCA U35
07 COLOM BI A D65 TL84

Then t hey pr epar e a shade band and send t o buyer w i t h ot her r el evan t d et ai l s t o get t h e
appr oval .
At t he end of t he Fabr i c i nspect i on pr ocess t hey have t o appr ove t h e GRN, w i t hout appr ovi ng GRN
no one can make i ssue not es because t he syst em has bl ocked i t aut omat i cal l y.
What ar e t h e r equi r ement s shoul d be f i nal i zed t o approve a GRN
 Inspect i on r epor t
 Shade band
 Shr i nkage r epor t
 M ar ker t yp e appr oval
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Af t er t he GRN i s appr oved onl y coor di nat or can i ssue FIN (Fact or y Issue Not e) or DAN (Del i ver y
Advi ce Not e) accor di ng t o pl ans coor di nat or i ssue DAN and FIN and gi ves i t t o St or es. Fr om t he
st or es t he go t hr ough t h e

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Si ngl e needl e / cut t er

At t achi ng Faci ng at t ach, pocket bag, J-st i t ch,
Fl y at t ach
Out l i ne Si de seam out l i ne
Doubl e needl e / 3needl e

At t achi ng pocket At t ach, pat ch At t ach
Out l i ne Si de seam, edge out l i ne,
Over Lock

At t achi ng Si de seam, i nseam, Back r i se, Fl ap
edge, f aci ng edge, f l y edge
f eed of t he ar m

Out l i ne
Cl ean f i ni sh
Si de seam, I nseam,
Kansai Speci al


Fr ont pocket , wai st band cl ose
Bar t ack

Fr ont pocket , Pocket bag O/ L ends,
Loop At t ach, Fl y
But t on hol e

Nor mal hol e, Key hol e, Eye hol e




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Zi g Zag

Decor at i on
st i t ch
Label at t ach,
Seam cor ner as a decor at i on
Bl i nd Hem

Bot t o m hem
Sl eeve hem





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QUALI T Y CHECKI NG PROCESS
Job Rol l of Qual i t y Super vi sor
Do cument s n eed:
1. St yl e f i l e - Cont r act seal commen t s
PP meet i n g mi nut es
Tr i m car d
2. Cont r act seal samp l e
3. Upd at ed mai l s (by quali t y i n char ge)

Li ne f eedi ng:
 Par t i cip at e t o t he PP meet i n g.
Di scussi n g qu ali t y i ssues w hi ch can be o ccur at t he pr oduct i on.
 Ch ecki ng t he con t r act seal samp l e w i t h cont r act comment s & st yl e f i l e, i n o r der t o
mat ch t he cor r ect co nst r uct io ns acco r di n g t o co mmen t s & st yl e f i l e.
 Par t i cip at e t o t he t echni cal meet i n g.
Di scussi n g al l t he i ssues w hi ch coul d o ver co me at t he pr o duct i on accor di ng t o wo r k
st ud y l ayout .
 Pr epar e co mpon en t measur em ent sheet .
Has t o f ol l ow sampl e & spech sh eet .
 Ch eck machi ne r eq ui r em en t s of t he st yl e.
(Thr ead t yp e/ Ti cket u mb er / col our es/ sh ad i ngs/ SPI)
 Fi ll t he f eed i ng check l i st sh eet .
Techn i cal super vi sor i s gi vi ng i nst r u ct i on s of t h e oper at i on & compl et e a p i ece. Then
M O has t o co mp l et e 5 p i eces. It shou ld be checked & f il l t he f eed i ng ch eck l i st sh eet .
Wh en t her e i s damage i n on e pi ece, i t shoul d be cor r ect ed & wr i t e o n t h e ch eck l i st
sheet r egar di n g t hat i ssue.Wh en t h er e i s d amage t h an in on e pi ece, sh ou ld gi ve
i n st r uct ion s t o cor r ect i t & M O has t o compl et e 5 pi eces agai n . Qual i t y sup er vi sor
should check i t unt i l t he oper at i on i s cor r ect ed unt i l t h e all 5 pi eces f i ni sh es.
Has t o f ol l ow con t r act seal sampl e & comment s
 Pr epar e mo ck up sh eet & app r ove i t .
At t hi s t i me shoul d gi ve qu ali t y i nst r u ct i ons of mock u p t o M O.
 Ch eck agai n t he cor r ect ed oper at i on s w hi ch w er e hi ghli ght ed bef or e.
 Gi ve q ual it y checki n g in st r u ct ion sh eet t o back t abl e, mid t abl e & en d l i ne t abl e
checker s.
(Qual i t y checki ng i nst r u ct i on sh eet sho ul d si gn by qu al i t y ch ecker , QC sup er vi sor &
QC
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In -ch ar ge.)
Shoul d f ol l ow st yl e f i l e & con t r act seal sampl e.
 Gi ve i n st ru ct ion s of l abel at t achin g t o M O.
Lab el should mat ch w i t h l ab el char t of t r i m car d .
Shoul d check t h at M O i s t r ai ned f or l ab el at t achmen t (t he t r ai ned o ne’ s should have
a pu rpl e col our band on t h ei r scar f )
 Fi r st 10 gar ment s o f t he lin e out sh oul d measur e, check & f i l l t he ho ur l y
measur em ent aud i t sheet .
Wh en it has damage, shou ld gi ve in st r uct i ons t o cor r ect i t t o QC & M O.
 Sen d t h ese 10 gar men t s t o w ash.
These gar m en t s should r et ur n w i t h in 2 d ays.
 Af t er r ecei vi n g, t he w ash gar men t s shoul d measu r e & check t h e q ual it y.
It sh ou ld be f i l l t h e hou r l y measur ement sh eet f or w ash gar ment s.
Fi r st 50 gar ment sh oul d b e send t o bul k w ash i n addi t i on o f 10 gar ment s
M ain l y con si der i ng t h e wo r kman sh ip.

