Simba Fashions Ltd.

SOP MANUAL

1
 APPROVAL
The Purpose of SOP manual is to define application of standard operation system in effect
at Simba Fashions Ltd., to implement the quality & operational procedure and fulfill the
requirements of the quality management system elements.
General details have been given in this manual on the organization structure,
responsibilities, relationship etc. and the method of carrying out the tasks for each element
of the system. Wherever applicable, references have been given the procedures and other
relevant documents which are not included in the manual but are controlled and maintained
by the relevant functions of the organization.
This manual is designed as a guide for the personnel of the company to carry out the tasks
in conformity with this documented system, orderliness and ensure clarity and uniformity
in description of work by different persons. Department heads are responsible for ensuring
that all their staff fully understand and implement the relevant system requirements.

I, hereby, approved and released 1st edition of Operation SOP manual for implementation
and follow up at Simba Fashions Ltd. (All units)

If any of the requirements from our customers differs from that of the manual, it will
supersede the internal SOP.

Mr. Navneet Bhagat

Managing Director

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 PAGE NO
SL CONTENTS
1 Authorization to stop the production for quality issue 5
2 Procedure for Document & Data Control 6-8
3 Corrective Action & Preventive Action 8
4 Training & Competence Enhancement T Procedure 9
5 Calibration Procedure 10
6 Light replacing Report 13
7 Measurement Tape Calibration 14
8 Quality Inspector Testing 15
9 Basic English test 19
10 Minimum lighting requirement 20
11 Color Vision test 22
12 Fabric Receipt, issue & storage 23
13 Fabric inspection, shade band & shrinkage 27
14 Fabric Bowing /Skewing Bias 28
15 4-point fabric inspection 29
16 GSM Check 33
17 Procedure for shade band 38
18 Shade Segregation 40
19 Spirality & detrition check sop 43
20 Trims & accessories receipt, issue & storage 45
21 Accessories/Trims inspection elastic inspection procedure 46
22 Nickle test 52
23 Accessories check list 53
24 PP meeting 57
25 SIZE SET & P.P.R SOP 60
Pilot Run SOP 62
26 First Production Output 63
27 Fabric Relaxation procedure 66
28 Fabric Spreading Procedure 68
29 Cutting Quality Control 73
30 SOP of Label Control 80
31 Button Pull Test 82
32 Snap attach policy 84
33 Heat Transfer SOP 84
34 Inline Process quality check 85
35 Traceability 87
36 Procedure For Statistical Quality Audit 88
37 Measurement Control Guideline 95
38 SOP For Controlling Rejection Due to uncut thread 96
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39 Procedure for In-line & prefinal Quality Audit 97
40 AQL Chart 102
41 Match Book SOP 103
42 Packing Method and Cutting 104
43 Embroidery & printing QI 104
44 Fusing Calibration Bonding Strength test 105
46 Broken Needle, Needle Exchange Handling & Metal Contamination 109
Preventive procedure
47 Sharp Tools Control Procedure 113
48 Quality Analysis & Improvement 115
49 SOP for Sticker allocation for finishing Quality checker 117
50 SOP For corrective Action 117
51 SOP For Re-check 117
52 Hazardous risk analysis 120
53 Jewelry Policy 121
54 SOP for change in Material, Components, Design or Manufacturing 122
Process of a Product
55 Sop For Handling Buyer Complaints 123
56 Sop For Supplier Approval and Performance 125
67 Approved Supplier List 127
62 SOP For Roving QC 131
63 SOP For QC Training 133
64 B4 wash spec sheet SOP
65 Sop for lab test
66 Sop for internal Audit

INDEX

4
Authorization to Stop the Production for Quality Issue

Simba Fashions Ltd. is committed to efficiently produce and timely deliver safe, legal &
good quality garments to the customers

In order to keep our commitment to the above, I hereby authorize all respective line QA,
QA Executive and above designations Quality Personnel to use their due diligence and stop
the production if the product quality is not up to the required standard.

Mr. Navneet Bhagat

Managing Director

5
 Procedure for Document & Data Control
1.0 Purpose & Scope:

To ensure that all documents comprising the quality management system, are controlled, and
distributed so that those employees requiring them use only current issues

2.0 Responsibilities:

The Quality Head has responsibility for directing activities relating to this procedure. Where other
functions have responsibility, they are so indicated

3.0 Procedure:
3.1 Document control for documents of Internal Origin:
3.1.1 Document Hierarchy:
3.1.1.1 Level I - Procedures / Plans / Standards
3.1.1.2 Level II – Work Instructions / Formats
3.1.1.3 Level III – Quality Management Records
3.1.2 Document Numbering System:

3.1.1.4 The documents of internal origin are numbered as SFL-XXX-$$$### where:

3.1.1.4.1 SFL stands for Simba Fashions Ltd.
3.1.1.4.2 XXX stands for Department / Function code
3.1.1.4.3 $$$ stands for type of document represented by 2/3 letters as below:
 PRO – Procedure
 WI – Work Instruction
 PLN – Plans
 FRM – Format
 CHL – Checklist
 MCP – Manufacturing Control Plan
3.1.1.4.4 ### stands for individual document number starting from 001
3.1.1.5 Any revision to the document is represented by an extension and
revision number as SFL-XXX-$$$-### -01 (Date)
3.1.1.6 If any document undergoes the revision, it will replace the old
version in use.
3.1.1.7 Department / Function Abbreviations are as below:

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 Code Department Code Department

HRM Human Resource STR Stores

QAS Quality Assurance CUT Cutting

DQA Dedicated Quality Auditor FIN Finishing

SEW Sewing MNT Maintenance

COP Compliance MSR Merchandising

Store(Fabric/
Accessories)
QMS Quality Management SQC Quality Control

3.1.1 Document Approval:

3.1.2 The appropriate personnel are authorized to approve the documents as below
3.1.3 All Quality Management System Procedures, Work Instruction, Quality Plan and formats are
approved by Head of QA.
3.1.4 All the Operations Procedures, Work Instruction, Plans and formats are approved by Head
of Operation.
3.1.5 All the Procedures, Work Instructions, Plans & formats related to HR & Compliance is
approved by Head of HR & Compliance and Head of QA.
All other documents are approved by the related Head of Department.

3.2 Document control for Documents of External Origin

3.2.1 All documents of external origin related to the Quality Management System are
controlled. The issue number or document number is not allocated simply because the
company is not authorized to modify such documents.
3.2.2 Law and buyer requirement:
3.2.2.1 All laws used as reference in the company will be kept by Head of QA.
3.2.2.2 All the buyer Manuals, Safety, Legal and Compliance documents will be controlled by
Head of QA.
3.2.3 All the documents of external origin will be retained for 1 years and shall be at the
disposal of regulatory authorities, customers, or top management upon request.

3.3 Document Review:

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 3.3.1 Anyone can propose the change in any document to the respective HOD. The
HOD will review if the change is beneficial to the company and can have
improvement in the processes related to the product quality, safety & legality.
3.3.2
Upon review, if required, the necessary changes will be done in the respective
documents and copy will be circulated to all the relevant persons.
If any document does not undergo any changes in last one year, these will be subjected to review
for ensuring continuous effectiveness

1.1 Handling / Withdrawal of Obsolete Documents:

1.1.1 The amended / revised document is issued to the copy holders of the document against
the deposit of the obsolete documents.
1.1.2 All the obsolete documents thus collected will be destroyed. If the obsolete documents
are preserved for any specific purpose, the same will be stamped as “Obsolete”.
The respective function in-charge is responsible to ensure the withdrawal & disposition of the
obsolete documents that is in use in his area

Corrective Action preventive Event

Sr. No.
CAP initiating report Applicable Format Circumstances
1 Quality Analysis & Weekly Analysis of finishing
Improvement Poor performance – Throughout the Week

Daily End line 100% Inspection

Daily Poor Performance
Customer Compliant – Formal / Informal
Customer Complaint Customer CAPA Customer Claim
2
CFS / DC / In Store Failure
During Factory Visit of Customer
General Issues
Product Test Failure
In-line / Pre-final Inspection Failure (Major)
Inspection failure Corrective Action Preventive
3 Buyer DUPRO / In-line Failure
action
Final Inspection Failure
Issues not covered under any other
circumstances
4 Internal audit / customer Reported NCs Non-Conformities recorded during Audit.
audit

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 Training & Competence Enhancement Procedure
1.0 Purpose:

To identify & review the competency needs of the personnel, administer the identified training
and/or any other action to ensure that individuals performing specific assigned tasks are
adequately competent.
2.0 Responsibility:

Head – HR along with the respective Head of Department is responsible for implementation
&
monitoring of this process

3.0 Procedure:

 The competence of the persons whose work affects the product quality, safety
or legality depends on experience, training, skills & education.
 The competence need is reviewed if arising out of (as the case be) -
 New Employees
 Promotion in job
 Job redesign
 New Machinery
 New Technology
 New Method
 Recurrence of any issues related to quality, safety, or legality of the product
 Buyer requirement
 Improvement in personal performance
 On job training.

 The training needs are developed based on the above review (3.2) and suitable training
program is selected or
 tailored training program is developed, and the trainer is identified.
 In case, there is no training module available internally or the tailored training can’t be
developed, the outside training may be provided.
 Once the training module is finalized, the employee or group of employees are notified
about the training schedule and are subjected to the training.
 Training includes all those activities where a learning opportunity exists such as
 Classroom style tutor lead training
 Hands on experience training (Induction)
 Individual or group coaching
 Mentoring
 Briefing
 Technology based training (CD, web based etc.) Workshops
 During the training, it is ensured that the employees undergoing training are aware of the
relevance & importance of their activities and how they contribute to the achievement of
the company objectives.
 The training records are maintained along with digital pictures by respective
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 departments and an individual training record is maintained in personal file by HR
department.
 On completion of training, the trainees give the feedback about the training session,
which serves a major input for improvement of training future training modules
 At the end of training, as the need be, the trainer / HOD sets the evaluation sheets to
understand the level to which the trainees have understood the input given during the
training.
 The effectiveness of the training is monitored through on the job performance of the trainees

Re-Training: After completing the evaluation, below standard

(grade-c) performer gets retraining and completing the retraining it
will be re-evaluation.

CALIBRATION PROCEDURE
1.0 Purpose:
To provide general guideline procedure for calibration of measuring & monitoring equipment,
devices / tools critical to product safety, legality, and quality in order to minimize the risk of
manufacturing defective, unsafe or illegal product

2.0 Responsibility:
The Maintenance Manager of the respective factory is responsible to implement & monitor the
process unless otherwise specified in the individual equipment / tool’s calibration SOP.

3.0 Definition:
Calibration is a comparison between measurements - one of known magnitude or correctness made
or set with one device and another measurement made in a similar way as possible with another
device.
4.0 Procedure:
All the critical measuring & monitoring equipment are identified and the master list of all the
equipment to be calibrated is prepared & maintained by Maintenance Head.
 4.2 The calibration frequency is derived at based on but not limited to:
 Risk to product quality
 Legal requirements
 Supplier efficiency
 Operating environment & conditions
 OEM recommended intervals
 Historical data
 Failure analysis
 Reliability centered maintenance program
 Industry Experience
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 The equipment calibration matrix is prepared as guideline document for calibration.
 Measuring & monitoring equipment are calibrated against the Master equipment duly
calibrated by BSTI (or equivalent competent agency) against the national / international
standard.

 All measuring devices will have calibration label firmly affixed with the following minimum
details:
 Serial number / id number of the equipment
 Date of calibration
 Due date for next calibration
 Deviation from the Master
 The equipment which are found out of specification / out of calibration, are:
 Taken out of service, Repaired
 Adjusted & readjusted as required before put into use again
 Rejected.
 Records of repair and/or adjustment / readjustment is maintained as per respective individual
SOP as required. The general guideline is given in Flow chart for Equipment out of
calibration
 If any inaccurate measuring & monitoring equipment found in use, documented
corrective action would be initiated if necessary.
 This procedure is applicable to all the identified measuring & monitoring equipment in
addition to the specific calibration procedures for each individual equipment as applicable.
5.0 References:
 Calibration Matrix
 Master list of equipment to be calibrated.
 Calibration Certificates from BSTI (o r equivalent competent agency) for master
instruments
Internal Calibration Records

Different Device’s Calibration Method

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 Light Replacing
Report

Name of the Equipment : Shade Matching Cabinet

Model No : Serial No :
Light Source : Meter Reading : Hrs :

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 Date of
Make No. of Lights Specifications Next Due Date Signature
Replacement
& Name

Light Source : Meter Reading : Hrs :

Light Source : Meter Reading : Hrs :

Light Source : Meter Reading : Hrs :

Light Source : Meter Reading : Hrs :

Light Source : Meter Reading : Hrs :

Measurement Tape Calibration

1.0 Purpose & Scope
This procedure outlines requirements for calibration of measuring tape.

2.0 Responsibilities
Respective Sr. QAM / QAM is responsible for implementation of this procedure.
Respective Maintenance In-charge is responsible for calibration of measuring tape and maintaining
calibration records.
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3.0 Procedure
Calibration

 All measuring tape is calibrated before issuing to any person for use.
 Calibration is done against a master steel measurement tape
 Discrepancy is recorded in the log sheet.
 When the discrepancy is over ± 1/8” over total of 36”, the tape is regarded as out of calibration
and must be replaced / taken out of use.
 The tape should be recalibrated after one months of use.
 Once issued for use, if the tape condition gets poor, (wavy edges, twisting or torn) it must be
replaced with a new one, even if the measurement discrepancy is within tolerance.
 Issue for use:
 Each tape after calibration is given a serial number and same is entered in log & written on
the tape as well.
 Calibrated tape is issued to a person for use, by entering all the details like Name, Emp. Code
& Date of issue.
 The name of person using the tape along with the id number, tape number, date of calibration &
next
 calibration due is also written on the tape before issuing.

