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Standard Operating Procedures

forManufacturing

units

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1. Order Cycle

Marketing

Merchandising

Imports

Costing

SourcingStores

Work Study

Cutting

Sewing

Printing

Embroidery

Finished

Goods

QC

Export

External Entities Production Process

Technical &ProductionPlanning

Sampling

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2. Production Flow Chart

Technical Package of style handedBy the Merchandising Department

Along with the T & A Plan.

Production

Technical

Q/A

Stores Packing

Cutting

Washing

Fabric & Trims In house as per T & A.Stores issue G.R.N

Within 24 working hrs.

10% Inspection by Q/A department.Report to be submitted within 48 hrs.

Trim Inspection.Fabric Inspections.

Shade Band 100%

10% Shrinkage.10% Fabric,4 Point

system

Fabric issued to Cutting as per cutSheet quantity.

All Samples should be Approved..

Fit / Proto Sample.

Contract Seal Sample.

Size Set/Rack Sample

Shading.WidthSkewin

g.Defects.

Pilot Run of 100 Units.

Merchandising will issueCutting Plan & Cut Sheet.

Bulk Fabric Laying & Cutting.Lay Sheet to be circulated Daily.Merchandiser.

ProductionManager.

Fusing & Assorting.

In put. Loading Plan by Production Manager.

Out PutSewing In Line Check. Final Line Checking.

Production StatusCirculated at 10.00 A.M

Final Inspection 24 hrs prior to delivery Date.

Exportation of Garments.

Washing Finishing Trimming

Final Checking.

PressingPacking.

ReconciliationWithin 24 hrs.

Cost

Finished Goods.

Fabric.

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3. Sampling

3.1 Objective: The throughput time for sample making should be 3 days from cut date.

To manufacture shirts 100% as per customer requirements.

Storage and presentation of patterns , samples , trims & fabric wirh proper

identification status for easy retreival.

To ensure that for all wash codes shrinkages are analysed roll wise either on a

sample lot or 100% roll based on customer requirement and multiple

shrinkage patterns are drawn where required.

To ensure that the samples are produced keeping in mind the responsibility of

the same in bulk and highlighting to customer if their specification cannot be

met in bulk.

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3.2 Process flow chart

Process Flow Sampling

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The sample Room is the “Heart” of any Apparel Manufacturing Organization. Hence

it is utmost important to the Sample room in charge to ensure high quality Samples

within a very short lead-time is submitted & approved by Buyer. Ensure your work

force is adequate to meet the ever-growing demand of samples.

After receiving the Tech pack, Study carefully & revert back within 8 hours for

queries.

As soon as a new tech pack is received, sampling dept. should submit the Mini

markers to the Marketing division & if any changes occur during the process, the

revised Mini marker should be presented immediately if the reason for revision is

valid. Further as a norm, once the mini marker is submitted to a certain styling, The

same yield or less should be maintained for the bulk production as well.

As Intimated above, No Sample is to be cut without the patterns had been checked

against the spec sheet along with the Pattern maker.

All non-wash Garments should be submitted within 3 days Maximum & wash

Garments should be submitted within 4 days.

No Sample is to be undertaken without the sample requisition form (Annexure-1).

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Samples to be made in the sample room Development Sample

Salesman samples

Fit Samples

Pre production samples

Testing samples

Size set

The sample room is not to make any T.O.P Sample or Shipment sample. These

samples should be submitted by the Q/A department & produced in the Production

floor.

The sample room should always maintain a Mini Stores, which should include Fabric

yardage, Zippers, Buttons Thread, buttons, Labels & Tags pertaining to all styles.

Once the Pre Production sample is approved, the size set should be submitted for all

styles & the final Graded pattern would be made. Strictly no pattern revision is to be

made after approval of size set without the approval of Sample room In-charge & the

concerned Merchandiser.

The Approved Pre production sample should be handed over to the R & D

Department during the P.P. meeting.

The Sample room should always cross check all the Shrinkages (Thermal, Cut, Steam,

Washing, Fusing) of the fabric before making samples & adjust patterns accordingly.

All reports / tech pack / manuals etc, should be documented & maintained.

A reference sample should always be kept in house as a representative of any sample,

which is submitted, to Buyers. This is utmost important & should be kept in the

sample room.

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3.3 Sample Stages:

3.3.1 Development/ Proto

1. The purpose of making a development sample for a buyer is to check for the

look of the style.

2. Receive sampling Indent and fabric

3. Develop pattern for the style.

4. Sample Cutting should be done as per the required numbers with the available

fabric and pattern.

5. Sample sewing: The samples are stitched with available fabric and trims.

6. Checking

7. Finishing and Packing

8. Sending for approval

9. Receive the comments

a. If passed then proceed to next stage with comments if any (new indent

to be issued)

b. If rejected then redo the sample as per comments (new indent to be

issued).

3.3.2 Fit sample

1. Receive sampling Indent

2. Fabric treatment

3. Pattern making/ correction

Rest all stages same as Development except that during checking it is now checked

for measurements and fit.

3.3.3 Pre production Sample/ Sealer/ Gold Seal

The purpose of making a pre production Sample is to check for the actual fabric and

trims and style.

Input: Comments on Fit sample, shrinkage report.

The process remains same as the previous stage.

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This is like a sealer for the production, so whatever changes if need to be done, should

be made before this stage.

So, the sample should be looked for production feasibility before this.

3.3.4 Size Set

The purpose is to check all sizes for measurements based on the graded spec.

The process remains same as the previous stage except that the graded spec is

required and checked in each stage.

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4. Research & Development

4.1 Objective: - The purpose of R&D department is to research on the style in all

aspects like construction details, methods, production feasibility and identifying

potential problems.

4.2 Interfacing Departments

4.2.1Planning

Sending the samples for SMV and Thread consumption calculation

Pilot loading plan and priorities (Annexure- 2)

4.2.2 Merchandising:

Merchandiser issues the work order to stores to open the bales and send for

shrinkage testing.

Sends the PP sample and comments to pattern master.

Giving the requirement for pilot if needed and how many samples are

required.

4.2.3 IED

SMV

Thread consumption

Layout

Operation bulletin

Manpower allocation

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4.3 Process Flow Pilot Run

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Receipt of file and PP sample

Receipt of shrinkage report

Pattern amendment and grading for base pattern

Making hard pattern

Pattern checking and Issue to pilot run

Getting fabric issued for required number of pcs

Cutting (manual)Checking cut panels

Loading and sewing

Pieces ready

Checking before wash measurements

Washing

Checking after wash measurements

Report given to master

Pattern amendment and grading

Cutting one size set (manual) Cutting 100/ 200 pcs (straight knife/ autocutter)

Checking cut panels

Loading and sewing

Pieces ready

Checking before wash measurements

Washing

Checking after wash measurements

Report given to master

Pattern amendment

Checking cut panels

Loading and sewing

Pieces ready

Checking before wash measurements

Washing

Checking after wash measurements

Report given to master

Pilot offeredProceed for bulk cutting Receive commentsAmendment

4.4 Purpose:

The purpose of making pilot is to see how the fabric will behave when constructed in

a garment during bulk production.

It is the representation of the bulk. It has to be done in actual fabric and actual sewing

trims.

A Pilot lot is a small cut across all sizes and colors, which will identify any potential

problem in manufacturing prior to the factory cutting bulk.

Pilot runs covering all colors & sizes are applied on all styles (even repeat style with

different fabrication) except for test orders.

Pilot run garments are carefully assessed on construction, making up method,

machines used, measurement, washing & pressing effect etc., & report is kept for

reference.

Necessary adjustment is made on pattern, machinery setting, seam allowance, sewing,

washing & pressing methods etc., prior to bulk cutting / production.

The sample size differs from buyer to buyer as follows:

Express : 3 samples per size covering all sizes in a color i.e. if there are 4 sizes

in one color then it accounts for 12 samples per color.

S. Oliver: 2 samples per size covering all the sizes in a color i.e. if there are

four colors and five sizes then it accounts for 40 pcs a pilot.

Armani Exchange/ Arrow/ Izod (Triburg): 5 samples per size covering all the

sizes in a color i.e. if there are four colors and five sizes then it accounts for

100 pcs a pilot.

M & S/ Esprit: 2 pc per size in all colors i.e. total 12 – 15 pcs in all colors.

Tommy Hilfieger: 4 pcs in M size for all colors and doing jumping sizes in all

colors. The requirement is minimum 25 pcs per pilot.

Marc O’ Polo: 2 pcs per size in jumping colors.

Monoprix: 2 pcs per size.

Levis Dockers/ Levis Signature : 3 pcs per size in all jumping colors.

This ultimately will ensure that bulk production will not be affected and that mistakes

if any will be made and corrected during the Pilot.

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Pilot lots are cut for the following reasons:

• It might be that factory is working on a new fabric type that it has not handled

before, therefore handling and machine settings must be looked at and set

accordingly.

• New construction methods.

• New machinery, or new settings

• Ensure that shrinkage allowances built into patterns are correct for steam shrinkage,

washing shrinkage or any other after treatment standard.

• Early T.O.P. approval. If there are no issues with the first Pilot cutting then the

factory will automatically have garments to send for approval.