Dai l y r ut t i ng:

 Ever y mo rn in g, should ch eck t he ab sen t eei sm of t h e l ine & oper at o rs who has b een
r epl aced inst ead o f absen t ees.
Shoul d be checked t h e qu al i t y of t he op er at i on s.
 Ever y mo r nin g machin e requi r ement o f t h e oper at i on s shou ld be checked.
 Do t he SPC (St at i st i c Pr ocess Con t r ol )
1. At t ribut e – (Consid er t h e wor kman ship. )
Do 8 t i mes p er d ay (wi t h i n 8 hou r s).
Consi d er back ar ea, f r ont ar ea & assemb l e of t he gar ment .
Ch eck 40% o f t he l ine out p er hou r .
Damages shoul d b e bet w een 5% - 0%
Wh en damages ar e over 5%, h as t o t ake an act i on.
2. Variable – (Consid er t h e measu r em en t s. )
Do f or cr i t i cal ar eas of t h e gar ment (low hip , f r ont r i se, back r i se)
Do i t f or 3 gar men t s per hour & 4 t i mes p er day.
Gar ment s t o be checked, shoul d not b e i n same si zes.

 M on i t or t he end l in e & mi d li n e hou r l y.
End lin e & mi d l in e sh eet i s f i ll ed by t he QC & i t sho uld b e checked.
 M easur e & check 10 gar men t s per day hour l y (r an do m sel ect i on )
Fi ll t he h our l y measu r emen t audi t sheet & en d l i ne garm ent r evi ew sh eet .
Revi ew t h e sh eet & w hen i t has been damaged, aw ar e t h e QC & M O r egar d i ng t h at
and co r r ect i t .
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 Send 6 above ment io ned gar ment s t o w ash (GAP).
 M easur egar ment s at af t er w ash& af t er i r on.
 Check t hem at af t er measu r e b y t he f in i shi ng depar t men t .
 Fi l l t h e hou r l y measur ement aud it sh eet al so f or w ash ed gar men t s.
(M easur i ng’ s shoul d b e don e accor di ng t o t he shr i nkage)
 When t her e i s measu r em en t pr obl em, in f or m t o t he qual i t y i n char ge.
 When t her e ar e col our shades of t he gar ment , i t shou ld be in f or med t o t he QC in -
ch ar ge & check and get t h e appr oval f o r t ho se co lou r shades.
Nor mal l y h as app r oval f or co lour sh ad es f o r si de t o sid e mar ker s.
Hang whi t e b and of l oop t o col our sh ad es bef or e i t sent t o w ash.
 Send QC t o f i ni shi ng Di v. 3 t i mes p er day t o check t he qu al i t y of washed gar ment s.
 Do r and om checki ng in t he l i ne.
 When it `s need n eedl e hol es (sp eci al r eq ui r emen t s), sh oul d pu t t h e need l e change
r epo r t .
Ch eck w het her t ho se needl es ar e ch an ged accordi ng t o t he r epor t (changing t i mes)
 When i t has but t on at t ach on t he gar m en t , h as t o f ol low bi n go card by t h e M O (f or cl ear
but t o ns)
Bi ngo car d should be checked t hat t h e M O i s f ol low i ng up it .
 At t he col ou r changes, i t shoul d send 10 gar men t s f or w ash & measur e i t .
 Han g gr een band on t h e l oop f o r dead d amages.
 M aint ain t he uneven f o undat i on o f t he gar ment s (w ai st band ).