Measurement tape calibration

QUALITY INSPECTOR TESTING

1.0 PURPOSE & SCOPE

 To calibrate the quality inspectors (QI) at the time of recruiting and at regular interval for
checking errors, eyes concentration and shade identification
 This process is applicable for all the quality inspector working in Simba Fashions Ltd.

2.0 RESPONSIBILITY

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  The QA Executive of the respective floor is responsible for implementation of this process
and the QA In-charge of the respective floor is responsible for monitoring of this process
for the existing quality inspector
 The HR executive of respective factory is responsible for implementation & monitoring of
this process for the new recruits as quality inspectors.

3.0 PROCEDURE

The calibration of the quality inspector is done on three areas:

Sr. Fresher Experienced
1 Basic English test Checking Errors
2 Eye concentration Eye concentration
3 Color Discrimination Color Discrimination

Checking Errors Calibration:

 This test is conducted only for the candidate with previous work experience
 Every experienced QI is subjected to the checking efficiency test at the time of recruitment
and every 6 months thereafter.
 If QA executive of a respective floor feels the improvement of a QI’s performance, the
same can be validated thru this process.
 Based on the analysis of the weekly quality performance, if the need be, a particular QI
can be recalibrated as per the decision of respective QA Executive.
 If any packed goods fail in independent inline / pre final inspection, recheck is done as
per the recheck SOP. The worst performing QIs may be subjected to Calibration checks.

 Concentration Calibration:
 All the new recruits as QI, are subjected to the concentration test to ensure minimum
concentration calibration required for QI.
 This test is conducted as supplementary to the Error Checking calibration
 Color Discrimination Calibration:
 Every QI is subjected to the color discrimination calibration at the time of recruitment and
every 6 months thereafter.
 This calibration is compulsory for all those dealing with shades.
 Basic English Test
 This is applicable only for fresh candidates without any working experience.
 The HR responsible will give basic English test form to the candidate which is marked for
10 marks
 Conducting the Calibration:

 The QI, who is subjected to the checking error calibration, is given one lot of garments.
No. of garments in the lot should be equivalent to one hour capacity of the quality inspector
based on the product type.

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 Once the QI checks all the garments in the lot, the defectives are noted in the Quality
inspector Evaluation Sheet and the defective garment are taken out from the lot.
 The DHU of the lot is calculated as per the formula given in the evaluation sheet and
entered in the form.
 The passed goods are given to an independent QA for audit purpose at a fixed sample size
of 25 pcs.
 The defectives found by QA are noted and entered in the format. The audit DHU is
calculated using the formula given in the evaluation sheet and same is entered in the form.
 Based on the QI checking DHU and QA Audit DHU, the quality inspector
efficiency is calculated using the formula in the evaluation sheet.

 Procedure for Concentration Calibration:

 The QI subjected to this test is given, the Concentration calibration form which has 10
crooked / mixed lines spreading from left to right overlapping each other.
 Each line has serial numbers at the stating end and the end point is left
blank intentionally.
 The QI under calibration must follow the lines from left to right using only eyesight (use
of finger, pen or any other means is not allowed) and write number to the right end of
line same as on left end.
 All 10 line need to be numbered within 50 sec.
 The time taken for numbering a l l the lines is recorded and the concentration level
is calculated as given time x 100 / actual time.
 Procedure for Color Discrimination Calibration:
 Each candidate is subjected to the primary color discrimination test using “Ishihara”
plates.
 The candidate is first given update by the HR responsible about the test.
 HR responsible will randomly select any 10 plates and show
the same one at a time to the candidate.
 The candidate is given 5 seconds to decide the details in the plates.
 HR responsible records the response of the candidate and verify with the actuals.
 If the candidate has all the response correct, he is considered as passing the color
discrimination test.
 3.3.3.1.6 If any one response is wrong, secondary color discrimination calibration is
conducted with the help of Farnsworth Munsell Color Evaluation test
 3.3.3.2 The calibration is done strictly under D65 light source in the dark room.
 Decision Criteria:

 Checking Error Calibration:

 The QI is graded based on the checking efficiency as below:
 Grade “A” – 70% & above (min requirement for new)
 Grade “B” – 60 to 70%
 Grade “C” – Below 60 %

 Concentration Calibration:

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  Based on the result the QI is graded for concentration as below
 Grade “A” – 80% & above (min requirement for new)
 Grade “B” – 60 to 80%
 Grade “C” – Below 60%

 Color Discrimination Calibration:

 Only “Average” & “Superior” discrimination is acceptable for QIs.
 Only “Average” & “Superior” discrimination is acceptable for QIs.
If any QI candidate scores “Low” discrimination calibration , is not considered for
recruitment
 Basic English Test:

 The candidate must score minimum 70% to pass the test.

 For existing QIs, the above result forms the basis for training needs, the placement in line
and/or performance evaluation.

For new recruits the below matrix is followed for the selection criteria:

Category Checking Concentration Color Basic English

Efficiency Test Discrimination Test

Experienced Minimum Minimum 80% N/A

Average
70%

Fresh N/A Minimum 80% Average Minimum

70%

Allocated Time: 50 sec

Name:
Actual Time:

17
 5

10

Evaluated By Performance Index %

Basic English Test

Name: Unit: Total Mark: 10

01. Avcbvi bvg, wcZvi bvg I gvZvi bvg Bs‡iRx‡Z wjLyb |

1.5
A. Name:
18
B. Father’s Name: C.
Mother’s Name:
02. Avcbvi ¯’vqx wVKvbv Bs‡iRx‡Z wjLyb |
2
Village:
Post Office: Police
Station: District:
03. wb‡b¥i A¶i ¸wj K_vq Bs‡iRx‡Z wjLyb|
2

Number Number Name Number Number Name

04. wb‡b¥i Av¶i¸wj µgvbymv‡i mvRvb |

05. A. wb‡b¥ msL¨vwU †hvM Ki“b|

1.5

06. wb‡b¥ kã¸wj Bs‡iRx wjL~b |

Evaluate By…………………..
Signature………………. Mark Obtain:

Minimum Lighting Requirements

1.0 Purpose & Scope

To ensure the minimum lighting requirement is maintained at the working area.
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2.0 Responsibilities
 The Maintenance In-charge is responsible for the monitoring and the implementation of
the minimum lighting requirements and to verify the same at regular intervals.

3.0Procedures
 Lighting requirements depends mainly on three factors:
 The work that will be performed e.g. Inspection, sewing, warehouse.
 Working area environment e.g., natural light, color of background, ceiling, and walls.
 The sharpness of the worker’s eyesight.

 To provide correct lighting Maintenance In-charge must try to:

 Make full use of daylight.
 Provide suitable light for the work performed.
 Use the right lighting device and fixture.
 Find the correct placement of the light source, appropriate light height and direction suitable
for the task performed.
 Avoid shadows and glare.
Ensure regular maintenance e . g . Cleaning of lamps, lamp replacement schedule
 The work area light must be measured using a light meter once every month and results are
recorded in Light Measuring Record
 Recommended light values to be ensured as below:

Department Minimum Lux

Fabric/Accessory Checking 1100

Inspection/Quality Control

Cutting/Sewing at needle point 900

Ironing 800

Warehouse for: Fabric/Accessory/Finished product 500

Printing / Embroidery 1000

All inspection points 1000

Finishing Packing 800

 If the light level is found below the requirement, Maintenance in-charge will set the correct light
level by following step 3.2

 The buyer wise suggested Lux values are as below

BUYER FINAL Intern LUX SIMB LUX MTR SIMB PRIMA SECONDA
INSPECTI al Pre MTR A STD INSPECT A RY RY LIGHT
ON AQL final
20
 LIGHT
SEWI ON
AQL STD SOURC SOURCE
NG ROOM
E

JCPENNEY 2.5 1.5 850 900 1200 1200 D65

MACY'S 2.5 1.5 850 900 1200 1200 D65 UL 30

TARGET 2.5 1.5 800 900 1100 1200 D65

C&A 2.5 1.5 750 900 1050 1200 D65

IMPULSE 1.5 1.5 750 900 1000 1200 D65

JORDACHE 2.5 1.5 800 900 1100 1200 D65 CWF

NEXT 2.5 1.5 800 900 1200 1200 D65

2.5 1.5 800 900 1050 1200 D65

OJG

Color Vision Test

1.0 Purpose & Scope
The Farnsworth-Munsell Hue Test offers a simple method for testing color discrimination. It
21
yields data which can be applied to many psychological and shop floor problems in color vision.
Its primary uses are to:
 Separate persons with normal color vision into classes
of superior, average, and low color discrimination
 To measure the zones of color confusion of persons dealing in color shades.

2.0 Responsibilities

 AQM is responsible to monitor and to ensure that all the persons dealing with color shades are
tested for color vision
 HR Dept is responsible for conducting the test, communicating the results and maintains the
records

3.0 Procedures

Material:
 The FM Hue Test includes a total of 93 colors mounted in plastic caps, housed in four
separate cases. Each case consists of two hinged panels which contain a quarter of the 85
numbered, removable color caps. (Two caps are repeated and fixed as pilot colors at
either end of one panel in each case, making a total of ninety-three caps.)
 I f the caps become severely smudged or damaged,
they should be replaced
 With normal usage, it is recommended that the caps be replaced every four years.

 Lighting:
 Test should be carried out under Day Light D65 in the lightbox.

 Since natural daylight is variable, the results cannot be expected to be as stable as when
the test is given under standard illumination.

 Ordinary incandescent room lights should be switched off or shielded from the test
area.

 Testing:
 Open one case and arrange the caps in random order

 Instruct the person being tested as below:

 To arrange the caps in order according to color and place them so they form a
regular color series between the two end caps (indicate)

 It should take you about two minutes per panel. However, accuracy is more important
than speed so you will be told when the two minutes are up but the panel will not be
taken away from him/her.

 Arrange them as best you can, but do not dawdle.

 Allow the person if necessary to arrange the caps in an order with which they are
satisfied.
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  If two minutes have passed, and the person is not through, quietly remind them that two
minutes are up, and allow more time to finish the task.

 Repeat the process for rest 3 cases.

 Record the time taken to complete the test.

 Enter the findings into FM Hue Test Scoring Software

4.0 Result Analysis

 Person with 'normal' color vision can be classified as
follows:
 Superior Discrimination
 About 16% of the population (exclusive of color defectives) has been found to make 0
to 4 transpositions on first test, or total error score of zero to 16. This is the range of
superior competence for color discrimination
 Average Discrimination
 About 68% of the population (exclusive of color defectives) make a total error score between
20 and 100 on first tests. This is the range of normal competence for color discrimination.

 Low Discrimination
 About 16% of the population (exclusive of color defectives) has been found to make total error
scores of more than 100. The first retest may show improvement, but further retests do not
materially affect the score. Repeated retests reveal no region of large maximum or minimum
sensitivity as is found in color defective patterns
 Total error scores represent the color discrimination ability of an individual at a given point in
time.
 It is possible that color discrimination ability for that individual may improve later because of
further training and experience.
 Identifying the color defectiveness:
 The pattern of color defectiveness is identified using the FM Hue Test by bipolarity, a clustering
of maximum errors in two regions which are nearly opposite.
 The severity of the defect can be gauged by the extent of the 'bulge', a severe degree of defect
showing clear bipolarity with high error scores; moderate cases show small 'bulges' and lower total
error scores; mild cases with good color discrimination may show no 'bulge'
 The position of the mid-point of the errors in the pattern will identify the type of color
defectiveness as below:
 To handle the shades, the person must score minimum Average Discrimination. But prefer to
keep all the people involved in shade discrimination with Superior Discrimination ability

Fabric receipt, issue & Storage

Purpose & Scope:
23
To receive, issue and store of the various fabrics
Responsibility:
The designated store officer / Jr. Executive / Executive are responsible for this process.

Procedure:
1.0 Receiving:
 Fabrics Receiving Preparation
 Fabrics received against Purchase Order (PO Sheet), Performa Invoice,
Commercial Invoice, Shipping Advise & packing list.
 Fabrics un-loading process done by tally
counting
 After received fabrics as usual 10% gets inspected, if getting shorts issue then it
should be immediately informed to the merchant to inform the concerned fabric
supplier
Inventory Check:
Inventory check as per packing list done by below procedure
 Style wise.
 Color wise.
 Shrinkage wise.

 Storage
 After completing the inventory bulk fabrics lots of wise storage at our Go-
down with bin cards pasted at are all cards and attached with yellow stickers
indication w a i t i n g for QC check.
 After QC check all pass fabrics batch wise keeping at rack with green stickers
in bin cards.
 After QC check whatever rejected fabrics, all red stickers attach in bin cards.
 Style wise Fabrics Swatch making with Merchandiser approval.
 Inventory receiving reports are provided to Merchandising Department.