This must be looked at as opportunity to find and iron out problems before bulk rather

than just another procedure. To standardize this process all sizes and colors have to

cut across a specified quantity. The assessment form must be filled in and counter

signed by a management, to ensure that all areas have been analyzed with a specified

course of action needed for bulk.

This must be filed in the Master style file.

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4.5 The working of the pilot department is as follows:

Receiving the PP sample and File:

After the PP sample is approved with some comments, it is handed over to pattern

section for making the patterns. The patterns are amended and graded. The required

shrinkage is added lengthwise and width wise and then issued for subsequent

processes. Style file contains all the critical details about a particular style. The file

build depends on the buyer. But primarily file includes following details.

Manual Work Order

PO Sheet

Bill Of Materials

Tech Pack

Buyer Comments

Pre production meeting comments

Fabric swatch(shade band, wash standards & hand feel)

Approved Trim card

Fabric/accessories/garment test report

Standard procedure

The pilot is cut and made in the required rolls of decided shrinkage.

Pattern Amendment

According to the fabric shrinkage report, the required shrinkage is added to already

graded patterns. The hard pattern for base size is then prepared and issued to pilot

section for cutting.

Pattern review

The pattern is reviewed. On the basis of shrinkage, before and after wash

measurements are prepared.

Fabric Issues

The required fabric rolls are issued in each color.

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Making the base size

The base size “M” is then cut in each color and loaded in line for sewing. As soon as

the pieces are ready, they are reviewed for before wash measurements and

construction and sent for wash if required and after required ironing/ pressing, the

samples are reviewed for after wash shrinkage.

Pattern amendment and issues

If the actual after wash measurements are not tallying with the required

measurements, the pattern needs to be amended. The report is given to the master and

accordingly after correcting the patterns, the hard patterns are prepared.

Making the size set

The extreme sizes (i.e. S and XXL for sizes S to XXL) in all colors are cut and

stitched. After washing (if needed) and ironing the size sets are reviewed. If any

discrepancy is there the report is given again for pattern amendment.

Based on these two steps, the patterns are finalized and then issued for cutting pilot.

Pilot Cutting

The marker for approximately 200 pcs across all the colors is then issued for cutting.

Depending upon the requirement, the full cut parts are taken from these cut lay and

loaded in the pilot line. The balance cut parts are taken for loading in and setting the

decided production line. (Annexure –3)

Outsourced process

As per the requirement for embroidery/ printing or in case of any outsourced process,

the panels are cut and sent outside with markings and other instructions.

Pilot Sewing

The actual trims and threads are used for making the pilot. The operation breakdown

for a style is done by the I.E. dept. along with the machinery requirement and layout.

The stitching is done by experienced operators under the supervision of trainers. The

whole stitching process is monitored by the technical manager so as to get a fair idea

of how to set the process for the bulk. Each operation is critically analyzed and

assessed so as to get maximum productivity from the assembly lines in the bulk

production maintaining the desired quality standards. The trainers after analyzing the

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operations help the operators in the sewing lines for critical operations and thus

minimize the area under learning curve (reduces learning time).

Taking before wash measurements

The master gives the before wash and after wash measurement sheet. The before wash

measurements are reviewed by the QC and in case of any discrepancy, it is

immediately brought in notice of the master. At this time the pieces are also checked

for any quality defects.

Outsourced process

If the embroidery/ print has to be done after garment is made, it is sent for

embroidery/ print with all the markings as per specifications.

Taking After wash measurements

After the pieces are received from washing, it is ironed as per the specification i.e.

clean press/ flat press/ only steam or no steam, no iron. These are then reviewed for

measurements and quality. The reports are handed over to master for immediate

pattern correction for bulk.

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4.6. Reports given by pilot department

Giving comments and amendments. The QA gives the following reports:

1. Measurement report (Annexure 4)

2. Pilot comment sheet (Annexure 5)

3. Amendment sheet (Annexure- 6)

4.7. Pilot decision and Offer

The decision has to be taken by the section head and the QA as to if the pilot is passed

and can be offered to the buyer. If the pilot needs to be redone, immediately action

needs to be taken for pattern amendment, cutting, stitching and sending for wash. The

pieces are offered to the buyer along with all the following:

Style file

PP sample

Patterns

Shrinkage report

Before and afterwash measurement report.

Pilot Comment sheet

Amendment sheet.

4.8. Receiving comments from buyer

The pilot is offered to the buyer and the comments given are incorporated into the

bulk.

The comments regarding workmanship is explained and discussed in the handover

meeting.

4.9. Proceed for bulk

The bulk is proceeded on the basis of the internal and buyer pilot review report.

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5. Industrial Engineering Procedures

5.1 Process FlowThe general process flow is as follows:

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Samples from the planning department

Operation bulletin

SMV calculation and setting the targets

Thread consumption

Line balancing and operator allocation

Line layout plan

Process plan

5.2 Work Measurement.

Work Measurement ( Time Study ) is an Integral part in the Manufacture of

Garments. It is utmost necessary for any Manufacturing unit to have this department

in house at full function, As it lends a supportive hand on many aspects as follows,

The provision of standard times for separate operations & complete process allows

better planning for the manufacture of Garment, by encouraging a conscious

numerical analysis before designing operations & process. This will enable to

maintain an improved level of productivity which would enable to meet Buyers dead

lines on a regular manner.

This system would enable the management to segregate its work force in a productive

manner which would be an effect on the CM ( Cut & Making of the Garment ), Where

excess & non productive workers could be utilized for other operations.

This system enables the management for a proper comparison between operations &

workers,& the worker productivity.

Time study supplies an essential item of information for making Investment decisions

as well. By working out this system, The management could Invest on Hi-tech

Machinery which would analyze the cost of labor.

Work study provides a sounder basis for Incentive payment schemes to workers,

because it allows comparisons to be made between individual operators on the same

task entrusted.

5.3 Time study procedures.Time study procedure may conveniently be analyzed under four headings..

Defining the operation to be timed.

Timing each element using a stop watch.

Rating.

Allowances or ex gratia

Pre Production work Instructions for Work study Officers.

 

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5.4. Receive sample from Merchandising Dept. Analyze the sample & prepare “ Operational Break down”.

Assign required M/C, Folders, Work Aids, SMV & Target within 8 working

hours.

Check available work aids & confirm the availability.

Refer “Data Base” to assign SMV.

Use “CMA” package to calculate SMV for new operations which is not in the

data base.

Calculate the total SMV for the garment & submit to the merchandising dept

within 8 working hrs.

Draw garments tree diagram according to critical path by using the PC.

Participate with the sample room during making of samples to analyze the

styling in detail.

Check the practicalities of all operations & ways to minimize operations &

M/C.

Prepare “ Critical Operation Analysis” report.

Prepare operational lay out plan for sewing section.

Discuss production schedule & manning allocations with Production Manager.

Lay out systems & special technical points.

Prepare lay out as per critical path.

Use M/C requirement list for manning, basic pitch time & target calculation.

Check complete lay out with production assistance & discuss with relevant

depts.

Submit M/C lay out Mechanic.

Participate in “Pre production meeting”.

Analyze workers performance records.

Ensure the submitted SMV is achieved always during production & ways of

reducing SMV.

The request is received from the planning department along with the PP

sample. The garment is studied and broken down into individual operations

and time is allocated to each operation, based on which the following are

calculated.

5.4.1. SMV Calculation

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SMV (Standard Minute Value) calculations are done based on pre-determined

standard motion studies. The Style is being broken in to individual operations and the

time for each operation is determined. The machines used for completing the style is

also determined. The SMVs calculated are listed in a operation Bulletin and the total

target is determined based on the total work-stations required.

Encl: Operation Bulletion-Annexure 7

5.4.2. Thread Consumption

The thread consumption for the garment is calculated based on the operation

breakdown. The factor is multiplied with the length of seam for each operation.

S.No. Type of M/c Thread factor/cm Thread WastageDetails of ThreadNeedle Bobbin Looper Total

1 SNLS 3 2 1 1   22 DNLS 6 2 2 2   43 OL(3T) 19 3 1   2 34 OL(5T) 24 3 2   3 55 F.O.A 14 3 2   2 46 B.H 60 NW 1 1   27 BUTTON 25 NW 1 1   28 BARTACK 30 NW 1 1   29 PINTUCK(PER Stitch) 7 3 1   2 310 PICOATING 35 3 2   4 611 KANSAI 14 3 2   2 412 FLAT-LOCK 33 3 2   1 313 BLIND STITCH   2" 1   1 214 KEY-HOLE 50 NW 1   6 7

5.4.3. Line Lay-Out (Annexure 8 )The total floor-layout is drawn to have a proper process flow for each department from cutting to Finishing.

5.4.4. Technical Lay-Out (Annexure 9)

The technical Lay-out is drawn based on the operation bulletin and the flow of work

process. The allocation of the work-stations is based on the SMVs and capacity of the

operators. The total process flow is drawn and the targets are set based on the total

available work-stations.

The technical layout also contains the type of folders and attachments to be used.

Layout for all styles should be standard.

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5.5. Technical spec detail sheet (Annexure 10)

The R & D department should give the technical spec detail sheet, which contains all

the details regarding the style.