KPI`S
 Lot audi t passi ng (w or kman shi p )
 M ain t ai n 97% FPY (Fi r st Pass Yi el d )
 Shoul d have 95% pass r at e of bef or e w ash audi t (10 p i eces f r om a b in i s aud it in g)





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Job Rol l of Qual i t y Check er

Li ne f eedi ng:
 Get qu al i t y in st r u ct ion s f r om t h e l in e super vi so r .
Fi ll t he QC Inst r u ct i on Sheet & it shoul d b e appr oved b y t he qu al i t y i n char ge.
 Ch eck qu al i t y of t he oper at i ons, unt i l gar ment s ar e r ecei ved t o t he t abl e.
 End lin e t abl e QC sho ul d hang on a sampl e i n f r ont o f t h e t abl e w i t h t h e 1
st
gar ment
r evi ew sheet w hi ch ap pro ved b y t he qual i t y sup er vi sor & qu al it y in char ge
Dai l y r ut t i ng:
 Foll ow t h e QC i nst r uct ions, w hi ch gave b y t he qu al i t y super vi sor .
 Wh en id en t i f y a damage mar k i t & r et ur n t o t he l i ne f or co r r ect i t .
 Wh en damage has cont i nuousl y, inf o r m t o t he qual i t y super vi sor .
 Fi ll t he mi d l in e/ end l ine sheet hour l y.
 Vi si t t o f in i shi ng depar t ment & ch eck w ash gar ment s.
 Co r r ect t he r et ur ned gar ment s w hi ch ar e comi ng f r o m t h e f i ni shi ng & sub mi t t hem
back.
 Bi n audi t should be passed .


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Job Rol l of Qual i t y I n char ge
Li ne Feedi ng:
 Par t i cip at e t o PP meet i ng.
Gi ve qu al i t y r eq ui r emen t s of t h e gar ment .
 Par t i cip at e t o t ech ni cal meet i n g.
Di scussi n g qu ali t y i ssues can occur at p r oduct ion .
 Ch eck t he con t r act seal sampl e wi t h cont r act co mmen t s & r evi ew i t .
 Pr epar e 1
st
gar men t r evi ew sheet .
 Gi ve qu al i t y i n st r u ct ion s t o quali t y super vi sor s at t he l i ne f eed i ng.

Dai l y r ut t i ng:
 M ain t ai n t h e LTO o f qu al i t y t eam.( Labou r Tur n Over )
 M ain t ai n t h e ab sent eei sm o f quali t y t eam.
 Par t i cip at e t o meet i ng of Pl an t M anager at 9.00 A.M .
 Par t i cip at e t o meet i ng o f Fact or y M an ager at 9.30 A.M .
 Foll ow u p t h at pr oduct ion pul lout s/ r ack samp l es ar e gi ven b y t he sup er vi sor s
cor r ect l y.
 Foll ow up t hat 1
st
10 & 1
st
50 gar ment s ar e r ecei ved f r om w ash& ch ecked t hem b y
sup er vi sor s.
 Ch eck t he mai l s & gi ve i n st r u ct ion s accor di ng t o up dat ed mai l s.
 Foll ow t h e quali t y l evel of t he pl ant b y gi vin g sol ut i ons wi t h in vo l ve t o t h e pr ob l em.
Ch eck t hat t h e mid l ine/ en d l ine sheet s & SPC i s mai nt aini ng cor r ect l y.
 Handl e t he cut t in g i ssues.
 Handl e shadin g i ssues.
 Get appr o val f or p r int i ngs i f necessar y.
 Keep r et ur n gar ment s f r om f in i shi ng at lo w l evel .