Issue:
Only issue pass fabrics which inspected by QC department with the fabrics inspections
reports & shade band reports

4.0 Left Over Fabrics Handling

 If there is any quantity left over in the store for whatsoever t h e reason, transfer
the same into separate designated location and maintain the ledger.
 If production floor notifies any leftover quantity, collect the same from the
production floor with the detail packing list, enter the same in ledger on verifying
the quantity and store in designated place.

24
25
 SIMBA FASHIONS LIMITED UNIT-2
Factory:SSFB - 03. Adamjee AEPZ, Siddirgonj, Narayangonj. Bangladesh
Inventory Report.
Buyer: TARGET STR/3/018
Suppler: SAN AURORA PACIFIC LTD ISSUE-1
Qty: 281 Rolls SQ….
Challan/ Invoice No: H7249-21
Rcvd Date: 02.11.2021
SL Rcvd
Item Name Style No Color Pac qty Unit Sho/Exe Rolls
NO Qty
1 Blue 14276 14276 0 108

2 Black 1600 1600 0 12

30% Recycle Polyester 62% Virgin Polyester 8%
Hybrid short Yds
Spandex 4 Way stretch
3 Almond 13889 13889 0 103

4 Mando Camo 6766 6766 0 58

G.TOTAL 36531 36531 0 281

Fabrics Inventory Report 36531 yds 281 Rolls

Prepared By Section Head GM

Inventory Report

Fabric Kept with Bin card

26
 Fabric Inspection, Shade Band & Shrinkage Test
1.0 Purpose & Scope
To identify and determine the extent of fabric defects, the different width and other quality
level of fabric lot received to ensure the fabrics confirms to the required standard before
spreading.
2.0 Responsibilities:
 The Fabric AQM is responsible for the monitoring and the implementation of the
fabric inspection system and to verify the authenticity of the fabric inspection report.
 The Fabric Inspectors (QA) are assigned to carry out the fabric inspection and to
maintain the inspection reports.
3.0: Procedure:
Shade Checking
Shade variation check
 To check shading in roll, fabric panels are cut from each roll.
 For one roll from each batch, divide the panel in four parts and mark it as below
Head 1 3 4
2

 Repeat the process at the middle of the roll and end (tail) of the roll.
Middle 1 2 3 4

Tail 1 2 3 4

 Cut each part and rearrange as shown in below figure:

Head 2 4 1 3

Middle 2 4 1 3

Tail 2 4 1 3

 Stitch the panels and observe in light box under D65 and buyer required light source.
 If any shade variation is observed between the panels horizontally or vertically, it is
considered as (running) shade variation across width or length respectively
 For rest of the rolls under inspection, the panel is cut only at the beginning of the roll,
and shade variation is checked with this panel at middle & end of the roll. Width way
shade variation can be checked while inspecting the fabric on the m/c by matching two
edges and matching each edge with center of the roll.
 No piece shall be accepted as first quality that exhibits a noticeable degree of shading

27
 from side-to-side or side-to-center.
 No piece shall be accepted as first quality exhibiting a noticeable degree of shading end-
to-end, when checked by laying panels, cut from the beginning of the roll, across the
opposite end
 Any variation observed is recorded in the fabric inspection report

 Fabric Bowing / Skewing / Bias

 Fabric bowing or bias should be within the following tolerances.
 Yarn-dyed in check pattern: No piece shall be accepted as first quality exhibiting more
than 1.5 inches (3.8 cm) of bow or bias on 60-inch (153 cm) goods.
 Printed in check or stripe pattern: No piece shall be accepted as first quality exhibiting
more than 1.2 inches (3cm) of bow or bias on 60-inch (152cm) goods

Bowing Calculation:

Bowi ng % = X / Y * 100
SKEWING CALCULATION

Skewi ng % = X / Y * 100

 Running Defect
 Any defect found to repeat and or run in a continuous manner will constitute a
running defect.
 Any piece having a running or repeating defect through more than three (3) continuous
yards shall be rejected regardless of the point count.
 More than one occurrence, more than three (3) yards, in an audit can cause the lot to be
rejected.

28
 4-point fabric inspection:
 The inspection is carried out for major fabric defects
 Major woven fabric defects are slubs, hole, missing yarn, conspicuous yarn
variation, end out, soiled yarn etc.
 Major knitted fabric defects are mixed yarn, yarn variation, runner, needle line, barre,
slub, holes, press off etc
 Major dye or printing defects are out of register, dye spot, machine stop, color out, color
smear or shading.
 Points are allocated to every fault as per the point’s table listed below:

29
Size of defects In Inches (default) In cm (if Customer demands in cm) Penalty Points

Up to 3 inches Up to 8 cm 1 Point
3 inches to 6 inches 8cm to 15 cm 2 Points
6 inches to 9 inches 15 cm to 23 cm 3 Points
Over 9 inches Over 23 cm 4 Points
A maximum of 4 points can be charged to one linear yard or linear mtr)

 If in same yardage, there are multiple defects, exceeding 4 points, consider the one with
more points.
 If more than one defect exceeds 4 points, consider the one which will have more
damage.
 All holes regardless of size, shall be penalized 4 points. There must be two or more
yarns broken at the same place, for the defect to be considered a hole.
 The fabric width should be checked a minimum of three times during the inspection of a
roll (at the beginning, middle and end).
 No piece shall be accepted as first quality where the usable width (which is the width
between the insides of the selvages or between the stenter pinholes) is less than the
minimum usable width as accepted

30
 Fabric inspection
Fabric Inspection Report.

31
Reporting and Acceptance

 Record each defect found under suitable defect category & penalty point on Fabric
inspection reports, as per 4-point system
 Calculate the total defects and the total penalty point for each roll as per the formula given
on the inspection report
 Acceptance Criterion :20 points / 100 Sq yards

 If the final percentage is more than 20 pt per 100 Sq. yards. The result is recorded and
AQM is informed.
 Another 15% yardage is taken for inspection and if that fails then the lot is failed.
 The following types of defects contribute to the rejection of the lot:

 Bowed or bias more than stated tolerances.

 Dye streaks or unevenness.

 High penalty point count.

 Loose, wavy, or tight selvages.

 Narrow width.

 Shading side-to-side or side-to-center.

 Shaded end-to-end

 Any combination of the above

 Note that for defects such as bowing or bias, incorrect hand-feel, narrow width, and
side-to-side/side-to-center/end-to-end shading no penalty points shall be assigned.
However, the entire roll shall be graded as second quality and should be rejected.

 The AQM re-inspects the non-conforming roll / sample and decides whether the roll
should be rejected or not and record the decision on Fabric Inspection Report. The
decision to reject the roll is based on the fact that whether the defects can be avoided in
Cutting and cut panel inspection or not.

 If the defects cannot be avoided in cutting or cut panel inspection and the wastage will be
too high then the Merchandiser is forwarded the Non-conforming Fabric Report who then
gets the customer approval

 Rejection rolls are identified by putting “Red” sticker and are kept in rejected goods area.

32
GSM Check:
 From each fabric roll of the 10% lot selected for inspection, cut the GSM swatch using GSM cutter.
 To check the GSM, each swatch to be weighed on the GSM balance. Before weighing the
GSM swatch, caliber the balance using the calibration weights in proportion to the
declared GSM.
 Record the GSM and prepare the GSM swatch board for production team.
Record the GSM of the rolls under inspection in the fabric inspection report

33
  Fabric Shrinkage Testing:

 The fabric shrinkage is done for 10% rolls of every dye lot for non-wash program. For
wash program, 100% of the rolls are tested for shrinkage.
 To ensure the color wise shrinkage of the fabric, the inspector has to cut a swatch
measuring 50 cm x 50 cm (or as specified by the buyer) of every color and quality of fabric
in a lot and mark 35cm X 35cm by using Shrinkage template.
 The two parts are cut and sewn with over lock from 3 sides.
 Wash this swatch to the correct approved washing standard for washed program
 The fabric inspector records the measurement after wash on shrinkage test report.
 The shrinkage % is calculated and results recorded

To obtain the shrinkage, the following formula should be used:

BW −AW
Shrinkage % = X100
BW

34
Make Shrinkage Blanket

35
Shrinkage Report

36
37
 Procedure For Shade Band
1.0 Purpose & Scope

To ensure all the shades of the fabric received are within acceptable limit and facilitate cutting to cut
shade wise in ratio

2.0 Responsibility:
The AQM is responsible to implement and monitor this process.

3.0 Procedure:
 Shade Band – Shade band is an acceptable range of shade groups varying in light/dark and
color/cast around master or standard shade.
 Once the stores segregate the fabric batch wise after inventory check, the respective QC person
cuts the sample for shade band and gsm from each & every roll. Every sample is marked with
batch # & roll #.
 A swatch of 6”x6” is cut along the grain line from every sample.
 If the garment program is garment wash or fabric wash, the below steps are performed:
 All the swatches of one batch is stitched together to form a blanket.
 The blanket is then marked with batch # & roll # on individual swatch with permanent marker
 The blanket is washed as per the customer required wash
 The swatches are again segregated from the blanket.
 The washed or unwashed swatches (as the case be), are checked under the customer recommended
primary light source by the QC nominated person with superior color vision.
 These swatches are segregated according to the matching shades and grouped.
 Each segregated group is again checked under secondary recommended light source (if
applicable) and under Incandescent A light and/ or UV light.
 If the shade variation is noticed within a group, the rolls are further segregated.
 The above phenomenon whereby two or more objects are perceived by the viewer to be the same
shade in one particular light source but do not match in a different light source is known as
Metamerism.
 Each group separated above is named as per the example given in below table:
 The shade groups are arranged from lighter to darker. The most lighter group is named as
1and darker 2 and so on.

 The shades are then compared with the gray scale for shading. The one with rating of 5 is
highlighted as perfect match.
 If any shade variation is noticed within the group under secondary light source or “A” light
source, the rolls which do not match with the majority within the group are separated and the
subgroup is named with additional alphabet as shown in below table:
 e.g., variation (metamerism) observed in shade group

38
  All the swatches are attached to a swatch board to form a shade band. The results are recorded in
the shade band report and the shade band is matched with customer approved standard under
primary light source.
 The respective Merchant signs the shade band swatch board if the given shadesa re approved.

Responsible: Fabric Quality in charge

39
 SHADE SEGREGATION
Purpose

 To identify the different shades within a lot/ color.

 To make shade blankets to determine different shades to obtain buyer’s approval.
 To segregate fabric shade wise of approved shades to follow in cutting for bulk
production.

How to use

 Fabric Quality in-charge has to collect complete details of fabric received from the stores
along with complete packing list, approved swatch and Fabric technical data (FTD) if
applicable for each Style from the merchant.
 Fabric Q.C. must cut a strip of 8” x 8” and mark the way of fabric considering fabric way.
This is very important that each strip representing each roll must be in one fabric way
when joining blanket with an Over lock machine. The dimension of the cut strips
may vary as per individual customer’s requirements.
 Must mark roll no, Fabric cut able width, with wash durable ink to make sure marking
will not be deleted in washing.
 If the style is having a wash, then must wash the blanket as per buyer’s approved wash
standard.
 After washing of blanket or after making blanket for Non wash garment, Q.C. must sort
out shades by using a light box as per light source recommended by the customer and
determine each shade and mark the Shade in each swatch.
 In case of white fabric, the whole blanket must be reviewed in the light box –
D65 light or customer advised primary light source.
 Two sets of Fabric swatches (color continuity cards) representing each shade should be
given to merchandiser to obtain approval from the buyer for each shade. One set to be
kept available at factory with the approval for factory reference. This will be the color
continuity card.
 Merchandiser must submit these color continuity cards to buyer and must obtain
approval for the same to proceed with bulk production where applicable.
 QM must ensure approved color continuity card from merchandiser to proceed with pre-
production activities for fabric.
 Must record details of each roll containing Color, Roll no., shade, and yardage for each
roll per color and Shade.
 Have to handover a copy of this record to stores/ cutting section for fabric segregation.
 Paste the internal shade sticker on each roll, based on which the cutting will double
check the rolls received are in the required shade and tallies with the shade segregation
report.

Out come

 Buyer’s approval for each fabric shade will be obtained prior to proceed with production.
 Avoid shade mix ups by using the shade labels and enable the factory to pack one shade
in one carton / PO / Country.

Cutting department will make country wise cut plan according to shade and shrinkage

40
light Box for shade segregation Before wash blanket – Face side

Before-wash blanket underside- yardage After wash blanket – Face side

41
and rolls numbers mentioned with marker

Shade segregation & grouping

42
The fabric rolls have the shade and shrinkage pattern mentioned on the bin card for easy understanding

43
 Spirality & detrition check SOP
1.0 Purpose & Scope
To determine any distortion or twisting defined as “Spirality”, which may occur after a garment is
washed.

2.0 Responsibility:
Fabric AQM responsible to test the distortion or spirality while doing the garment wash test or fabric shrinkage test.