It includes the following:

Order qty

Style description

Fabric details

Cutting details

Sewing details

Sewing trims

Process flow

Special instructions

5.6. Risk Analysis

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There are risks associated with manufacturing processes which can result in failure of

the product, either in production or in use by the customer. Understanding and

militating against these risks at the design stage is fundamental to the success of the

product. By assessing the risks sufficiently early in the design process, delays in

production and right first time products can be achieved.

The factory must carry out some kind of Risk Analysis process (e.g. a meeting which

includes members of the key production departments)

The factory must be able to demonstrate that the procedure is understood and can

identify potential risks with raw materials, process methods, equipment, storage, end

user safety.

5.6.1 Risk Analysis procedure

Quality and safety must be designed, planned and built into the product. It is

sometimes difficult to foresee all the possible modes of failure allowing for all the

conditions of use or indeed misuse. Without a systematic approach, it is likely that

some element will be missed resulting in a failure and possible injury to the wearer.

This risk analysis procedure is designed to provide that opportunity to identify and

forestall those potential hazards. By examining each design or process in detail and

identifying the effects of failure, together with possible causes, it is possible to

propose actions to introduce controls to reduce the failure rate and/or minimise the

impact of a failure.

When considering potential failure it is important to have access to data relating to

failures which occurred on similar components/ assemblies in the past.

Risk analysis should be a team activity relying on input from experienced personnel; a

typical team would consist of design, development, industrial engineer, production

manager and quality manager. The completed risk analysis should then be circulated

to relevant departments with a request for comments. It is important to obtain

feedback from all departments so they may, from their own unique experience, have

the opportunity to suggest other potential failure modes which the team carrying out

the analysis may not have considered.

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5.6.2 Analysis

The analysis will consider all areas of potential failure and establish preventative

actions, which may include special test requirements, inspection recommendations,

preventative maintenance or operational constraints. The analysis starts with the most

basic component and works progressively through the complete system. It is essential

to ensure that every selected component, sub-assembly and design feature within the

product is adequately covered by the analysis. The person responsible for the Risk

Analysis, ideally senior production managers, should ensure that all recommendations

resulting from the analysis are carried out. The Risk analysis is documented using a

standards form, attached, which is designed to guide the team to ask the correct

questions and effectiveness of the analysis will depend of their accurate completion of

this form.

The procedure (Annexure 11)

1. Clearly identify every component being studied, including assemblies and sub-

assemblies.

2. Describe the purpose of the component or assembly. This is very helpful in

identifying the possible models of failure.

3. Anticipate and describe the possible way the part could fail. Consider how the

failure could be observed. A safety failure must always be considered more

serious than a quality failure.

4. Assume the failure mode has occurred and then describe what the effect would

be in terms of what would be noticed. The effects noticed both locally and on

the whole should be listed. E.g. the colour bleeds off the product and

contaminates accessory. There could be more than one effect and the same

effect could apply to a number of failures.

5. List every potential cause of failure for each of the failure modes as the design

currently stands. There is a low risk if potential failure is certain to be detected

before the product reached the customer, and high risk of it would be

impossible to detect the potential failure before the product reaches the

customer. In order to improve detection it may be necessary to specify

additional controls at an earlier stage so that a potential failure is more easily

detectable.

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6. Recommend corrective action. The action required to correct a possible failure

should be clearly stated. If an action has already been taken it is helpful to

record the current status.

7. Identify the most appropriate person for implementing the recommended

action.

8. Document the action taken. In every case where recommended action is

required state what action has been taken to eliminate the cause of failure,

reduce the degree of severity; reduce the probability of its occurrence.

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6. Fabric & Trim Stores6.1 Objectives:

GIR to GRN through put time <7 days.

Ensure no short supply of fabric. Trims before bulk production

No stock out on consumables.

Approval of trims to sought before bulk production.

Issues of trims to sewing with 2 hours of receipt of the indent.

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6.2 Process Flow

Process module fabric stores

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6.3 Pre-Fabric Receive Activities

The monthly planner for fabric in-house should come to the store in-charge with the

weekly updates and changes should be communicated at the very instant of the

occurrence.

The fabric purchase team should make sure to in-house the planned initial yardages of

the fabric at least before 20 days to carry out pilot run and for bulk maximum 8-10

days. The necessary follow-up in reading should be done by the store in-charge.

If in case fabric is late by the planned date for receiving then the same should be

intimated to the planning, cutting, and merchandiser so that the necessary priority can

be changed and required follow up can be done.

For making the packing slip either of the following is required.

1. Fabric end bits should be received from the supplier prior to fabric in-house

clearly mentioning the lot no., roll no in reference to their dispatched rolls and

meters.

2. Shade cards (Annexure 12) should be received by the fabric purchase team

and then same should be given to the fabric inspection team.

3. The invoice or Delivery Chalan copy should have a mill /supplier packing slip

having following details: - Roll No., Shade, Meters, Width.

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6.4. Fabric Receive:

6.4.1 Unloading the fabric:

Unloading should be done in the presence of fabric in charge/supervisor and person

responsible for fabric receive as per the stores structure.

The supplier invoice or the transporters copy of the Delivery Chalan should be

checked by the fabric in charge and then unloading should be done in the quarantine

area. The bale numbers are counted and cross checked against the supplier’s packing

list while unloading and it is verified by the fabric receive person.

If quantity is less then the transporters is informed and recorded on collection advice /

Invoice / DC.

The Invoice copy along with fabric swatch should be filed in “Daily fabric receive

file” and at the end of the day material inward details should be updated by the fabric

receive person.

The information of fabric received against the Purchase No. is informed to the

purchase person and the concerned merchandiser.

The packing list should be made which includes roll no. (Supplier roll no), length,

width and shade.

How to unload the fabric

Unloading should be done manually.

Maximum of 3 to 4 persons are required in unloading activity.

The unloaded bales from trucks have to be kept on Cart Trolley by 2 Persons.

Two persons will move that loaded cart trolley to the quarantine area.

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6.4.2 Stacking the bales in quarantine area:

Storing of bales has to be done as per color wise/lot wise by two persons on the

wooden palettes.

If in the same lot too much variable meterages are there, and then care should be

taken while stacking the rolls, the bigger value of meters should preferably be kept

first and then the smaller ones.

In case of meterage folds the fabric should be staked in linear form of one above

another. All the fabric bales/roles should be stacked in pyramid form in the quarantine

area.

The bales should be covered by the plastic sheets. It is must for meter fold and

optional for roll form of fabric because it comes in poly packing.

All lots should have a identification card showing brand name, supplier name, fabric

receive date, fabric code, lot no, color and shade no, invoice qt. and total rolls.

Design Approval: The fabric swatch is taken and sent to the concerned merchandiser

for the design, and face approval (Annexure 13).

6.4.3 Issuing fabric for Inspection

10 % fabric from each lot and shade is offered for fabric inspection.

In the above 10% fabric the sample rolls will be decided by the random number

generator software where the number of rolls received will be input by the fabric

inspector. The number of sample rolls will be generated and the same should be taken

from packing slip (S. No.) for inspection.

6.4.4 Shrinkage testing (Annexure 14)

The shrinkage should be tested warpwise and weftwise. The shrinkage testing method

is as follows:

1. Take the fabric swatch.

2. Mark 25cm X 25 cm on the fabric in the centre excluding the selvedge.

3. Cutting Shrinkage (Only for specific fabric types): Cut the swatch and relax

for some time. Measure the swatch again.

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4. Note the fabric shrinkage due to cutting.

5. Sewing shrinkage: stitch the four sides using 3 thread overlock. Measure.

Check for sewing shrinkage.

6. If it is a wash program, then send for washing.

Make sure to use fillers according to the capacity of the machine. For e.g. for a

5 kg load, if the fabric accounts for half a kg, the balance capacity should be

filled with fabric/ garments.

7. The recipe should be exact as required for bulk.

8. Finishing/ ironing shrinkage: Depending on the required Iron/ Press, the

swatch is to be steamed/ ironed and then shrinkage is measured.

a. For a non-wash program, the shrinkage will include cutting, sewing

and the ironing shrinkage.

b. For a wash program, the shrinkage will include cutting, sewing,

washing and ironing shrinkage.

Depending on the buyer’s requirement, the sample size for shrinkage can be

10% or 100%.

6.4.5 Keeping the fabric in racks after Inspection:

1. When the inspection for a particular lot is completed and the received fabric is

“Passed”, the complete lot should be moved to racks width wise.

2. All material movement should be on cart trolley or V-trolley.

3. All the fabric in the racks should have an identification card (bin card) having

brand name, fabric code, fabric receive date, lot no, total meters and total rolls.

Make the GRN (Goods Receipt Note) for the passed goods (as per bin card)

(Annexure 15)

All fabric details like continuity cards, shade cards, lab dip reports, shrinkage

reports buyer wise should be maintained in the fabric quality department.

Shrinkage testing should be done as per the garment wash.

6.5. PACKING SLIP FORMAT

A packing slip received from supplier or maintained by stores/inspection on advance

receives of the bits of the dispatched fabric lot from supplier should follow the

specified format:

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Roll No. Shade Length(Mts) Width(Cms.)

6.6. Inward fabric Quality checking

All the roll color swatches should be separately received so no need to cut fabric bits

from the incoming rolls.

If color swatches are not coming separately or no shade card or shade details on

supplier’s packing slip, then 10 cm wide bit will be cut from each roll.