KPI`S
 FPY shoul d be at 97% of t he pl ant (Fi r st Pass Yi el d)
 Bef or e w ash p ass r at e o f t h e pl ant should be 90%
 Pl ant lo t audi t p ass r at e 97%
 Fi nal pass r at e of t he shi pment should be 97%
 M ain t ai n SPC o f t he p l ant i n 5%

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FI NI SHI NG
W ashi ng r ecei vi ng – wash receive supervisor.
(process map is in page 36)

1. Check the packing list & tag on the bag.
2. Unloading - 3 helpers & 1 leader
 Leader should check the packing list & tag on the bag.
3. Delivery the garments to store.
4. Store on racks.
5. Selecting the garments for audit.
6. Auditing – 3 auditors
 First 50 auditing for new styles.
 Pass – Release to finishing.
 Fail – Calling for the meeting, person who are related.
Resend the garments to prepare damages.
 Bulk auditing.
 Pass – Release to finishing.
 Fail – Inform to the relevant QC supervisor of the sewing floor.
Re-auditing after prepare the damages.
 Fill the 1
st
50 analyzing report.

7. Bring to size break. 4 helpers
8. Size breaking according to PO –

Fi ni shi ng & Pol y bag Pack i ng–2 finishing in charges/8 line leaders
(process map is in page 35)

1. Bringing the garments from wash receive. 2 helpers.
2. Cutting loops.
3. Removing dust in pocket bags.1 helper.
4. Attaching buttons – 3 M/O.
5. Thread trimming – 2 helpers.
6. Wash quality checking (WQC) – 3 Q.C
7. Sucker – 1 helper.
8. Ironing – 3 helpers.
9. Topper – 1helper.
10. Final quality checking – 3 helpers.
11. Measuring- 1 helper.
12. Quality auditing. –1auditor.
13. Damage repairing – 1 M/O.
Folding method(5 helpers)
 Match book & price ticket attaching.(joker tag)
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 Dust removing (if necessary)
 Folding.
 Leg sticker attaching.
 Pre pack separating.
 Insert to poly bag.
 Paste the pre pack sticker & doing CNI (Conformity Necessary Information).


Hanging method (5 helpers)
 Remove the hanger.
 Price ticket attaching.
 Put the hanger with punch & remove dust (if necessary)
 Put the size tag.
 Hang on the rail.
 Get the garment from rail.
 Hang on the bar.
 Put the poly bag.
 Hang the garment on rail.
 Paste the bar cord stickers.
 Hang on the railings to deliver the ware house.


Car t on pr ocess In charge

1. Bring the garments from line out.- 2 helpers
2. Doing CNI (Conformity Necessary Information).- 3 helpers
3. Deliver to needle detector.
4. Garment passes through the detector. 2 helpers
5. Get the garment from the detector.
6. Deliver to the size break.
7. Separating to sizes. 5 helpers for flat & 1 for hangers.
8. Store in size wise.
9. Carton packing
i. Make carton for pack.
ii. Write the necessary information on the carton.
iii. Packing the garments 7 helpers
a. Pack folded garments in carton (pre pack & bulk).
b. Pack garments with hangers in carton.
iv. Close the carton

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Doi ng FA ( Fact or y Audi t ) 2 auditors
(process map is in page 37)
1. Select the cartons according to AQL.
2. Check shipping mark (Address/PO/Qty/carton no/of no)
3. Doing CNI for the carton.
4. Doing random CNI for hangers according to packing list.

WARE HOUSE Incharge
Car t on
1. Bring the cartons to ware house.
2. Doing EDI (Electronic Data Interchange) on the carton.
3. Mark the quantity & carton number on the carton.

CI F ( Cent r al I nspect i on Faci l i t y)
1. Attach the PO sheet with packing list & offer to the CIF.
2. Select the cartons for CIF.
3. Send the selected cartons for CIF.
4. CIF auditing
 Pass- release to loading.
 Fail – recheck & give again to CIF.
5. Do the packing at CIF room.

Loadi ng
Cartons
1. Delivery the cartons to loading bay.
2. Check the carton number & of number by security officer at the loading.
3. Doing random checking (in side of the carton)
4. Loading to container.
Hangers
1. Doing loading CNI.
 Should have 40 garments on a rail.
2. Delivery to loading bay.
3. Counting by the security officer at the loading.
4. Loading to container.

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Syst em char t pr ocess map







































W ASH RECEI VE
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FI NI SHI NG/ POLY BAG
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FI NI SHI NG / CART ON PAKI NG
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FACT ORY AUDI T
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