3.0 Procedure:
Spirality Test: During wash test, after wash, if the spirality is evident, the overlocked seam originally placed
at the side of the garment will have moved sideways, causing a new natural fold or side seam as seen in
below picture

Compare both sides of the garment from the new natural fold to the overlocked seam. Record the distance
in millimeters - this is referred as “D”.
Measure the length “L” of the new side seam of the folded fabric

Calculate the spirality using below formula:

The maximum spirality allowed is 3 %

44
Distortion Test:
Distortion testing is done to determine whether the fabric skew movement fulfill the requirement at the
earlier stage before bulk production and prevent twisting during the bulk production

 The distortion test is carried out for 10% of the rolls taken for inspection
 The same template as used for shrinkage test is used for distortion test.
 After the specimen is washed for the shrinkage test, measure length of AC & BD as per the
below diagram.

 Calculate the distortion % = 100 x 2 (AC-BD)

-------------
(AC + BD)

 The maximum allowed distortion is ± 3 %



Trims & Accessories Receipt, Issue & Storage

Purpose & Scope
To receive, issue and store of the various trims & accessories items

Responsibility
The designated store officer / Jr. Executive / Executive is responsible for this process.
Procedure

1.0 Receiving:
 Receiving
 Inventory Check
 Sort out the consignment according to item, size, color or if any other classification as
applicable.
 Open all the cartons one by one if intact.
 If the carton is found in open condition or during counting if any packaging mistake is noticed,
call the respective commercial person, and show him the discrepancy.
Verify the quantity by physical count, weight, and any other measure as applicable for at least 10% of the
quantity selected on random basis. If any discrepancy is noticed between document quantity and physical
check, inform commercial and merchandising department through mail.

 Storage

45
  Report and record all received quantity according to buyer, style# and item description
 Select the storage rack based on quantity accommodation and store the item in the rack
 Prepare BIN Card for selected rack # and attach the same with rack and put yellow sticker
indicating quality check pending.
 Inform QC Department of the consignment arrival with all the relevant details.
 On completion of the QC check, the QC submit the result of quality pass or fail. Based on the
QC result, change the BIN Card sticker to Green or Red for pass & fail respectively.
 If there is any special storage i n s t r u c t i o n from the supplier (e.g. Temperature, Light etc) ,
follow the same strictly.
 If the quality is ok, allocate the storage rack and enter the rack number on the challan copy
and stock register for easy tracking.
 Storage should be done Buyer, color, size wise or as per the specific instruction if any.
Prepare the BIN CARD for selected rack and attach the same with rack

3.0 Issue
 Issue is done as per the accessories invoice copy received from the production floor duly counter
signed by planning department and approved by respective merchandiser.
 Check the production unit on the invoice with item wise required quantity and other information
related to Buyer, Style #, PO# etc.
 Collect the trims/accessories swatch card from QC with QC pass seal and merchant signature for
the respective PO / style.
 Production floor submits the requisition for item required.
 Issue all the items available based per the approved invoice as per requisition and update the
BIN Card.
Maintain a file for Invoice copy and requisition

4.0 Left Over Material Handling

 If there is any quantity left over in the store for whatsoever reason, transfer the same into separate
designated location and maintain the ledger.
If production floor notifies any leftover quantity, collect the same from the production floor with the
detail packing list, enter the same in ledger on verifying the quantity and store in designated place.

Accessories/Trims Inspection SOP

1.0 Purpose & Scope
To identify and determine the extent of Trims defects before issuing in the line.
2.0 Responsibilities
 The AQM is responsible for the monitoring and the implementation of the trims inspection
system and to verify the authenticity of the trims inspection report.
 The trims Inspectors (QI) are assigned to carry out the trims inspection and to maintain the
inspection reports.
3.0 Procedures
 QI perform the trims inspection as per buyer requirement.
 Fabric AQM should collect the approvals from the relevant merchandiser before
proceeding for the inspection.
 Initially 01 pc per size, for trims & accessories will be cross checked with the PO sheet /
commit sheet / artwork sheet / approved layout (actual details of composition) and the test
report (trims) and the same will be prepared as a swatch card.
 The prepared swatch card should be taken to the relevant merchandiser for approval.
 Inspection is based on two types as countable and uncountable. If any item such as labels,
Hangtag, button, zipper etc which can be counted in numbers are taken as countable and the
46
 inspection will be carried with 1.5 AQL Level II. If any items such as Elastic, Velcro etc,
which is measured in yards or meter is treated as uncountable and the inspection will be
performed by 4-point inspection with 10% from each consignment the received. If any
customer provided others requirement, inspector should be following their requirement.
 All the material where the color check is mandatory, color must be judged under customer
specified light source.
 During the audit the auditors do visual check, measurement, and bar code check as
applicable.
 All the trims are also tested for wash durability by attaching one pc on actual fabric and
performing wash. In case of any issues after wash, the trims are rejected.
4.0 Acceptance:
 The acceptance criteria is applicable for
Countable item – AQL1.5 L II (Count by major defects only)
 Any critical defect, the consignment is treated as Fail.
 If the lot is accepted, QC passes the lot and release clearance is given to store and the green
sticker is pasted on the Bin card
 The defectives are transferred to the quarantine area and information is given to the
respective Merchant for further action

Accessories Check

47
Thread Inspection Report.

Wash Down Report

48
5. Inspection & Shrinkage Test of Elastic: A meter of Elastic will get home
laundry wash as advised with detergent for 30 minutes in room temperature & dry normally than
measure the Elastic again & calculate the % of shrinkage against customers’ requirement
10 % elastic roll receive from carton & should be inspection by 4-point system. Point calculated
Panalty point/Total Yards x100
Note: For elastic item if found stretch-ability problem, measurement problem & safety or
regulatory issues, it will be treated as fail

Elastic Inspection Report

Collect Approved Elastic Swatch Card & match the elastic & shade with Approved Swatch card.

 Check yarn defects & missing

 Check Elastic Width
 To check have any Spot
 To check Stretch ability
 To check expire date

49
Width Measurement of Elastic

Approved Trim Card

50
Before Strength Check- 24 CM

Strength Check- 48 CM

51
 After Strength check-24 cm

Nickle Test procedure:

Purpose: To ensure all metal accessories without nickel
Procedure:

Nickel Test according to AQL 1.5 (Base on total packet) Nickle test for Metal item from Each

packet 01 pcs.
 Must take white color cotton Bar.
 To take Two drops chemical (Ammonia & Dimethylglyoxime) on cotton bar

Cotton Bar

52
Rubbing the dissolved cotton bar on the metal item for 30 seconds
 If the cotton bar turns pink color after rubbing, then it must be understood that
there is Nickle and whole lot. The product will be rejected, and the report must
be prepared and reported to the responsible merchant, and they communicate
to supplier to change material.
If the cotton bar Don’t turn pink color after rubbing, then it must be understood that
there is no Nickle.

Accessories Check List

TAPE
A. WIDTH
B. CONTENT
C. COLOR
D. COLOR VARIATION WITHIN ROLL
E. TYPE OF DEFECTS
F. STRUCTURE
G. COLOR MATCHING TO BODY
FABRIC
H. COLOR MATCHING TO STANDARD
I. SHRINKAGE (IF COLOR TAPE)
J. COLOR FASTNESS
THREAD

A. COLOR MATCHING WITH APPROVED SWATCH CARD.

B. COLOR NUMBER
C. TICKET NUMBER / COUNT

LABEL
A. INSTRUCTION
B. COLOR
C. DIRTY MARK
D. WASH TEST
E. COUNTRY OF ORIGIN
F. R N NUMBER / UPC NUMBER / REF
NUMBER G. SIZE / BRAND
H. SPELLING
STICKERS
A. SIZE

53
B. STYLE NO
C. COLOR
D. PRINTING SETTING
E. SEASON F.
F . DIVISION
G. LANGUAGE
H. DESCRIPTION
I. WIDTH/LENGTH
J LETTER COLOR/BACKGROUND
ELASTIC

A. STRETCHABILITY
B. GAUGE
C. COLOR
D. COLOR VARIATION WITHIN ROLL
E. CONTENT
F. DEFECTS
AVAILABLE
G. SIZE
H. ROLLING LENGTH
I. KNOTS PER ROLL
J. WASH TES

BUTTONS
A. DIAMETER LINE
B. EMBOSS OR PAINT SETTING (LOGO)
C. NO OF HOLES PER BUTTON
D. SHAPE
E. COLOR
F. NICKEL FREE
G. SURFACE
H. HOLES SIZE
I. BROKEN BUTTONS

DRAW CORD
A. COLOR
B. COLOR VARIATION WITHIN ROLL
C. LENGTH
54
D. TIP SHARPNESS
E. CONTENT

HANGER

A. SIZE
B. COLOR
C. DEFECTS AVAILABLE
D. TYPE
E. METAL HOOK AVAILABLE
F. PULL TEST
G. ADJUSTALE
POLYBAGS

A. LENGTH
B. WIDTH
C. WARNING
D. COLOR
E. DEFECTS AVAILABLE
F. LETTERING
QUALITY
G. NO. OF LANGUAGE
H. SYMBOL
I.VENT HOLE AVAILABLE
J. TYPE
SNAPS / EYELETS / GROMMETS
A. DIAMETER LINE
B. COLOR
C. NICKEL FREE
D. POST LENGTH
E. SHARP SURFACE

PRICE TICKETS / HANGTAGS

A. CONTENT/SPELL CHECK
B. COLOR NUMBER
C. BARCODE SCAN
55
 D. PRICE
E. ARTICLE
F. PRINT QUALITY

ZIPPER / ZIPPER PULLER

A. LENGTH
B. WIDTH
C. CLOSED END
D. OPEN END (LEFT IN OR RIGHT IN)
E. COLOR
F. TAPE COLOR
G. TEETH COLOR
H. STOPER COLOR
I. PULL(TAP) QUALITY OK
J. NICKEL FREE
K. WEAVING DEFECTS
L. WASH TEST
M. OPERABILITY
N. SHRINKAGE
CARTONS
A. NO. OF PLIES
B. DIMENSION (L X W X H)
C. CARTON MARKING
D. COLOR
E. GSM
F. DROP TEST

56
 PP MEETING
1.0 Purpose & Scope
1.1 Review the approved Sample.
1.2 Highlight the potential product safety, quality & productivity issue.
1.3 Communicate all potential points with related supervisors, QAs & Other persons

2.0 Responsibilities

2.1 The technical team is responsible to monitor and to implement the pre-production
meeting procedure.
Planning & central QA is assigned to ensure that the meeting is conducted before start of
production, and maintain the records

3.0 Procedures
3.1 On receipt of the style file from planning, the unit in-charge gets the approved sample from
P&D.
3.2 Unit in-charge reviews the sample along with the production executives, technical
executive & floor QA Manager.
3.3 After the review, Size set samples stitched in each size / color, checked for
workmanship, styling, and measurement, and submitted to P&D for approval.
3.4 Upon size set approval, the results are communicated to technical team & planning.
3.5 Planning checks the material in-house status and calls for pre-production meeting.
3.6 Pre-production meeting is chaired by technical in-charge and attended by
representative from related floor QA, Maintenance, Merchants, Store QC, IE, planning,
P&D, Stores, Product safety Officer and central QA
3.7 During the PP meeting following activities performed:
3.7.1 Buyer approved sample is reviewed.
3.7.2 Size set sample report is reviewed, and the deficiencies discussed.
3.7.3 Making sure of the correct trim’s placement.
3.7.4 Highlighting potential product safety, quality & productivity issues
3.7.5 Discussing print & embroidery placement and appearance as applicable
3.7.6 Discussing finishing & packing details
3.7.7 Discussing production plan & delivery issues
At the end of the meeting, all the attendees sign off the minutes

4.0 Related Documents:

4.1 Pre-production meeting guiding format.

57
PP Meeting Report
58
59
 PP Meeting Report

SIZE SET & P.P.R SOP

SOP for Size Set
Purpose: To measure and control measurement and quality before starting the bulk of every new style in
line (Any style is the gap is more than 15 days then it needs to follow the PP meeting protocol).

Scope: The procedure is applicable to all the products being manufactured at all the production unit of
Simba Fashions Ltd.

Responsibility: Production Manager along with line technician will be responsible for the size set making
and the AQM sewing will be responsible for the report to be filled and all documents submitted to the tech
team while reviewing the size set

Team handling the PP activity:

1. Zaman Technical manager & Biplob AQM will do the measuring of the size set and the PPR before
wash and after wash.
2. Nalaka to check randomly the measurements done by Biplob and correlate of matching or not.