Only 10% inspection is sufficient if 10% inspection fails then we can go for 20%

inspection and above.

Arrange all the roll swatches both Rigid & W/F per shade grouping and get a prior

approval on that from Product Development/Quality Assurance Team & send the

same grouped swatches to merchandiser for approval from buyer.

Give the shade details color wise/ lot wise to fabric In-Charge so that it can be

updated in the bin card.

6.7. Fabric Inspection

As we will be doing 10% of inspection. The back feeder should get the 10% roll

details for inspection Color wise/ Lot wise from the Fabric Stores ( fabric receive) In-

Charge ,who in turn will give random rolls no. (Based on random generating

software) as described above in issuing fabric for inspection process.

Rolls selected for inspection should be kept in “For Inspection” racks only in

Inspection area.

The back feeder with the help of operator should take the rolls from racks without

hitting any point of the rack to avoid any damage to fabric.

The back feeder will take roll to inspection table area.

The opened roll should be gently kept on the back feeding roll of inspection m/c by

the back feeder with help of operator.

The open end of the fabric roll should be pulled upwards & to be fed to the operator.

The operator has to measure the skew ness, fabric width (usable and full width) and

other fabric defects noticed during inspection and recorded in the inspection book

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(Annexure 16). The points will be awarded on the basis of 4-point system (Annexure

17).

The operator has to roll it partially on to the tube and stick cellophane tape at

three/four places of the roll so as to avoid folding.

The inspected roll should be gently kept in the “INSPECTED” rack by the operator

with the help of back feeder after wrapping with the plastic wrap and the wrapped roll

should be pasted with a sticker with the details of roll no., roll length, shade, color and

lot no.

6.8. Fabric Issue

Fabric stores would receive the initial cut plan (Annexure18) (specifying the no. of

cuts required to complete that order) from CAD department which clearly mentioned

the marker length and width of the fabric. This initial cut plan would be used to plan

the fabric issue.

Stores should receive the cutting plan one day prior to plan cut date.

Stores has to issue the fabric along with travelling work order (Annexure 19) & cut

no as mentioned in the table plan the fabric store will then issue 3% extra fabric over

the length required according to the marker length in the same width as mentioned in

the lay sheet.

Issuing racks in the ‘fabric issue’ area of the stores should be divided into table-wise.

The fabric for planned cut should be stored in the specified rack as per the table plan

width wise and shade wise with clear identification of- Brand, WO no, cut no. Meters

issued, width and shade.

6.9. Fabric Issue Procedure to Cutting

This activity is done manually with the help of maximum two to three persons.

As per the plan, all required rolls should be taken out from the concerned rack

associated for that particular table.

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Preferably all the rolls in the same width should be taken out first and precaution is

taken while keeping on the trolley, as different shades should be kept separately.

Issuing fabric rolls when taken from racks should be kept on issuing trolleys and then

moved to cutting section.

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7. Cutting

7.1Objective: - To ensure feeding of cut panels to sewing lines in correct quality & quantity as per schedule.

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7.2 Process Flow

Process Module Cutting Room

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7.3 Cutting Plan

Weekly Cutting Plan

On the basis of the monthly delivery tracker a cutting plan is made for an entire week,

which is reviewed on a weekly basis for the accomplishment of the plan and on first

day of every week a plan versus actual report is generated for the just concluded

week.

Daily Cutting Plan

On receiving the packing list and swatch from the stores the CAD department should

make a cut plan of the complete order based on the fabric details (width and shade )

from the stores, the cut plan (Annexure 20) should mention the marker length,

number of plies to be used in the along with the width of fabric.

*The packing list contains the information of cutable width of fabric along with the

meterage of the fabric available in that width.

From the weekly cutting plan a daily cutting plan is made by keeping WIP status as

mentioned in WIP report (Annexure 21) of the assembly lines in consideration.

7.4 Table PlanThe table plan will be generated for the individual spreader for a day on the basis of

the daily cutting plan. The table plan (Annexure 22) contains information of different

cuts for the styles planned on that day.

The Work order will be given to CAD, which will then divide the whole order

quantity into cuts required to clear the complete Work Order quantity and the markers

for the individual cut will be made according to the widths of fabric available as

mentioned in the packing list of the fabric provided by the fabric stores. These marker

length and width will be mentioned on the lay sheet one copy of this is given to the

cutting supervisor second copy will be kept in the CAD and the third copy of this lay

sheet will be given to fabric stores.

The cutting plan for the day will be made considering the cutting WIP status for the

sewing lines. The sewing line having the least WIP will be given the highest priority.

Thus the cuts as mentioned in the lay sheet by the CAD will be selected as per the

cutting plan for the day. The table plan for an individual table will be made and the

WO no & cut no will be written on it.

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* The cutting plan will be made one day prior to the actual cut date.

7.5 Information sources for cutting planning

7.5.1 Monthly Delivery Tracker

The planning department of the factory prepares the monthly delivery tracker

(Annexure 23); the tracker contains information about different styles that are going

to be manufactured in that specific month in the factory. The information is under

following headings

Buyer, Style, Color, Quantity, Delivery Date, PP Status, Trim Status, Fabric Status,

Planned Cut Date, etc.

7.5.2 Production Plan

The planning department of the factory prepares the production plan (Annexure 24);

this plan contains information about the line allocation to the styles to be

manufactured in that specific month in the factory.

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7.6. Pattern & Marker Checking Procedure

Whenever a style comes into bulk cutting the hard patterns for bulk production

duly signed and sealed by the pattern master has to be issued to the cutting by the

pattern master. On receiving the patterns these has to measured and the measurement

filled in pattern checking report (Annexure 25) and checked against the specification

sheet and if any discrepancy is found, the same has to be reported and informed to the

pattern master and necessary corrective actions must be taken.

Whenever a style is cut for the first time the marker generated should be checked

against the hard pattern for any possible errors in marker making or printing, one

complete garment patterns of the middle size should be checked. The hard patterns

will be placed on top of the marker at the respective position and the periphery will be

traced and if there is any discrepancy found has to be informed to the CAD as well as

cutting.

Stripe marker has to be paired face to face

* The Technical Manager must approve all the markers.

7.7. Marker Ordering

The table plan will be given to the CAD and the CAD will take the print out of the

marker on the basis of Work Order no. & cut no as mentioned in the table plan.

The cut that is planned first will have the highest priority and the subsequent cuts will

be lower in priority. All the markers must be ready on the same day on which the

table plan is given to the CAD.

7.8. Stores Requisition

The table plan thus generated in the previous step will be given to the fabric stores.

Based on the WO no & cut no as mentioned in the table plan the fabric store will then

issue 3% extra fabric over the length required according to the marker length in the

same width as mentioned in the lay sheet.

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The cut that is planned first will have the first priority and the subsequent cuts will be

lower in priority. All the fabric must be ready on the same day on which the table plan

is given to the fabric stores.

7.9. Mock-ups preparation

After the handover meeting of the style to the production floor, the style requirements

as discussed in the meeting should be converted into the visual standards (Annexure

26) and displayed at all relevant work stations as guide for the work.

7.10. Laying

Once the table plan is handed over to the laying batch they will lay the cuts mentioned

in their table plan in the order as per the table plan.

The laying batch must cross check the width and shade while laying and any

discrepancy found should be immediately reported to the laying and cutting

supervisor. The laying batch has to ensure the correctness of no of plies as mentioned

in the table plan. The laying batch also will fill the spreading sheets the quality

checker has to ensure that the spreading sheets (Annexure 27) are being filled

properly and completely. During laying the laying batch has to follow the work

instructions as mentioned in the work instruction sheet for normal table laying

(Annexure 28) or pin table laying (Annexure 29) as the case may be.

At the start of the lay the quality checker has to check for the face side of the fabric

and educate the layer about the same also he has to check for one way fabric and

pattern requirement in garment and instruct the layers accordingly. After the

completion of lay he must check it for quality and must document the same in the lay

checking report (Annexure 30).

Defect marking should be done at the laying stage using a contrast colour fabric stripe. All the drill marks has to be done before cutting panels.

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7.11. Cutting

Once the laying is complete and quality checker has checked its quality only then the

cutting has to commence. The cutter has to take the spreadsheet and write their name

and sign it in case of straight knife cutting and in case of a lay being cut on auto cutter

a separate log of the cuts being processed by the auto cutter has to maintained by the

auto cutter operator. During the process of cutting the cutter has to follow the work

instructions as mentioned in the work instruction sheet for straight knife cutting

(Annexure 31) or auto cutter cutting (Annexure 32) as the case may be.

In case of block cutting of components or interlining the cutting has to be done by

band knife. For band knife cutting the cutter has to follow work instructions as

mentioned in the work instruction sheet for band knife cutting (Annexure 33).

Pin table should be used for all check fabric cutting.Ticketing (numbering) should be done on the same cutting table.The cut panel having contrast colour stripe should be inspected before ticketing for the defects.

7.11.1 Cutting Storage Procedure

All the cut components from one cut should be stored in one baker’s trolley. The

cutting helper has to ensure that no mixing of the parts takes place while placing the

cut components in the trolley.

The cutting helper has to pick up cut components from the cutting table in case of

straight knife cutting and from the auto-cutter bed in case of auto-cutter cutting and

place them in an empty baker’s trolley. The work instructions as mentioned the work

instruction sheet for cut component storage (Annexure 34).

7.12. Assorting procedure

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Numbering Plan

A continuous numbering plan (Annexure 35) is made for a Work Order in that Work

Order no two garments will be given the same number. From the lay sheets a

numbering plan is made say sizes were s1 s2 s3 s4 and no of plies were 100. Then s1

will be given number from 1-100, s2 will be given number from 101-200, s3 will be

given number from 201-300 and size s4 will be given number 301-400.

7.13. Bundling

Separate bundles are to be made for following parts

Front

Front bundle will have both left and right front, front placket and pocket.

Back

Back bundle will contain back panel and both top and bottom yoke.

Sleeve

Sleeve bundle will have the both sleeves, top sleeve placket and under sleeve placket.

Collar, cuff and neckband

This bundle will have both top and bottom panels of collar, cuff and neckband.

The bundle size to be used is 20-25.

7.13.1 Bundle Cards

Bundle cards are tied to every bundle and these contains following information

Bundle no

WO No

Style No

Cut No

Size

Qty

Serial No

The bundle cards are also color coded such that every size has their unique color of

bundle card for easy identification at all the times. These color codes are mentioned in

the bundle card color code sheet (Annexure 36).

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7.14. Fusing ProceduresFusing has to be carried out as per the conditions specified by the interlining supplier,

every four hours one sample of the fused component has to sent for washing and peel

bond strength testing and also the testing of the temp, pressure and time has to be

carried out. In case of failure on any of these all the bundles fused in last 4 hours on

that machine has to be recalled and refused. During fusing the fusing operator has to

follow work instructions as mentioned in the work instructions sheet for fusing

(Annexure 37).

7.14.1 Testing procedures for fusing

Testing procedure for various test mentioned above are as follows

Temperature

Using three thermo-paper strips take the temperature across the width of the press or

machine belt.

Check and record the temperature with the recommended speed and fusing time.

The press will need to be adjusted if variation of more than 5°C below or 10°C above

the recommended fusing temperature is recorded.

Time

Check time with a stopwatch for the actual period for which temperature and pressure

is applied on the fused composite.

Washing

Carry out durability wash test daily on the fused components per fabric per color.

Peel Bond Strength

Use three strips of fabric, each15x5cms, placed evenly across the belt, position the

interlining to cover the fabric with no overlap

Fusing

Wash testing, temperature testing, pressure testing, time testing

Issue to sewing lines

Recall all bundles fused in last 4 hours

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Set the recommended fusing conditions for bulk production and allow it to cool.

Conduct peel bond strength test

Ensure an even bond and acceptable peel bond strength before production.

Fusing – all Interlining fusing has to be ready finished(block cut)a. Woven interlining – Sewing allowance to be ¼”.b. Non fusible woven - ----do---------

All the interlining pattern has to be aligned with shell pattern 1/8" less all around For order size more than 2000 pcs for lining cutting die should be used.

7.15. Outsourcing Procedure

Incase of an outsourced process like embroidery, printing, etc. keep a style wise

record for pieces sent for the outsourced process and the pieces that are received from

the outsource process.

When the material comes back from the outsourced process into the cutting section

check it for the correct pattern or shape of the embroidery or printing. Also check for

the placement of the print/embroidery if it is found correct only then this has to be

loaded to the sewing lines, other wise sort the pieces that are correct and load only

correct pieces to the sewing lines for rest carry out re-cutting and send for embroidery

or printing again. The information of the incorrect pieces has to be sent to concerned

merchandiser as well as the organization that has done that process.

7.16. Cutting Issue Procedure

The planning department makes loading plan, it contains information about the style

no. and quantity to be loaded/ issued to the sewing line on a particular day. This plan

is given a day in advance to the actual loading date, once the loading plan is received

the individual batch leaders will then make arrangement for making ready the loading

for the sewing lines that they are responsible for.

Only the cutting that has been passed by the quality department can be moved into

sewing lines and for the cutting not passed by the quality department has to be

corrected for the defect found in the cutting before loading it to the sewing lines.

The sewing line supervisor must acknowledge the cutting for quantity by signing on

the bundle card at the designated place.

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All the operators will have to follow the work instructions pertaining to the operation

that he/ she are carrying out.

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8. Sewing Floor

8.1 Operations Hierarchy:

Flowchart 1:

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V.P. Operations

Factory Manager

Floor Manager Floor Manager Floor Manager Floor Manager Floor Manager

Floor In charge

Line ………. …….. ……

……

Supervisor

Quality controller

Line feeder

Operators

8.2 Process flow for Sewing

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8.3 Objective:Producing an optimum quality product, setting the process as a benchmark for the

whole garment manufacturing industry.

Floor operations are divided in to 3 parts

8.4 Pre sewing operations:Pre sewing operation includes all the operations, which are required to be executed in

order to make the sewing operation flawless and make the work flow smooth.

8.4.1 Production planning

Production plan is crucial for the effective planning of resources in order to execute

production efficiently. Production planning includes the allocation of the job to use

the resources available to maximum extent.

To achieve the desired level of productivity, processes should be set as per the

following guidelines given by Industrial Engineering Department

SMV break down for the style

Operator allocation

Machine allocation

Tech layout (Attachments, folders, machines and other resources)

Any requisition for work aids and machines should reach Maintenance department

before 2 days. And arrangements should be made 1 day prior to the production.

To carry out Bulk production following information should be referred

Style file (including PP meeting comments)

Style file and PP sample must reach the production floor at least before 2 days.

Approved PP Sample received.

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Buyer approved PP sample should accompany the Style file. Every production line

must contain 1 approved sample hanging in front of line. Buyer comments sheet

should be hanged with the sample. It should contain the layout of the line to be set.

PP comment sheet, Description of critical points.

In any case production must not be started without the PP sample, style file and

production hand over meeting.

8.4.2 Cutting received (Line feeding)

Cut panels must be received from the cutting department at least 1 day prior

to the production.

Cut panels must be received only when all the cut parts are available.

Random checking of bundles must be done to ensure the proper formation of

bundle and cut pieces.

Lay plan and bundle number sheet must accompany the cutting.

Feeding helper must keep the record of all the cutting received and recut parts

(Annexure 38).

8.4.3 Trims receiving and issuing procedures

Trims must be issued according to the work order and cut plan received by the

production. In order to prevent any miscommunication the trims should be issued

according to the cut plan.

Trims should be issued 1 day prior to the production.

Trims receiving and issuing records should be maintained.

It must be ensured that all the trims are available before starting bulk

production.

In case of, Short or absence of any trim should be resolved by the production

Manager and take the necessary action to resume the production.

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8.5 Sewing operationsQuality garments are made up through a sequence of operations, which themselves

have, specific and defined levels of quality. The following are individual areas, which

affect end quality and the systems that need to be put in place to control these areas.

These key areas will not only affect quality standards, but also will also impact on

delivery schedules and overall costs.

All the template used in production line should be duly signed by the technical dept. + QCTemplate:a. Collar run stitch marking (Metal sheet)b.Collar assemble templetec.Pocket markingd.Button down markinge.Pocket pressing

No marking should be used for button holes.

Button attach marking should be collar down.

Each line should have two checkers for parts and one for assembly.

Work instruction should be displayed at all work stations.

8.5.1 Machine Repair & MaintenanceEach factory must ensure that they keep proper machine repair records (Annexure

39).A full time team of mechanics must be employed and have a well-stocked and

organized workshop. Machine repair records must exist for each machine and the

summary record are kept in the workshop. The mechanic and head mechanic must

sign it each time that work is carried out.

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.

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template example(metal sheet)

8.5.2 Needle policyThe following procedures are particularly designed for Kids garment production but

can also be translated for other products such as knitted and embroidered fabrics and

components where needle are used in production.

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.

When all parts are found a new needle can be issued.

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8.5.3 Label policy

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.

9. Checking of sew-in labels must be included in end of line inspections.

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.

8.5.4 In Line Process ControlsThe importance of first time quality is the key, in today’s changing business

environment. The ability to turn around quality goods in a short span of time is

essential. With the correct procedures and correct management attitude, this can be

achieved, very successfully.

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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.

Immediate reference for all operations at each needlepoint.

8.5.5 Quality performance sheets To achieve pre determined productivity levels the level of quality must firstly be

defined and achieved before any operator is issued a target.

To achieve the optimum quality level.

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.

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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.

8.5.6 Traffic Light ProceduresQC inspects 10 garments of an operator.

No defects- mark card GREEN to go to next operator.

ONE defect - mark card YELLOW, circle defect type# 1,2,3,4,5,6,7 or 8.

Inform and show operator fault. Move to next operator.

TWO defects mark card RED, THREE defects mark card BLACK, circle

Defect type# 1,2,3,4,5,6,7 or 8.

Inform and show SUPERVISOR of faults.

SUPERVISOR must stay with operator until 20 consecutive (for RED), 30

consecutive (for BLACK) garments/parts/operation pass.

SUPERVISOR initial (Signature) at the RED/BLACK to indicate 20/30

garments have passed consecutively.

If an operator has consecutive inspection RED, FLOOR MANAGER must be

informed to re-train the operator or take necessary follow up actions. Please

indicate this by using BLACK.