Procedure:

1. When a fit sample is sent then the Risk assessment will need to be done along with COO and the
same Risk assessment will be done after the PP sample is done and before the size set is done and
again to repeat after the Pilot run / PPR is done.
2. Nalaka / Nehal to issue the Patterns for the Size set.
3. Roll to be selected for making the size set
4. Get the fabric as per this direction
5. Size set to be cut as per the below SOP

Size
2 4 6 8 10 12 14 16 18 Ttl
Fab shrinkage Roll # Base size

4x7 1 1 pc 1 pc 1 pc 2 pc 1 pc 1 pc 1 pc 1 pc 1 pc 10

6 x 14 2 1 pc 1 pc 1 pc 1 pc 1 pc 5
1 pc 1
Non wash 16

6. Size set cut should be matched with the hard patterns.

7. White thread or contrast thread to be used on all garments at the waist band marking and at the
seam marking at the inseam and out seam

60
 8. Line chief / Line technical and the mechanic will be involved in making the size set and will be done
by the production operators.
9. The line chief and the technician will check the size set in process and will ensure that the process
is ok as well as it meets the before wash specs
10. Special attention will be given to the balancing of the garments as well as the other technical
aspects highlighted in the risk assessment.
11. This team submits the size set to the AQM and he makes the other accompanying reports like
measurements etc.
12. The shrinkage panels need to be submitted to wash along with the size set and PPR from the fabric
roll from which the size set is made.
13. 3 leg mocks also need to be submitted along with the size set for the wash for the washing trials.
14. This size set and the PPR needs to be sent in a separate challan and needs to be personally handed
over to Claudio in washing.
15. Washing unit to note down all the steps they followed in the making of the size set and submit
after returning from the wash to the factory PP activity team.
16. Washing team to ensure that the hand feel , shade and wash effects are matching as per wash
standard and should also make a note of the measurements before wash and after wash.
17. After wash measurements need to be done after ironing like in finishing.

18. If actual trims are not inhouse then will continue with available/ substitute trims.
19. Line chief and line technician will sign their confirmation and will fill in the format to be filled while
submitting the size set.
20. Size set will be cut by placing the 2 roll lays from the different shrinkages and will be cut by the
cutting machine and not by hand scissoring.
21. Roll numbers to be mentioned in the size set and every size set garment will have a number to
check the before wash and after wash comparison.
22. Number of pcs to be made in the size set = 1 set covering all sizes and colors
One set of jumping set to verify the measurements and 1 pc extra in the base size.
The number of pcs to be cut are as below and the size range and shrinkage is mentioned for
example purpose only

Size
2 4 6 8 10 12 14 16 18 Ttl
Fab shrinkage Roll # Base size

4x7 1 1 pc 1 pc 1 pc 2 pc 1 pc 1 pc 1 pc 1 pc 1 pc 10

6 x 14 2 1 pc 1 pc 1 pc 1 pc 1 pc 5
1 pc 1
Non wash 16

23. The extra garments in base size will not be sent to have a reference of the before wash garment.
24. The Size set measurements will be verified by the technical dept and then if the size set has minor
variations from the requirement, then can proceed with the same for the PPR, but if the variation
is high and non-uniform then will need to make a revised size set.

61
 25. Size set will be accompanied with the checklist and the wash recipe log sheet along with the
approved samples.
26. Exceptions:
 When the style is of _______ pcs or less then the factory can directly proceed with the
bulk upon the approval of the size set and if there is no special clause from the buyer for
not doing so.
 When the repeat fabric comes from the same mill and if the shrinkage is matching to that
of the previous shrinkages, then no need for a size set or PPR, and can directly go for bulk
for that style.
 If the style has different colors and the shrinkage is same, then only size set sample will be
needed to verify the color wise trims and accessory. Pattern-wise the factory can proceed
for bulk of the other colors when the shrinkages match

The below checklist needs to be filled before submitting the size set

Not
S NO Description OK
Ok
Kamruzzaman reviewed Tech pack rcvd.(Kvgiæ¾vgvb ‡UK c¨vK wiwmf Kivi ci wiwfD
1
Ki‡e)
2 Beforewash measurement sheet rcvd.(Iqvk Gi Av‡M †gRvi‡g›U kxU wiwmf)
3 Approval reference sample compared.(Aby‡gvw`Z ‡m¤új Gi mv‡_ wgjv‡bv)
4 Are all actual threads used.(mg¯Í cÖK…Z myZv e¨venvi)
5 Finished Pattern Measurement Check.(wdwbk c¨vUvb© ‡gRvi‡g›U †PK)
6 Feed Dog, Pressure Feet & Folder Setting checked.(wdW WM, †cÖkvi wdU Ges †dvìvi †mwUs †PK|
7 Elastic is washed or non wash.(Gjvw÷K Iqvk n‡q‡Q bvwK Iqvk nqwb|)
8 Elastic is preshrunk or not.(Gjvw÷K msKzwPZ bvwK bv|)
9 Kansai Machine Setting/ FOA Setting.(KvbmvB †gwkb †mwUs/ Gd.I.G †mwUs|)
10 Contrast thread at FR/ BR. (d«›U ivBR/e¨vK ivBR K›Uªv÷ †_ªW w`‡q gvwK©s)
11 Contrast thread at waist band marking.(K›Uªv÷ †_ªW w`‡q I‡q÷ †eì gvwK©s)
12 Contrast thread at inseam /outseam. (Bb wmg/ AvBU wmg K›Uªv÷ †_ªW w`‡q gvwK©s)
Size Label/ Main Label/ Care Label Right Place.
13
(mvBR †j‡fi/‡gBb †j‡fj/ †Kqvi †j‡fi mwVK ¯’v‡b jvMv‡bv n‡q‡Q)
All Operations done are free and no excess cutting or excess pulling done.
14
(mg¯Í Acv‡ikb †kl Kivi ci AwZwi³ KvUv Ges AwZwi³ Uvbv)
15 Internal PP Meeting done - PPR. (B›Uvibvj wc.wc wgwUs- wc.wc.Avi)
Are the size set and PPR garments serial number given.
16
(mvBR †mU Ges wc.wc.Avi Mv‡g©›Um wmwiqvj bv¤^vi †`Iqv Av‡Q)
17 Wash Standard & Hand feel. (Iqvk ÷¨vÛvW© Ges †nÛ wdj †PK)
Operation Bulletin confirmation Process wise sample is ok.
18
(Acv‡ikb ey‡jwUb wbwðZKiY cÖwµqv Abymv‡i bgybv wVK Av‡Q)
19 Found difficulty in below operations. (wb‡Pi Acv‡ik‡b Amyweav cvIqv †M‡Q!)

Pilot Run SOP

Purpose:

62
The “Pilot Test Run” enables us to understand the full process flow and understand where what is
going wrong so that we can correct the same before going into bulk production and helps us achieve
this in the early stages of production.

Responsibility:

QC, AQM, SR.QM, AGM, Sr.PM, APM and technician will be responsible for the implementation and
maintenance of this procedure respectively.

Procedure:

 The pilot test will be run to ensure the implementation and implementation of the decisions taken at the
PP meeting.

 200-300 pcs are cut for the pilot run and stitched in the line. The pilot test quantity for making garments
should be mentioned in “PP meeting format”.

 The production team of sewing, and finishing of the Style will check all the technical and quality points
and note the areas which is not conforming to the standards.

 After completing the pilot test run, the garments will be checked by the floor quality team and reported
to the AQM, GPQ in charge of the style, and to the Senior quality management.

 AQM and Quality Manager analyze the checked garments and reports to ensure that the decisions taken
at the PP meeting have been properly implemented.

 If the corrections are required to be done in the patterns then these are done or any other process then
that is also modified and the permission to go for bulk is given by the quality team.

 The Pilot run or the next 1st bulk cutting to cover all the shades and shrinkages so that in the first bulk all
the shade ranges are covered to submit to the buyer and based on the approvals the rework on certain
shades can be done or decision to reject and not cut certain fabric rolls is taken.

First Production Output

1.0 Purpose and Scope:
 To do trial cut, stitch and pack the garments to ensure that all the pre-production activities
are done are ok and the bulk production will be meeting the requirement as per the buyer
approved sample and specification.
To check the first output from each process from cutting to packing to ensure the bulk is meeting
all required product quality, safety & legal standard

2.0 Responsibility:

63
The Sr.QAM is responsible for implementation of this procedure and the AQM is responsible for
monitoring of the process

3.0 Procedure:
 Pre-Finishing Process:
 Once the PP meeting is conducted for a new style planned for production,
cutting incharge and merchandiser plans the trial cut prior to the bulk
production based on following:
o Ratio in order
o Total no. of colors
 The Cutting Executive receives the required material from store as per
approved consumption for trial cutting of 200 pc -500 per color max.
 Cutting executives receives latest rectified pattern from CAD.
 Cutting QA / Marker Man receives the Marker from CAD and checks the
same against the hard pattern to ensure the correct marker is received.
 Spreading & cutting done for max up to 200 pc.
 All the cut parts are checked against hard pattern by taking panels each
from top, middle and bottom layer.
 If the cut panel matches with the hard pattern, the input is given to the line.
 5 -10 pcs from all sizes in each color are stitched first as 1st output.
 The 1st output in a l l s i z e / a l l c o l o r i s c h e c k e d f o r
w o r k m a n s h i p , measurement and construction and compared with
buyer approved sample and against specification.
 The findings of workmanship and construction are recorded in trial cut
report and the finding of the measurement is recorded in measurement
sheet.
 If any workmanship issue is noticed, it is corrected during bulk production.
 Any construction issue is discussed with the technical manager and
necessary corrective action is initiated.
 If any measurement discrepancy is recorded, then in consultation with
CAD,
 the pattern is rectified as required, before bulk cutting.
If no issues found during trail cut, the bulk cutting can proceed without any corrective action

64
65
66
 Fabric Relaxation Procedure
1.0 PURPOSE:

To do the Fabric relaxation before spreading, to have proper measurement control in the final
product.

2.0 RESPONSIBILITY:
 The Cutting Manager of the respective production unit is responsible to ensure
& implement the procedure.
 The AQM of the respective production unit is responsible to monitor the
process.

PROCEDURE: All the fabric, depending on the packing method and the structure, need to be
relaxed before spreading as per the below criteria:

Relaxation Time (Minimum)

All Knit fabric in roll form 24 hrs
All Knit fabric in folded form 12 hrs
All Elastomeric fabric (Knit & Woven) 24/48/72 hrs
 The fabric must be relaxed as per the above criteria by opening the fabric roll and
converting it in the folded form using Fabric Loosening machine.
 The height of the relaxed roll should not exceed 12”
 The fabric should be stored in the fabric relaxation racks and allowed to be relaxed for
the specified time.

Each fabric roll is tagged with the relaxation card as below:

FABRIC RELAXATION INFORMATION

Date
Customer
Style No.
P/O No.
Batch No.
Roll No.
Start Date & Time
End Date & Time
Simba Fashions Ltd. (Cutting Section)

67
 The details of the all the rolls relaxed is entered in the fabric relaxation status
 The fabric can be taken for spreading purpose only after completion of the specified
relaxation period.
 Fabric Spreading Procedure
1.0 PURPOSE:
To have a faultless layering of fabric to issue good quality cut input to sewing
2.0 REPONSIBILITY:
The cutting in-charge is responsible for implementation and monitoring of this process.
3.0 PROCEDURE:
 Cutting manpower is divided into team for spreading & cutting
 Before the start of the spreading, the cut-plan is checked, and Supervisor ensures the
QA has signed the marker for marker accuracy.
 The no. of layer to be given in the spread is decided based type of fabric, gsm etc. ensuring
maximum lay height of 4”.
 While spreading, it is ensured that the fabric is fully relaxed as per the Fabric Relaxation
Procedure
Before taking the rolls for the spreading, the shade band is checked to ensure the spreading is
have one batch and one shade covered in one cut number.
 Once the above points are confirmed the spreading is done as below:
Solid Fabric:
 Mark the layer length as per the marker length on the
table correctly.
 Layer length will have additional 2” allowance to the
marker length to compensate for layer shrinkage during cutting.
 Put the spreading base paper as per the layer length &
width.
 Lay the planned no. of fabric plies efficiently and
correctly as per marker length.
Ensure no tension is applied while spreading and the laying is done flat with no looseness.
 Precisely align one side of the layer (width wise) while
spreading to avoid
 ‘LEANING’ of the layer so that CAD marker too can
be placed on top of the layer aligning to that side, to
accommodate for the deviations in the fabric roll width.
Spreading Check report
Layer Report
 Stripe or Check Fabric Spreading:
Arrange the table with metal plates according to the quality of the fabric. Here need to take in to
account the fabric bowing/skew-ness levels and decide the angle of the metal plates, no. of pins & the
layer length based on the difficulty of the check/stripe fabric to ensure best possible cut quality &
 Draw the marker manually carefully on the top-ply of the layer using approved patterns.
 After Laying of each layer, ply end must be cut/tear-off carefully accurately to reduce
fabric wastages

 If any major raw material defect is identified which is beyond tolerance levels & due to
which
required quality and/or given consumption cannot be met then notify relevant parties immediately &
take appropriate actions as per the given instructions. (i.e., contaminations, holes, color shade,
bowing/skew etc)

End- bit (Cut Piece) control:

 Roll end-bit control; Keep remaining part of each roll (if any) properly for
future use
if ended, special for sewing section Requisition re-cutting.