If a high defective rate is found on one particular operation in any one hour at

100% END LINE inspection, QC must inform LINE SUPERVISOR

immediately and not wait until the end of the day.

This system will work very well in reducing repair levels on hourly, daily basis if

used properly. Proper communicating among different inspection stages on defects

found and timely follow up actions is vital.

8.5.7 End line inspections

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All end line inspections tables must be set up as follows.

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.

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8.6. Post Sewing Operations

8.6.1 Washing

A daily in / out record between factory and laundry should be maintained to

monitor a smooth production flow.

All garments should be segregated by shade lot with proper identification on

each garment before sending to laundry for washing.

All garments should be washed by shade lot in the same washing load for

shade consistency.

A washing control technician from factory should be sent to laundry to check

the garments from each washing loads to ensure color shade, washing effect,

hand feel and measurements are within customers’ acceptable level. Anything

rejected must be recorded and followed up for correction / improvement

before the next wash

Garments returned from laundry must be firstly checked against approved

shade band, washing effects and hand feel before accepting for 100% final

inspection. Anything off approved standard must be rejected and returned to

laundry for re-wash immediately with record.

Daily inspection results from the washing control technician, control point on

accepting garments returned from laundry and final inspection must be

reviewed together. Any issue like garments shade varies within a washing

load, washing defects, broken stitches, over washed, trims over abraded, bad

smell, etc. that needs improvement must be communicated to parties

concerned for immediate improvement.

8.6.2 Ironing Procedures:

Irons, boilers and presses need as much attention to them as sewing machines and

again there must be planned maintenance programs in place as well as daily cleaning

routines.

Boilers and steam lines must be regularly checked and cleaned. Stains can

arise from areas like this, if they are not cleaned regularly. Pressing covers

must also be regularly changed as spoilage or damp spots can cause staining.

Teflon shoes must be used on delicate fabrics and sensitive colors.

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It is also a good idea to put tension cords on irons to help eliminate over

pressing on garments.

Needle boards are recommended to be used on velvets and corduroys.

On Cut and sew it is important that full measurement specs are available to

spot check measurements. It is also a good idea that key areas are marked up

on the pressing tables to ensure that we are controlling sizing issues and

sensitive shape issues.

Materials that contain Lycra need much more care during the pressing process.

Over pressing can cause sizing and fit problems especially in the hip area.

With care and the establishment of proper pressing methods, issues such as

this can be prevented.

Vacuums on the pressing tables must be used only after the garment has been

pressed. It is there to dry the garments off before packing. Running vacuums

in conjunction with pressing will results in seam impression, glazing and shiny

marks and possible color change.

Established pressing standards, must be clearly displayed for all to see and be

available to all as a point of reference.

8.6.3 Final inspection

Final inspection should be done after all sewing and finishing operations are

complete, but prior to bagging or packaging. It is important that all sewing

defects found are logged and traceable back to the operator who performed the

operation. This is an important QC function that requires organization and

good management.

This is normally possible since at this stage of the process, piece rate or bundle

tickets should still be attached to the budles. The following are recommended

actions for an effective final inspection programme:

Sewing operators should make their own repairs and outside repair station

does not provide incentive for the operator to do it correctly the next time, or

to immediately repair her / his mistakes as they occur

The inside of the garment should be 100% inspected. It may be preferable to

perform this inspection prior to pressing.

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Critical measurements should be spot checked frequently by each inspector.

This greatly increases the chance of catching a sizing problem that may have

been missed by the in process inspection.

Any non-inspection function, including excessive thread trimming, tagging

and folding, should be separated from final inspection.

Cross train and rotate inspectors whenever possible to help maintain focus and

improve overall inspection. A tired and bored inspector is not a good

inspector.

Provide good quality floor mats to stand on and stools for occasional leaning /

sitting to avoid fatigue.

Provide well-lit work areas with the necessary room for good, thorough

inspections. Final inspection areas need to meet the JCP recommendations for

proper QC work stations.

Keep inspection areas clean, organized and remove inspected and defective

garments frequently.

Evaluate performance, provide necessary training and encourage improved

inspections.

For the purpose of operator (and inspector) performance evaluation and

corrective action, detailed records by defects and by operator, should be kept.

These results should be combined with the in process audit results to

determine the true performance of each operator, over an appropriate period of

time. Detailed record keeping in your Final (100%) Inspection area will

indicate specific trends with certain operations, products and operators. This

important information allows you to take necessary prevention action steps for

future production.

8.6.4 Packing

Packing standard & instruction should be available within packing section.

Garments must be packed into poly-bag & cartons according to size / color

ratio as per the packing instruction.

Packing mock ups should be there in packing department so as to be used as

reference.

Packing list should be available with the buyer approved packing procedure.

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8.6.5 Pre-final quality auditsThere has to be a separate Factory QA team, who conducts in-process audits & final

audits on finished goods daily. They must report daily to the factory manager on the

results of these inspections.

When the products are continuously produced in high volume or require detailed

packaging, the final auditing can be done before packaging. If the sample audit fails,

the merchandise can be re-inspected more efficiently, without destroying packaging

material and wasting labour. If this approach is taken, regular daily audits should be

made on packaged stock, to prevent packaging problems. These units inspected for

packaging need not be opened and inspected for workmanship, if all were part of

passed Final Quality Audit (Annexure 43).

8.6.6 Order Closing Report (OCR)After shipment of goods, the OCR should be made within a day which includes the

order quantity, cut quantity, shipped quantity, balance break-up (seconds break-up) so

that the party responsible for the production loss can be debited.(Annexure 44)

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9. Quality Assurance

9.1 QUALITY POLICY

MADURA GARMENTS EXPORTS LTD. is committed to comply with requirements and continuosly improve the Quality management system and supply high quality garments on time to enhance customer satisfaction through training and involvement of employees.

9.2 QUALITY OBJECTIVES

1. To increase the Production from the existing level every year.

2. Continuous improvementa) Productivityb) Waste eliminationc) House keeping

3. To make employees multiskilled through training and development.

4. To maintain and improve Workorder throughput time

5. To reduce seconds percentage

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9.3 Quality checkpoints Sampling Plan

NOT OK

OK

Quality passed trims and fabric

Visual inspection passed fabricaccording to sampling plan

NOT OK Visually identify the problems and check for the following

OK points in the laying process

Quality check at the beginningof the lay

Check for the first ply.

NOT OK OK

NOT OK Quality check in between lay

OK

After laying

62Is W.O.no,Centre line,Repeat,Balancing,St line,one way okay?

Re-Do

Is W.O.no,size,parts bundleno,numbering,lay no okay?

Check forW.O no,bubbling,Fused thread,Stain,lining

Check for W,O no,weaving defect,Style verification,Centre notch,Fabric Damage,pairing,shape,St line

Quality check

Issue of Quality passed cut parts to sewingRe-DoRe-DoRe -Do

Check trims& fabric as per sampling

Cad checking against master copy, marker length & width,

proper scrambled sizes, all parts in marker, Line balancing?

Laying

Style descriptions, Fabric code, W.O. no,

Design approval, Fabric one way or two way?

Re-do

Shade, width-wise lay,

Waviness, Bowing?

Fabric& Trims status

Issue to Cutting

RTS

Re-do

Is W.O .no, size, central line, notches, straight line, repeat width, Line balancing, pairing, shade ok

Marker placement, Line balancing, No. of plies?

Re-do

NOT OK

NOT OK Check the following points at the start and end of cutting process.

NOT OK

cut parts; check the OK following points

during bundling.

NOT OK

Quality Check in relayOK (if check/stripes)

NOT OK Parts inspection check

OK

Quality check during fusing

NOT OK OK

Quality approved cut parts

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Check for W.O no, bubbling, Fused

thread, Stain, lining

Quality check during fusing

Issue of Quality passed cut parts to sewing

Is W.O .no, size, central line, notches, straight line, repeat width, Line balancing,

pairing, shade ok

Is W.O. no., Centerline, Repeat, Balancing, St line, one way okay?

Is W.O .no, size, parts, bundle no, numbering, lay no

okay?

Check for W.O. no., weaving defect, Style verification, Center notch, Fabric damage, pairing,

shape, St line

Re-do

Re-do

Re-do

Re-do

Re-do

NOT OK

Collar visual

OK Standard, measurement collar NOT OK

Left and right front parts.Visual standard, measurement

NOT OK OK

Assembled shirt, Measurement,

NOT OK OK visual Standard.

OK

NOT OKIdentify first quality

seconds and rejects

NOT OK

OK

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Display of reference shirt with comments & receive information for checking

Check point 1

Collar inspection

Check point 2 front

pairing

Check point3 trimming

& inspection

Re-WorkIn- line inspection by Traffic light System

Checkpoint 4 Final Inspection

Seconds & alterations

Release to finishing

Re-Work

Re-Work

End Line AQL Audit at AQL 2.5

Re-Work

Trolley wise AQL audit (2.5)

Folding & PackingFolding &

Packing

R OKEJ AQL NOT OKCTS

OK

ACCEPT

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Pre Final Audit/Finished Stock Audit(10%, 25% and 50%)

Release to Warehouse

Offer for final

inspection

9.4 Quality Procedures9.4.1 Fabric Inspection Report

No sooner Fabric is in house, The Fabric inspection report, Shrinkage report & 100%

Shade bands should be submitted within 48 hours. Fabric is to be cut only after the

above reports are submitted & only if they are approved for bulk production. Initially

10% of the Fabric is to be inspected on a 4 point system & if the fabric is in doubt,

further 10% should be Inspected. While submitting the Fabric Inspection reports, all

trim inspection reports should be submitted too. If Fabric is cut without been

Inspected, Total responsibility will be on this department as it is a violation of a

critical aspect. The below reports should be submitted to Buyers & the relevant

Merchandiser.

Fabric Inspection. ( Inspection on 4 point system ).

Purpose: To decide acceptance or rejections of fabric roll ( For Wovens )

Activity Requirement

1. Take the roll.

2. Check the roll as per 4 points system.

3. Give penalty points for defects.

4. Calculate index for each individual roll.

5. Calculate final average index for the

total no. of rolls inspected.

6. Decide acceptance or rejectance of the

fabric

Roll to be chosen at random

Points / 100 sq. yd. =

Total points in roll * 36 * 100

Total length in yards * width in

inches.

Record: Fabric inspection report

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Classification P E N A L T Y P O I N T S

1 point 2 points 3 points 4 points

Faults showing in the

warp direction of fabric.

( Holes and tears excepted

).

Less than

3inch.

Over 3 inch

but less than

6 inch.

Over 6 inch

but less than

9 inch.

Over 9 inch.

Faults showing in the

weft direction of fabric.

(Weave stripes, weft

irregularities, holes and

tears are excepted).

Less than

3inch.

Over 3 inch

but less than

6 inch.

Over 6 inch

but less than

9 inch.

Over 9 inch.

i). Length of the faults is to be measured in the warp or weft direction and the

direction in which the fault is longest is the fault direction. However when the warp

and weft length are same and when the penalty of the shorter direction is heavier, take

the fault of the direction in which the penalty is heavier.

ii). When the fault in the warp direction is over 1yd, the part which is over 1yd is

deemed as fault of the same kind of others.

iii). When two or more faults overlap, apply only the faults which penalty is the

heaviest.

iv). When there are two or more faults within the length of 1yd and the penalty points

come over 4 points, the points over 4 points are not added.

v). The inspector needs to be at a distance of 3 feet away from the inspection table and

the linear speed of inspection not to be less than 0.1mtrs per second.

Minimum fault sizes are shown on the Sears Fabric defect scale :-

Knots Slubs

A – do not count A - do not count

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B- Count as 1 point B - do not count

C- Count as 1 point C- Count as 1 point

D- Count as 1 point D- Count as 1 point

E- Count as 3 points E- Count as 1 point

  F- Count as 3 points

  G- Count as 3 points

Standards for Passing Fabric:-  

Average index for inspected rolls not to exceed » 28 points / 100yd².

Maximum index for any roll not to exceed » 40 points / 100yd².

9.4.2 100% Shade Bands.

If the style is a wash garment, Before & after wash Blankets should be submitted ( 3

sets each ) covering all rolls and it has to attached in the shade continuity card

(Annexure 12)

A 100% shade band covering all rolls & all colors pertaining to a certain style /

Consignment should be made & approved prior to cutting of bulk Fabric.

Process.

No sooner the Fabric is in house, The Q/A department must ensure they get

the panels representing all rolls within 6 hours from Stores.

Cut 6” from end of each roll. Over lock & join all panels in correct grain line

direction to be in a Blanket form.

If the Style is a non-wash program, Two sets should be prepared.

If the Style consists of a certain wash, Then 4 Blankets should be prepared. 02

Blankets non-washed & 2 Blankets with the exact approved wash of the style.

Once the Shade bands are ready, Dye lot or color segregation has to be done.

If the Shade Band consists of 2-3 different shades, Such shades should be

segregated in to families marked A,B,C Etc. A copy of the Segregation of

shades should be handed over to the Stores, Cutting, Merchandising &

Production departments.

Stores will issue & the cutting / Production will proceed as per the segregated

shades without getting mixed.

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9.4.3 Shrinkage reportA 10% Shrinkage report should be submitted for all styles

and the washing shrinkage has to be performed as per the wash type required for the

bulk.9.4.4 Trim Inspection reportAll trims been In house should be inspected

( 10% ) & the reports submitted accordingly.Trims Inspection Purpose: To check

defects and to decide Acceptance / Rejectance of trims.Scope: Interlining, Collar

bone, Label, Button, Packing Materials, Swing Ticket, Poly bag, Product box.

Activity RequirementA. Interlining

1. ½ meters of lining to be sent to lab.

a. Bond strength 1.Take 10” * 4” of fabric strip and lining strip.2.Cut rectangular slit 6”*1” in Tissue paper of 8 ‘ * 4”.3.Sandwich Tissue paper between interlining and fabric then fuse.4.Check Pull strength.

If by varying fusing conditions sufficient strength is not achieved the lot is rejected.

b. Shrinkage Test .1. Send two collar to lab every day for

shrinkage test.

c. Visual Inspection 1. Select the roll as per sampling plan.

Reject the lot is not ok.

EPI / PPI and GSM

Note the temperature, pressure and speed.

Pull strength to be atleast 1 kg / sq.cm.

Check for uniformity, micro dots, uniformity of shade.

Record : Interlining Inspection report.

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Activity RequirementB. Labels

a. Visual Examination 1.Check lettering , color, edges as per the Master and Specifications.

b. Color fastness test 1. Take few labels get it stitched on the

white fabric.2. Wash with soap and wash petrol.

If color bleeds rejects the lots.

No weaving defects.Shade continuity.Smooth and straight edges.Centered labels.

No color bleeding.

Note: Selection Of all trims for the inspection to be as per sampling plan.

Activity RequirementC. Buttons 1. Check buttons for shade, chip around

the edge.2. Get stitched 10 buttons breaks

stitched in machine.3. If any one button breaks, then check

for 10 more buttons.

If there is breakage reject the lot.

D. Packing Material

1. Check edges, slots and slot spacing.

Uniform in shade, gauge.No chip.NO breakage

No breakage.

Even edges for all the trims. Slots and Slot spacing as per the specifications.

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Activity Requirement

E. Swing ticket 1. Inspect visually the lettering.

F. Product Box

1.Check for lettering, hinge, marks and color.

G. Polycovers

1. Check for lettering, uniformity and scratches.

H. Collarbones

1.Check for edges and points.

2.Stick few collarbones on fabric to check for glue.

If gum is insufficient, reject the lot.

No stains and misprints.

No misprints and spread hues

No misprinting and spread hues. Shade continuity to be maintained.

No cut edges, point to be as per specification.Should fix firmly to the fabric.

Record: Trims inspection report.9.5 Size setBulk production cannot be started without the QA Department approving the Size set for each new style. Once the size set is approved, The Pattern should be checked & authorized by this department for utilization. 9.6 PP MeetingA PP meeting should be organized & conducted prior to bulk production including Buyer’s Representative, Merchandiser, Production Manager & all sectional heads, Supervisors & Q/C’s involved with the particular style. No Production is to start without a PP Meeting & all points to be discussed & documented in the PP meeting format (Annexure 45). The QA Manager or the Technical Manager should write down the minutes & file the PP meeting comments in the style file “ Technical, Quality, Packing, Washing, Shipping ETC”. 9.7 Pilot RunOnce the Production submits the Pilot run, Bulk production should be approved based on the performance of this cut. If it is not satisfactory, a new pilot run should be made.9.8 Test to failure9.8.1 Purpose Testing mock up pieces (36) to demonstrate consistency in fabric, threads, machinery. The test pieces are pulled with a force until they are destroyed establishing the kilograms at which they are break apart.Results details- are recorded as = Z factor.Where there is a consistent result the Z factor will be 4 or above – Pass.Where there is inconsistency the Z factor will be less than 4 – Fail.9.8.2 ImportanceThese tests and the documentation are our evidence of the control to ensure the product we make is safe. It also allows us to identify if there is any inconsistency which we need address to improve the product safety.The TTF results are required to accompany the master style file and should be

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discused at the time of hand over meeting. 9.9 Pull Tests 9.9.1 PurposeTo ensure the application is button, stud, snap can withstand a set kilogram of pulling. The recommendations are specified by our customer at 7 kg per single pull but as a safe guard MGEL recommend our procedure is pulled at 8 kg.9.9.2 ImportanceTo ensure the application can withstand the desired amount of strain in normal wearing conditions. 5 Pcs randomly must be monitored closely due to product safety.9.10 Durability Wash 9.10.1 Purpose This wash test is carried out in the laboratory to ensure the garments construction is robust (strong). The laboratory test highlights any change to the following areas: Seam breakdown, fused components, change to colour appearnace, optical brightner and fabric handle, effects on accessories, colour fastness, pleat sharpness and any wadding. The wash is carried out at 10 degrees higher than the recommended label wash tempreture. The laboratory also need a garment reference- for the pre-wash inspection and then the after wash inspection. 3 garments minimum requirement.9.10.2 Importance To ensure all our methods, fabric and trim accessories are suitable to the style and will perform over numerous times of wear. To prevent customer returns and customer dissatisfaction.9.11 Quality procedures in cutting department.Rolls segregated & laid as per shade band separation.