Spreading Quality Control

1.0 Purpose & Scope
To ensure the accuracy of Spreading Process to prevent / minimize the issues in final product.
2.0 Responsibilities
2.1 Cutting QC is responsible for the implementation of the Spreading Quality Control System.
2.2 The Cutting QC is responsible to carry out the spreading quality control activities.
3.0 Procedure
 Before starting the spreading, check & ensure that the fabric inspection report is passed
and shade grouping is done on the batch.
 The QC must check for the defects mentioned bellow & record the observations on
spreading quality control report
Table Marks: Check for table marks as the table is marked. Allow no minus tolerance for the splices

Shade Group: Ensure the rolls taken for spreading belongs to same shade groups as per the shade band report

Marker: Ensure that no markers are creased, damaged or have overlap parts

Ends: Check both end of fabric layers to ascertain whether is straight or not

Tension: Check the Tension during spreading. This is very important on knit fabric

Shading: Check for shading. It is essential to have a system to control shading

Splice: After completion of spread, check splice laps to see that both plies extend passed the splice mark
by no less than half inch & no more than one inch.
Narrow Goods: After completion of the spread, check the “Far Edge” of the spread to see that all plies extend
beyond the marker line.
Count Check: Verify the count after the completion of spreading, and before cutting, a count all plies must be
taken at both ends. There is no tolerance.

Leaning: Check carefully and to ensure that one edge of the fabric is aligned with the tabletop.
Fabric Faults: All major fabric defects are identified using arrow sticker.
Marker Placement: Check that the marker is placed on the spread with the edge parallel to the salvage
of the piece goods. To verify that all cut pieces will be complete.
for marker, count check, fabric faults, ends, marker placement, narrow good, shading and table mark faults the
spreading QA inspector can stop the spreading process and ask cutting dept. to take corrective actions
 Cutting Quality Control
1.0 Purpose & Scope:
To ensure the accuracy of Cutting Process to prevent / minimize the issues in final product.
2.0 Responsibilities:
 AQM is responsible for the implementation of the Cutting Quality Control System.
 The Cutting QC is responsible to carry out the cutting quality control activities.
3.0 Procedure:
 Cutting Quality Audit

 The Cutting QA should check each part for cutting accuracy. The accuracy includes
the visual check for the below defects:
 The Cutting QA should check for following issues in cutting process:
Miscut:
o Check for miscut or failure of the cutter to “split the line.”.
o Tolerance is ± 1/16“. Report all defects of Miscut
Matching Plies:
o Check top ply, middle & bottom ply. Compare all to see exact match.
o Tolerance is ± 1/8“. Report all defects.
Ragged Cutting:
o Check for ragged cutting. This is judgment defect and is more important on
o critical parts. If the part must be re-cut, it is a defect.
Notches (Cut Mark) :
o Check the notch location by placing the pattern over the top & bottom
o ply. Tolerance is ± 1/8“. If the notch is more than 1/8“off, report as defect.
Pattern Check:
Compare the pattern to paper marker to ensure that the correct marker used.
cut panel inspection report
Cut panel Replacement report

TOP, MIDDLE BOTTOM CHECK REPORT

Marker inspection Report
 SOP of Label control
01. Purpose:
To ensure proper label controls and follow standard systems for avoiding incorrect label
02. Responsible:
The unit In-charge of the respective floor is responsible for implementation and monitoring of this
process

03. Procedure:
 Labels on receipt at main store, get inspected as per the Trims & Accessories
Inspection and stored in controlled manner to avoid theft, misplace & damage.
 Line will receive required quantity as per the production plan from Main-store and
ensures storage as per Style & Customer in secured manner.
 When needed for the use in line, input man will receive the required labels from store
as per the cut quantity mentioned in the cutting challan.



 QC monitors and supervisor issues the label to the operator as per the bundle in
process to ensure the correct size and correct number of labels are issued.
 Operators are not allowed to keep various sizes of labels to avoid incorrect attaching
and extra labels in their custody.
Operators attach the label as per mock-up card information as required for the syle in production.

 Supervisor is responsible for exchange reject / damage (if any) quantity from
store and issue to operator.
 After style production is over, supervisor & roving QC will hand over all
kinds of labels to main store with proper re-conciliation.
 The inventory records for all types of labels maintained by the store.
 Button Pull Test
1.0 P u r p o s e
 To ensure that the manufacturing process and m/c settings are capable of meeting the
buyer requirements for pull force to failure.
 To ensure the buttons attached are complying with the safety requirements of respective
buyers
2.0 Scope
 This process is applicable to all the garments produced with Buttons and rivets
3.0 Responsibilities
 AQM is responsible to monitor and to implement the pull test procedure.

 QC is assigned to carry out the pull test and to maintain the pull test reports.
4.0 Procedure
 Pull Test Machine Calibration
The Pull test machine must be calibrated using 15 lbs (6.82kg) calibration dead weight before start of pull
test
 In line Process Control
 The inline process control is exercised with the button pull force check at defined
intervals.
 At the start of the day, perform the pull test on mocks
 To continue the production for the day, specimens test results should be above
buyer specified requirement.

 If the result fall below b u y e r r e q u i r e m e n t , the production should

be stopped. After adjusting the setting, the test needs to be performed again till the result is ok.
Pull Test
 The mechanic checks the button machine pinch settings with a vernier caliper every morning
 Every day the samples are checked for button pull test from each style as per buyer requirement
For each button during pull test the pressure is applied gradually and increased up to buyer
recommended maximum force ( eg, 90 N ) and hold for recommended time.
 If button is pulled out with the said pressure, then the test result is deemed failed and the specific
machine stopped and informed to the maintenance. Even if the button withstands the pressure but
develops a crack & or sharp edge then too the test is deemed as failed.
 After adjusting the machine, the test is performed again and If pass, then the production is
continued.
In case of snap button, if any mold is changed, then after setting the new mold, 3 buttons are checked for the
pull test on the mock made specially with the same number of layers as bulk garments If it is passed then we
go for the bulk attach with the new mold
 Machine mock and tested specimen display
On the button attach m/c, after bobbin change, the thread tension should be reset correctly.
 The first button from each new spool, should be sewn onto a spare
fabric mock, which is attached to the mock display.
 The last button from the spool, should be cut off the garment.
 Buyer Wise Requirements

EQUIVALENT
PULL FORCE TIME BUTTONS
BUYER KG ON PULL FREQUENCY
REQUIREMENT FOR PULL TO CHECK
TEST M/C

Walmart 90 N 9.2 kg 10 sec 1 2 Hrs

Jordache 90 N 9.2 kg 10 sec 1 2 Hrs

H&M 90 N 9.2 kg 10 sec 1 4 Hrs

OJG 15 lb 6.8 kg 10 sec 1 2 Hrs

Macys 15 lb 6.8 kg 10 sec 3 3 Hrs

 Pull Test Report

Snap Attaching Policy

At SFL, product safety is of almost importance. Snap attaching process is one part of product
safety.
In order to ensure proper snap attaching process, the following steps are being ensured:
 The data sheet and mold is collected from supplier.
 The persons setting the machines are trained in press fastener attachment.
 We use only pneumatic machine.
 The snap attaching machine is set in accordance with the data sheet and setting checked
by vernier caliper for pinch setting
 Machine is placed on the grated mat.
 Regular pinch setting & Pull force is checked
 A visual standard is attached on the machine for easy understanding
 Pull test is done on mocks every 2 hours of production.
The above policy is mandatory for all the snap attaching programs.

Heat Transfer SOP

 The data sheet is collected from supplier well in advance before doing the Size set
sample.
 The Data sheet to contain the parameters like Temp, Time and Pressure as well as the
style and fabric being used
 We use only pneumatic machine.
 The Heat Transfer machines are set in accordance with the data sheet and setting
checked by Wash durability test.
 Heat transfer peel method is explained to the finishing team
 A visual standard is attached on the machine for easy understanding
 Data sheet is displayed on the machine being used at all times
 The Bed temperature of the machine gets checked twice daily during the day with a
thermo strip
Many a times there are special instructions given for heat transfer handling and may involve
storing temperature range. A moisture meter is placed in the stores to monitor the ambient
temperature and if special handling is required then the care is taken to follow those special
instructions.
 In-Line Process Quality Check
1.0 Purpose & Scope:
To check the quality of in process in the sewing line.

2.0 Responsibility:
The inline product checker is responsible for this process and t he roving QC along with
line Supervisor is responsible to monitor this process.
3.0 Procedure:
 Before the start of production, the AQM is responsible for the following:

 To study the Critical to Quality report for different operation.

 Buyer comments, o r a n y special attention requirement.
 Identify if any process exists in line after which, the repair is not possible. (e.g. Bartack,
Snap Attach etc)

 AQM deploy one p r o d u c t checker (Q I ) to each identified critical Operations to check the
output from the respective operation.
 Once the production starts the assigned QI inspects the 100% output from the identified
critical operation.
 If any defect is found, the garment is returned to the operator for correction.
 Operator rectifies the defect and returns the garment.
 All inspection results are r e c o r d e d in the In-Line Quality Check Report on hourly basis.
In-Line Process Quality Check
 Traceability
We have tracking system of the fabric receipt till packing of the lots being produced.
Every section has got the formats given to follow and track and are given below
General Traceability and is displayed on every production file in the factory.
 Procedure for Statistical Quality Audit
1.0 Purpose & Scope:
To ensure that produced goods are within Acceptable Quality Limit
2.0 Responsibility:
Respective QA is responsible for audit the produced goods at the stages as per below chart and maintain the
record

3.0 Procedure:
 Lot Size for Audit: Identify the correct lot size for the audit. The lot size for
different stages of audit is as below –
 End Line Audit – Hourly quantity passed by the end line checkers
 Finishing Audit – Done twice a day. The quantity passed by final checkers
from the time last audit was conducted.
 Packing Audit – Daily Packed Cartons
The lot must consist of one style for End Line, Finishing audit and one PO for packing audit.
3.2 The AQL Standard: All audits are conducted at Normal sampling plan level II for AQL as per table
below

Audit Type AQL

Workmanship – sewing / finishing 2.5 / 1.5
Measurement 2.5
Packing Accuracy No
 Selecting correct Samples to check: Tolerance

 Determine the number of pcs to select for inspection by following AQL Sampling Plan (ANSI / ASQ
Z1.4 - 2008) at Normal Inspection Level II for the given lot size.
 Select the required number of pcs at random from the entire identifiable lot.
 Mark or identify the lot so that the garments are not moved until the audit is completed.
 Reading the AQL tables
 Suppose the lot size is 8,000 pcs . You are doing the audit at normal inspection level.
In the table below, you see that the corresponding letter is L
  AQL table 1:

3.4.3 Now turn to the next table. (It is only appropriate for normal-level inspections). The letter L gives you
the number of samples to draw at random: 200 pcs.

3.4.4 And for the AQL, s u p p o s e you allow 0% of critical defects, 1.5% of major defects, and 2.5% of
minor defects. The maximum acceptable number of defects is 7 major and 10 minor. In other words, the
inspection is failed if you find at least 1 critical defect and/or at least 8 major defects and/or at least 11
minor defects.
AQL table 2:
Understanding Defects and Defectives. A defect is any nonconformance of the unit of product with the
specified requirements. A defective is a unit of product which contains one or more defects. Failure to meet
requirements with respect to quality characteristics are usually described in terms of defects or defectives

 Understanding Defect Classification: Applicable at Finishing audit Stage

 Critical - A critical defect is on that judgment and experience indicate is
 Likely to result in hazardous or unsafe conditions when using the product.
 A deviation from delivery requirements which prevents the product from being received
and/or distributed
 Major – A Major defect is one that is likely to
 Result in a customer complaint or return
 Result in product failure after a period that is unacceptable to the customer or end user.
 Minor - A Minor defect is one that is
 Unlikely to result in customer complaint or return.
 A deviation from the required standard, but one that is unlikely to affect the usability of the
product.
 Audit Procedure: Workmanship (Visual Inspection)
 Inspect each garment from the selected sample carefully & thoroughly.
Get Up Check: The customers interpretation of quality: this is affected by how they see the garment,
touch the garment, experience the garment. Hence, first check for the defects which gets noticed in the
oversight.
Some Examples:
Twisted sewn seams Careless pressing Incorrect thread
size Unmatched thread
Inappropriate stitch techniques Unclean & unfinished edges
Improper packing techniques Loose threads
Unbalanced seams/edges
Misaligned buttons
Stains & dirt

Workmanship Check:
 Lay the Garment face up on the inspection table in good light

 Inspect the front side for soil & fabric defects. Then inspect every operation on the
garment individuality. Establish routine operations & follow the same routine on every
Garment
 We start from the top & work down
 Turn the garment over and check the back in the same way you checked the front. If you
follow the same procedure for every T-shirt you inspect, you will eliminate the possibility of
overlooking an operation
 Inspect all seams by grasping the fabric on each side of the seam and applying slide pressure
to see into the seam. This method enables you to see needle cuts, open seams and broken
sewing stitches
 Repeat the process to inspect the inside of the Garment.
 Use buyer manufacturing specifications and/or approved sample as the inspection guide

 Identify all defects as classified above for each items inspected. It is important for the
Auditor to know the defect codification system.
 Mark all major defects with an adhesive arrow sticker, label or similar method and hold.
 Review defects after audit with the QA Executive, Supervisor and as needed with the Unit In
 charge.
 Identify the Operation.
 Understand the brief description of the defect and the correct defect code.
 Discuss the required corrective action
 Provide the quick feedback of major quality issues to Sr.QM
 Audit Procedure: Measurement Audit
 Measurement audit is applicable only at the finishing audit stage.
 Select the samples for measurement audit as per the AQL sampling covering all sizes.
 Check the measurement at all the points as per the spec sheet.
 Enter the results in the measurement sheet Unless otherwise specified by the buyer, follow the
AQL 2.5 for acceptance for defectives.
 Audit Procedure: Packing Audit
 Packing Audit is conducted only for packing accuracy.
 Select the number of cartons as per the sampling plan.
 Check the cartons for holes, dents, or other damages.
 Check the placement, accuracy and legibility of all cartons marking.
 Check the count & ratio for each cartons selected. Check for incorrect accessories