Relaxation of Fabric for Stretch & Knit at least for 12 Hours and fabric relaxation report maintained (Annexure 47)

Fabric Width. Checking of Marker lay out. Control of Layers as per Fabric construction. Checking of Panels against pattern board after cutting. Random check of panels for Fabric flaws. Fusing parameters like temperature, pressure and time are controlled at fusing

machines periodically and recorded in fusing quality report (Annexure 48) to ensure optimum bond strength.

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9.12 Quality ControlQuality control on the product, Packing & stacking should be maintained at the

highest level.

A full functional traffic light system (Annexure 46) should be maintained at all times.

Statistical process controlling ( SPC ) should be implemented for every line to

minimize rejections. No Garment should be passed with inferior quality &

rectification to be made with immediate effect & documented.

9.13 Traffic Light System.

This System is a very affective approach in curtailing & discontinuing defected panels

& garments with discrepancies from moving in the Line. There are three colors to

identify the progress of the operator & the quality.

Green, Amber & Red bag with the Instructions of Operation descriptions to be

audited.

* Green – If this color is flagged by the Line Q/C on top of a machine, It

indicates that the Operation is under control & of good standing & could proceed to

the next operation or machine.

* Amber - If this color is flagged, It high lights that the Operation produced

by the Operator is in a tolerance margin & needs close observation from Superiors.

* Red – If the Line Q/C has flagged this color on top of a machine, You

should halt the machine & the operation immediately & rectify same without any

delay & ensure the productivity is not affected. In the same time the Line Q/C must

record Instruction paper what is in color bag & her operation file to follow up & same

Q/C will issue a Pink token to the Supervisor to rectify same & to follow up in three

consecutive instance’s in the same Operation ( To Ensure 0 defects are maintained in

a particular Operation) & cross check with the Q/A.

•The roaming Q/C must continue for each & every machine Incorporating the same

process in the Line ( Not more than 32 machines per line ), Minimum four times a

day.

•Each Line Q/A dept should have two “In process Audit stations” for 100%

components check with the defect statistics (In line Inspection report Annexure 42)

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maintained which could be analyzed hourly on each Operation to rectify prior to a

Assembling Garments.

•Each end Line should have a QA Audit station performing 100% Inspection of

Garments prior to moving to the next Process & the Defects to be maintained in the “

Defect Analysis Report”(Annexure 43).

No inline & end line checkers should have trimmers.

9.14 AQL Audit.

Apart from the 100% Inspection at End Line, The Q/A Dept should Audit the

Merchandise randomly to ensure the Quality standard set by “MGEL”. Each Auditor

should cover 5 Production lines & every hour as per the given AQL (Appendix 43). If

the Standard is acceptable as per the below stipulated table, The Goods can be

processed for the next Operation. However if the Merchandise is not up to the

required Criteria, Total Qty should be returned back to the Production Line for

immediate rectification & the same Auditor should closely Monitor until the

rectification is complete. You have to strictly adhere to maintain an AQL level of 1.5

during Inline Inspections.

9.15 Random Measurement Audit.The QA dept should inspect measurements of Garments randomly covering all styles,

Color & Sizes to ensure the Merchandise is meeting the required Specification before

& After wash. (Annexure 4)

9.16 Pre Final AuditPrior to handing over merchandise for final Audit to Buyers, the Q/C department

should do an interim Inspection & submit copies of the reports to the G/M Production

& marketing, Production Manager & the relevant Merchandiser for each P/O. This is

Mandatory. A count & accuracy report should be submitted as well.

 

9.17 Outgoing Quality LevelAll the external audit reports should be compiled into one final report with the defect

penalty points will expressed as percentage of total defectives found over the total

quantity shipped out for that month. Also a report of total external audits failed over

total external audits faced in that month should also be prepared.(Annexure 50)

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9.18 ReportsAll inspection in Production & finishing should be daily documented by using Inline

reports & a copy of these reports should be submitted to the relevant Merchandiser at

least twice a week without fail.

9.19 SamplesThe QA Department should submit the following samples, T.O.P – Within 3 days of

bulk input as per buyers required size & Shipment samples as per buyers requirement,

one day before final audit. This should be strictly adhered to.

i) It is mandatory that all Line Quality Supervisors & controllers should patrol their

respective lines on a daily basis

prior to starting bulk production in the morning to ensure that the Line is geared to

Produce high quality Apparels.

* The following aspects should be taken in to awareness,

a) Cleanliness of the Floor – No Garments, Dust, Stickers, Stains etc to be on

floor.

b) Cleanliness of Machines –

1) Well cleaned without any dust.

2) Oil level & Stains on M/C to be checked.

3) Needles to be checked & should be fluff free & not blunt.

4) Any M/C with “Red” flags on & if, Mechanic to be questioned.

c) Check for Reject Garments – No Reject garment is to be brought forward from

the previous day without been rectified. All Reject Garments should be rectified on

the same day & not kept separately inside the line.

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List of Annexure

SL NO DOCUMENT CODE DESCRIPTIONANNEXURE 1 MGEL-SP01 SAMPLING INDENTANNEXURE 2 MGEL-RD01 PILOT LOADING PLANANNEXURE 3 MGEL-RD02 PILOT CUTTING LOG BOOKANNEXURE 4 MGEL-RD03 PILOT MEASUREMENT REVIEW SHEETANNEXURE 5 MGEL-RD04 PILOT COMMENT SHEETANNEXURE 6 MGEL-RD05 AMMENDMENT SHEETANNEXURE 7 MGEL-IE01 OPERATION BULLETINANNEXURE 8 MGEL-IE02 LINE LAYOUTANNEXURE 9 MGEL-IE03 TECHNICAL LAYOUTANNEXURE 10 MGEL-RD06 TECHNICAL STYLE DETAIL SHEETANNEXURE 11 MGEL-RD07 RISK ANALYSIS FORMATANNEXURE 12 MGEL-ST01 SHADE CARDSANNEXURE 13 MGEL-ST02 DESIGN APPROVAL CARDANNEXURE 14 MGEL-QA01 FABRIC SHRINKAGE EVALUATION SHEETANNEXURE 15 MGEL-ST03 BIN CARDANNEXURE 16 MGEL-QA02 FABRIC INSPECTION BOOKANNEXURE 17 MGEL-QA03 4-POINT SYSTEM FOR FABRIC INSPECTIONANNEXURE 18 MGEL-CT01 CUT PLANANNEXURE 19 MGEL-ST04 TRAVELLING WORK ORDERANNEXURE 20 MGEL-CT02 MONTHLY PLANANNEXURE 21 MGEL-CT03 WIP REPORTANNEXURE 22 MGEL-CT04 TABLE PLANANNEXURE 23 MGEL-PL01 MONTHLY DELIEVRY TRACKERANNEXURE 24 MGEL-PL02 PRODUCTION PLAN SHEETANNEXURE 25 MGEL-QA04 PATTERN CHECKING REPORTANNEXURE 26 MGEL-QA05 CUTTING VISUAL STANDARDSANNEXURE 27 MGEL-CT05 LAY SPREADING SHEETANNEXURE 28 MGEL-CT06 NORMAL TABLE LAYING INSTRUCTION SHEETANNEXURE 29 MGEL-CT07 PIN TABLE LAYING INSTRUCTION SHEETANNEXURE 30 MGEL-QA06 LAY CHECKING REPORTANNEXURE 31 MGEL-CT08 WORK INSTRUCTION FOR STRAIGHT KNIFE CUTTINGANNEXURE 32 MGEL-CT09 WORK INSTRUCTION FOR AUTO CUTTINGANNEXURE 33 MGEL-CT10 WORK INSTRUCTION FOR BAND KNIFE CUTTINGANNEXURE 34 MGEL-CT11 WORK INSTRUCTION FOR CUT COMPONENET STORAGEANNEXURE 35 MGEL-CT12 NUMBERING PLANANNEXURE 36 MGEL-CT13 BUNDLE COLOR CODE SHEETANNEXURE 37 MGEL-CT14 FUSING WORK INSTRUCTION SHEETANNEXURE 38 MGEL-SW01 CUT PART RECIEPT SHEETANNEXURE 39 MGEL-SW02 MAINTAINANCE CARDANNEXURE 40 MGEL-SW03 NEEDLE POLICY FORMATANNEXURE 41 MGEL-SW04 OPERATION SPECIFICATIONANNEXURE 42 MGEL-SW05 ENDLINE ALTERATION REPORTANNEXURE 43 MGEL-SW06 PRE FINAL AUDIT REPORTANNEXURE 44 MGEL-SW07 ORDER CLOSING RECORDANNEXURE 45 MGEL-QA07 PP MEETING FORMATANNEXURE 46 MGEL-QA08 TRAFFIC LIGHT SYSTEMANNEXURE 47 MGEL-QA09 FABRIC RELAXATION SHEETANNEXURE 48 MGEL-QA10 FUSING QUALITY REPORTANNEXURE 49 MGEL-QA11 DEFECT ANALYSIS REPORTANNEXURE 50 MGEL-QA12 SAMPLING PLAN AQL

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ANNEXURE 51 MGEL-QA13 OUTGOING QUALITY LEVEL

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