 Reporting:
 Enter all defects found, in the respective report.
 Enter defect code number from the Defect Classification & Codes.
 Enter brief description of the defect.
 If the total defectives are not within acceptable limit, then the whole lot
fail and is rechecked.
 Informs the section supervisor and asks them to sign the Inspection Report.
o The In-Line Quality controllers arrange for the 100% inspection of the rejected lot.
During re- inspection the defects found are identified by using Arrow stickers and all
defected garments are segregated.
o The defected garments are sent to the relevant production line for repair and
inspected again.
o The segregated good garments are re-audited by the auditor the results of re-audit are
recorded.
 BUYER FINAL INSPECTION AQL Internal Pre final AQL

JCPENNEY 2.5 1.5

MACY'S 2.5 1.5

TARGET 2.5 1.5

C&A 2.5 1.5

IMPULSE 1.5 1.5

JORDACHE 2.5 1.5

NEXT 2.5 1.5

2.5 1.5
OJG

Pre final Audit Report

Measurement Report
Hourly Audit

Measurement Control Guideline

1.0 Purpose & Scope
To control final stage Rejection/Rework due to the Measurement Variation
2.0 Responsibilities
The r e s p e c t i v e u n i t in-charge and the AQM is responsible for the monitoring and the
implementation of systems to control measurement variation.
3.0 Procedures
 The reasons for measurement variation can be classified as below :
Fabric- Poor Dimensional Stability
 If the fabric has poor dimensional stability i.e. poor shrinkage property, this will affect the
measurement. Before cutting, the shrinkage test to be carried out to ensure the fabric shrinkage within
allowable limit.
 In case of wash garment, the shrinkage must be incorporated within the pattern to achieve the desired
measurement after wash.
 Spreading & Cutting
 Fabric Relaxation
 The fabric when arrives in the factory is either in roll form or in folded form compactly packed thus
in stretched condition. If it is just spread directly, the cut panel will shrink as the stretch tension is
relaxed. It is therefore necessary to open the fabric roll and allow it to relax for sufficient time and
should be as per the guideline given eg spandex fabric is to be relaxed for 48 hours.

 No. of plies during spreading

No of plies plays very important role in cutting. If the ply height is too much, this might lead to
fabric slippage during the cutting stage. As a thumb rule, the maximum ply height should not
exceed ½ the height of cutting knife. In SFL, all the cutting m/c is 10”. Hence the maximum ply
height could be 5”. But we have fixed a limit os 4” height as the max height of the lay

 Excessive dragging during spreading

The spreading must be done at normal tension. If the normal tension is not maintained during the
spreading process, the fabric gets laid in stretched condition. After cutting, as the tension gets released
on the cut panel, the panel tends to shrink thus resulting into short measurement. The roving QA in
cutting has to check if the spreading is done with normal tension

 Blunt knife edges

The edges of the cutting knife needs to be sharp enough as the blunt edges leads to uneven shaping.
The cutter has to check for this and do the sharpening as required
 Pattern Making
 Seam Allowance
Depending on the fabric characteristic and the process, the proper seam allowance to be given to
 achieve desired measurement in the final product. If the seam allowance is not given, the measurement
might be short
 Sewing
 Excessive Trimming waste
 Due to lack of awareness in sewing line, the workers not following the proper guide and trimming
off the excessive edge particularly is over lock operations may lead measurement discrepancy.
 Incorrect machine tension
If the m/c setting such as feed dog movement does not correlate to the fabric type, lead to excessive
tension on the fabric resulting into pull / puckering
 Finishing
 Poor handling during ironing
At iron table, the measurement pattern is provided. If the ironman do not follow the pattern and / or do the
ironing with excessive stretch by not following the proper process, may lead to measurement issue
 Control Check Points
To ensure the garments being produced are as per the required dimension, the measurement is checked at
various stages of production as described below:
At cutting stage, the fabric relaxation tag is used for each roll being opened. This gives the details as when the
fabric is relaxed and ensures that the roll is not spread before 24 hrs.
 The cutting QA & cutting i/c ensures the no. of plies within required number to ensure no slippage
while cutting.
 The roving QA in cutting doing the spreading quality control, checks the spreading tension and
ensures the spreading is done with normal tension.
 The cutting Qc performs the matching plies activity. In this he takes a panel from top, middle &
bottom of the lay and matches the same against the hard pattern to ensure the proper cutting quality.

 100% of the garments produced in the line are checked for measurement at key measurement points
after ironing and findings recorded
The line roving QA checks 5 garments of each size being produced twice a day subject to 10
minimum per day. (Before & after lunch) for all the measurement point as per the spec sheet.

SOP FOR CONTROLLING REJECTIONS DUE TO UNCUT THREAD

1.0 Purpose:
Providing the guideline for taking preventive action for avoiding the garments rejection
due to uncut thread.
2.0 Scope:
The procedure is applicable to all the production units of SFL for all the styles.
3.0 Procedure:
 Production floor receives the Operations Bulletin from Central IE Team.
 Production Executive, Floor IE Executive and QA Executive along with other
concerned persons review all the operations and identify the operation needing thread
trimming to be controlled.
 After the size set is made in the line, the same is also reviewed to verify the
 processes identified for thread trimming controls.
 When the bulk production starts, out of the first 10 pcs, one garments should be
 stitched without any thread trimming and checked against the identified control points
to validate the same.
 Once the control points are finalized, the team will decide on who will trim the excess
thread for each identified process, who will monitor, check and the control.
 The control plan will be prepared as per below format:

 Sr.  Process  Who Trims  Who  Who

N Controls Monitors
o.
   Machine /  
Manual

 The machines will be adjusted to the most possible precision by the maintenance team
and all the manual trimming persons will be briefed / trained by the line supervisor for
proper trimming.
 Any uncut thread found at the final check tables will be returned to the respective
trimming process owner thru the line QA.

Procedure for In-line & Pre-final Quality Audit

1.0 Purpose & Scope:

To check & ensure that packed goods are within Acceptable Quality Limit before offering for final
inspection

2.0 Responsibility:
Respective DQA or GPQ is responsible for auditing the packed goods for in-line & Pre-final as per
the required standard

3.0 Procedure:
The in-line AQL Audit by GPQ / DQA is conducted as per below schedule of production
completion:

10% in finishing 50% in finishing 80-100% in finishing

The pre-final inspection is conducted on completion of packing of entire PO o r 8 0 % before

offering the lot for final inspection
 Lot Size for Audit:

 Identify the correct lot size for the audit. The lot size is the no. of units packed at the
time of pulling out the sample for audit.

 Unit – A unit is pieces or packs packed as per the terms of agreement in the PO
  The Sampling Levels & AQL Standard:
 All audits are conducted as per AQL mentioned below following ANSI/ASQ/Z 1.4 –
2008 Sampling Plan unless otherwise more strict sampling plan specified by the respective
Customer.

Audit Type Sampling Plan AQL

Workmanship ( Visual ) if PO quantity is < Normal Level II Critical – No Tolerance
3200 units
Major Defects - 1.5
Minor Defects - 2.5

Measurement ( Critical Points ) Special Level S4 AQL 2.5

Packing Accuracy Special Level S4 No Tolerance
Metal Contamination ( As Applicable ) 20 pc per inspection No Tolerance
Moisture Content Check 10 pcs per Color No Tolerance

 In some special cases, as per the advice from GM-QA , sampling plan may be altered.
 Carton Selection Process

 The no. of cartons should be selected in such way to cover all the sizes /
colors/assortment as available from the lot

 Apply the square root of the total cartons in the lot to determine the number of selected cartons
as per the following table.

No. Of Cartons Carton Sample Size

≤ 1500 √ No. OF Cartons + 10
1500 to 3000 √ No. OF Cartons + 20
≥ 3000 √ No. OF Cartons + 30
 Take the samples out of selected cartons for Packing / Workmanship / Measurement
Audits as per the respective sampling plan.
E.g. 18000 units packed in 1800 cartons
No. of Cartons Taken = 63 ( √1800 + 20 )
No. of Garments for Workmanship Audit = 315 ( L II → Code M )
No. OF Garments for Measurement Audit = 50 ( S 4 → Code H )
No. Of Cartons for Packing Audit = 32 ( S 4 → Code G )
Select the required number of pcs at random from the entire identifiable lot.

 Reading the AQL tables

 Suppose the lot size is 8,000 pcs . You are doing the audit at normal inspection level. In
the table below, you see that the corresponding letter is L.
 AQL table 1:
  Now turn to the next table. (It is only appropriate for normal-level inspections). The letter L
gives you the number of samples to draw at random: 200 pcs.
 And for the AQL, suppose you allow 0% of critical defects, 1.5% of major defects, and
2.5% of minor defects. The maximum acceptable number of defects is 7 major and 10 minor. In other
words, the inspection is failed if you find at least 1 critical defect and/or at least 8 major defects and/or
at least 11 minor defects.
AQL table 2:
  Understanding Defects and Defectives.
 A defect is any nonconformance of the unit of product with the specified requirements.
 A defective is a unit of product which contains one or more defects.
 Failure to meet requirements with respect to quality characteristics are usually
described in terms of defects or defectives.
 Understanding Defect Classification :
 Critical - A critical defect is on that judgment and experience indicate is -
 Likely to result in hazardous or unsafe conditions when using the product.
 A deviation from delivery requirements which prevents the product from being received
and/or distributed
 Major – A Major defect is one that is likely to -Result in a customer complaint or return.
 Result in product failure after a period of time that is unacceptable to the customer or
end user.
 Minor - A Minor defect is one that is -

 Unlikely to result in customer complaint or return.

 deviation from the required standard, but one that is unlikely to affect the usability of the
product.

 Audit Procedure: Workmanship (Visual Inspection)

 Inspect each garment from the selected sample carefully & thoroughly.

 Get Up Check: The customers interpretation of quality: this is affected by how they see
the garment, touch the garment, experience the garment. Hence, first check for the
defects which gets noticed in the oversight.

Some Examples:

Twisted sewn
seams Careless
pressing Incorrect
thread size Unmatched thread
Inappropriate stitch techniques
Unclean & unfinished edges Improper packing techniques
Loose threads
Unbalanced seams/edges
Misaligned buttons
Stains & dirt

Workmanship check:

 Lay the Garment face up on the inspection table in good light

 Inspect the front side for soil & fabric defects. Then inspect every operation on the garment
individuality. Establish routine operations & follow the same routine on every Garment.

 We start from the top & work down clockwise

  Turn the garment over and check the back in the same way you checked the front., you will
eliminate the possibility of overlooking an operation.

 Inspect all seams by grasping the fabric on each side of the seam and applying slide pressure
to see into the seam. This method enables you to see needle cuts, open seams and broken
sewing stitches

 Repeat the process to inspect the inside of the Garment.

 Use buyer manufacturing specifications and/or approved sample as the inspection guide.

 Identify all defects as classified above for each items inspected. It is important for the Auditor
to know the defect codification system.

 Mark all major defects with an adhesive arrow sticker, label or similar method and hold.

 Review defects after audit :

 Identify the Operation.

 Understand the brief description of the defect and the correct defect code.

3.9 Audit Procedure: Measurement Audit

 Select the samples for measurement audit as per the AQL sampling plan covering all sizes /
Color.

 Measurement Audit as per sample size S4 is applicable only for “Critical Point of
Measurement” as per the spec sheet

 The list of critical points is as below :

 Length
 Bust / Chest
 3.9.3.3 Arm Hole
 3.9.3.4 Sleeve Length
 3.9.3.5 Neck Opening Stretch
 3.9.3.6 Waist ( relaxed & Extended )
 3.9.3.7 Inseam
 3.9.3.8 Hip ( Bottoms Only )
 3.9.3.9 Sweep ( Tops Only )
 3.9.3.10 Back Rise
 3.9.3.11 Front Rise

 Enter the results in the measurement sheet

 Unless otherwise specified by the buyer, follow the AQL 1.5 for acceptance for
defectives.
 Audit Procedure : Packing Audit
 Packing Audit is conducted only for packing accuracy.
 Select the number of cartons as per the sampling plan.
 Check the cartons for holes, dents or other damages.
 Check the placement, accuracy and legibility of all carton marking.
 Check the count & ratio for each cartons selected.

 Label Audit
 Label Audit to be conducted as part of packing accuracy audit.
 Check the pcs as per level S4 sample size for correct accessories & placement.
 Record the non-conformities if any in the audit report.
 This audit is a “Zero” Tolerance audit

 Metal Contamination Audit

 The metal Detection audit should be carried out on all kids items and as
specified by the buyer as applicable.
 The sample size for this audit is 20 pcs
 Pass 20 pcs out of selected 20 through the metal detector to check the
garments are free from the metal contamination

 If any garment does not pass through the metal detector, the metal
detection test is recorded as failed for metal contamination.

 Moisture Check Audit

 Moisture check audit is carried out as a part of Mold prevention guideline.
 Check the moisture content of the garment using the moisture meter at 3
places in some garments (min 5 garments ) selected as sampling.

 Reporting :
 The findings are recorded in the respective reports.
 Enter defect code number from the Defect Classification & Codes.
 Enter brief description of the defect.
 If the total defectives are not within acceptable limit, then the whole lot fail
and is rechecked.
 If the lot is fail, enter the failure code in the report.

 In case the lot is rechecked, the segregated good garments are re-audited and the
results of re-audit are recorded.

AQL CHART
Table 2:
 Match Book SOP
1.0 Purpose & Scope:

Ensuring that the Match book attaches without SKU mistake & production process is
smooth and efficient with regards to quality & productivity and in supplying a quality
garment to our customer

2.0 Responsibilities:

The Asst. Manager, Finishing is responsible for the overall operation of the department
& supervisor to assist him

3.0 Procedure:
3.1 Match Book on receipt at main store, get inspected as per the Trims & Accessories
Inspection and stored in controlled manner to avoid theft, misplace & damage.
3.2 Line will receive required quantity as per the production plan from Main-store and
ensures storage as per Style & Customer in secured manner.
3.3 When needed for the use in line, input man will receive the required Match book from
store as per the cut quantity mentioned in the cutting challan.
Roving QC monitors and supervisor issues the Match Book to the operator as per the bundle in process
to ensure the correct size and correct number of Match Book are issued

1.1 Operators are not allowed to keep various sizes of labels to avoid incorrect attaching and
extra Match Book in their custody
1.2 Operators attach the Match Book as per mock-up card information as required for the
style in production.
1.3 Supervisor is responsible for exchange reject / damage (if any) quantity from
store and issue to operator
1.4 After style production is over, supervisor & roving QC will hand over all kinds of
Match Book to main store with proper re-conciliation.
1.9 The inventory records for all types of Match
Book maintained by the store

Related Documents

4.1 Sectional Production Recording Sheet ()

 Packing Method and Cutting
After receiving a file of a style at sewing floor, the cutting In charge & the production manager has to
check the major point of the file with importance that is Size, order quantity, ratio & packing method of that
style.
Packing method plays an important role in Garment technology.

There are four types of packing method being followed as per Buyer instruction which are –
1) Solid colour solid size
2) Solid colour assort size
3) Assort colour solid size
4) Assort colour assort size
Solid color solid size

As per Buyer instruction, with this method packing will be done by one specific colour and size.
According to the shade total quantity of s p e c i f i c size of specific colour has to check during cutting and
right quantity has to supply to sewing section. Production and quality will be improved if sewing section
produce as per color & size wise & there will not be any back log at finishing section.

1) Solid color assort size:

With this method cutting must be done according to the ratio & size by maintaining the
right colour shade. With this method production & quality will be improve as well as there will not be any
back log at finishing section

2) Assort color solid size:

According to packing method CTN must be done by one specific size of one specific color. During the
time of production o n e specific size of each color must supply. With this Method, P r o d u c t i o n & quality
will be improved as well as there will not be any back log at finishing section
3) Assort colour assort size:

This method is bit difficult. According t o packing method during the time of cutting different size ratio of
different color must be cut with maintaining the right color shade. Cutting quantity will be such a way that
all color & size will be as per ratio.As a result when it will be supply to sewing section there will not be any
back log at finishing section. Concentration will be on color, size & ratio during cutting time & then there
will not any difference. At the same time during the time of production if right size of right colour & ratio
are supplied then production & quality will be improve & there will not be any back log at finishing section.
If cutting & sewing section maintain this method with importance, it will be easy to produce more, quality
will improve & shipment will be happened at fixed time.

Embroidery & Printing QI

1.0 Purpose & Scope
To identify and segregate the rejection in the embroidery & printing process.
2.0 Responsibilities
AQM is responsible to monitor and to implement the embroidery & Printing quality control procedure.
QI is a s s i g n e d t o c a r r y o u t t h e c h e c k i n g , g i v i n g f e e d b a c k t o t h e AQM and maintain the reports.

3.0 Procedures
 The assigned QI to check the produced panel 100% for the defect before delivery to the sewing
line.
  Once the inspection is carried out, the defects found to enter in the respective quality report.
 Show the defective panels to the AQM and recut the panels from the end bit to send for the same
process.

FUSING CALIBRATION BONDING STRENGTH TEST

1.0 PURPOSE AND SCOPE
To check the bonding strength of the fusing operation to ensure the temperature, pressure & timing set for the
fusing m/c is appropriate for the operation.
2.0 RESPONSIBILITY
The AQM is responsible implementation and monitoring of the process.
3.0 PROCEDURE
 The bonding strength is checked using the spring balance and the result is used for reference and
comparison against the required.
 The test is done by following the simple steps as below:

Step 1 :
 Following the m/c direction or the warp direction, interlining is cut into 17cm x 7 cm
 The outer fabric is cut slightly bigger than the interlining to avoid the contamination of the
conveyer belt of fusing m/c

Step 2 :
 A small piece of fabric is inserted between the outer fabric and the interlining is such a way that it is
easy to pull.
 The temperature strip is inserted with reading face to fabric
Step 3 : The specimen is passed thru the fusing m/c with recommended temperature, pressure & time

Step 4 : The temperature strip is taken out by cutting alongside of the strip and the temperature is noted

Step 5: The specimen is cut in 5 cm width

Step 6 :
 The edge of the outer fabric is folded and stitched to form a loop and the hook of the spring balance is
inserted inside the stitch
Step 7 :
 The fabric is laid flat on table holding down the spring balance with one hand.
 The small fabric is grasped with another hand and pulled gently with moderate speed for about 10
cm.
 The reading on the spring balance is noted as Bonding Strength

 The bonding strength is recommended by the interlining supplier, however for 2.5 N or
higher is considered ok.
 If the bonding strength is not found ok, the necessary adjustment is done to the fusing m/c
setting and/or other corrective measures taken as the case may be.
 This test is to be performed on twice a day.
 Broken Needle, Needle Exchange Handling & Metal Contamination
Prevention Procedure
1.0 Purpose & Scope:
To define the requirements for handling broken needles, needle exchange and the prevention of metal
contamination

This applies to all possible sources of needles, broken needles and metal contamination within the factory (including
but not limited to: sewing machine needles, tagging gun needles, hand sewing, and embroidery machine needles)

2.0 Responsibility:
The Maintenance In-charge along with GM QA of the respective factory is responsible for
implementation of this procedure.

3.0 Procedure:
 Only designated Needle Controller is authorized to possess the spare needles in a secured
location within each production floor.
 A new needle may be issued only when:
 The operator produces a complete needle
 The operator produces all pieces of a broken needle
 Contaminated product is quarantined (current work piece, near-by bundles, etc.)
 For exchange of needles within sewing floor including but not limited to: Exchange for
quality, for style change, for m/c change etc)
Broken Needles

 Broken needles (all pieces) must be secured in a broken needle log with the date, the line/machine
number, and the operator’s name.

 When a needle break occurs, the following steps must be taken

 Stop production.
 Inform supervisor.
 Locate all broken needle fragments.
 If all fragments cannot be found, immediately quarantine the affected product.
 Pass the affected product (parts of product) thru the metal detector or thru hand-held metal
detector.
 Once the product passes metal detection, it can be returned to the production area.
 If affected product does not pass metal detection, locate, and remove needle fragments OR destroy
product
 Carry all the parts of the broken needle in a designated box with the magnet fitted at the bottom
and handover the same to the designated needle controller authorized to replace the needle.
 Needle controller checks all the parts against new needle to
ensure all the parts received and issues the new needle.
 Incase all broken needle parts not received; the new needle is issued only against written
authorization from the Unit In charge.
 Update the broken needle log.
 Thoroughly clean the affected equipment and production area (i.e. sewing machine, worktable,
storage bins, floor, etc.)
 Line mechanic replaces the needle.
 Resume production.
Needle Excha nge

 Good Needles might need to exchange for quality reasons, style change or m/c change etc, is also
covered by this procedure.
 If the needle needs to be exchanged with another type / size, the line supervisor takes
approval from the PM & QA Executive and handover the same to line mechanic.
 Line mechanic carries the needle in a designated box with the magnet fitted at the bottom and
handover the same to the designated needle controller authorized to replace the needle.
 Needle controller checks the needle size and issues the new needle as per the requirement.
 Needle issue log is updated accordingly.
 Line mechanic replaces the needle

Metal Component & Tool Control

 Scissors, trimmers, tweezers, & other production tools to be attached to the workstation in a safe
and secure manner. When not feasible to attach tools to the workstation (e.g.: scissors used at cutting
tables), these tools must be controlled through a tool board, tool log, or other adequate control
method.
 Metal objects (e.g.: machine parts, screws, tools, etc.) must be controlled and separated from the
production environment when not in use.
 Metal components (including but not limited to snaps, grommets, etc.) must be stored in boxes
and controlled within the production environment.
 Pins and other small metal devices may not be used in cutting area (or, if pins must be used due to
fabric type (e.g.: feed stripes, engineered stripes, etc.), the pins must be controlled thru sub-store.
 Metal office supplies (e.g.: staples, paperclips, etc.) must be separated from the production
environment.

 Packaging & Packing Areas

 Needle control, broken needle log, and general metal contamination prevention procedures
also applicable to tagging equipment.
Metal Free Zone

 Packaging area is strictly maintained as a needle free area.

  All personal movements in the metal free zone is controlled thru register entry and displaying the
picture of the authorized person at the entry.
 If any metal objective needs to be used inside the metal free zone, the same is controlled to issue
register in sub-store as below:
 Sometimes due to nature of packing depending on the style, some metal object e.g. tape cutter,
hanger with metal clip or metal hook etc. needs to be used inside the metal free zone.
 In situation mentioned in 3.19.1, the sub-store in the floor, maintain a register for issue of
accessories containing metal items which is issued to metal free zone.
 In case some tools containing metal need to use inside metal
free zone, it is issued against person at start of the work and is deposited back at closing time

 100% of the garments going inside the metal free zone, are passed thru the metal detector which is
calibrated every hour as per “Needle Detector Calibration Procedure” and is serviced by authorized
agents at OEM’s recommended frequency.
 The garments passed thru the metal detector are kept is separate
quarantined area t i l l t h e next c a l i b r a t i o n cycle. Once t h e m e t a l detector calibration is found
ok, the garments are passed for the next process.
In case the metal detector is found out of calibration, the same is set first and
all the garments in the quarantine area are reprocessed thru the metal detection process and record are
maintained.
 The metal detector is controlled by having the machine key with the finishing AQM
 If sometimes, the garment styling includes metal and cannot be passed through
the metal detector and the customer does not demand metal detection then in that case the garments are not
passed through the metal detection machine
Dangerous Tools Control
All the tools with sharp points which might create safety issue is controlled on the production floor.
Missing Needle Report
Broken Needle Report
 Exchange needle report

Sharp Tool Control Procedure

1.0 Purpose & Scope:

To control the sharp tools used on the production floor to avoid any injury to any person (this includes
both, who are involved in manufacturing of the product and also the consumers) and to avoid any
chances of Sharp Objects being shipped

2.0 Responsibility:

Respective Department Head / Section Head is responsible and accountable for implementing the process
in his / her department/ section.

Head of quality of respective factory is responsible for ensuring the effectiveness thru the periodic
internal audits.

3.0 Procedure:

 In the garment production floor, various kinds of sharp tools are being used. The issue, use and
disposal of such tools are controlled as per the Sharp tool policy as if any of the tools or part of
tools are found in a garment, they can cause serious injury or a potential hazard to the ultimate
customer, result in customer complaints as well as a possible serious fine, which can amount to
thousands of moneys.
 The sharp tools refer to metal or nonmetal components having sharp edge which may lead to
injury or uneasiness, itching, irritation on contact.
 The control of sharp tool is as below:
 As a policy, the use of pins, staples are strictly prohibited on the production floor.
 100% of the garments are passed thru the metal detector and use of jewelry by the persons
working after the metal detection is controlled thru the jewelry control policy.
 All kinds of needles and parts of needles are controlled as per the Broken needle handling
procedure
 The cutting machine knifes are controlled thru the cutting knife control procedure
 Usage of Sharp Tools:
 All trimmers are scissors must be tied with a string in such a way that after hanging down from
workplace, the distance from the floor is 01 foot above the ground level. It should not be kept
loose on machine, table or in surrounding of workplace. They can injure any individual or can cause
damage to garments.
 All the sewing machines should be equipped with eye guard and needle guard as applicable to avoid any
injuries to workers.
 Cutter man should always use metal gloves while using the cutting machine.

 Storage of Sharp Tools:

 All the usable sharp tools must be stored in the secured place provided in the respective section with
lock & key arrangement.
 The respective inch rage / supervisor designated is responsible for control of sharp tools.
 The individual tools is assigned to the persons and the employee id is written on the tools. When the
person is absent, tools are kept in locked condition.
Records of Issue & Receipt:
 Line in charge is responsible to issue & receive the sharp tools and maintains the record.
 This is applicable for trimmers, scissors, cutting pins, metal clamps, hand gloves etc.
 Control of Machine Parts & New Sharp tools:
 All the machine parts and new sharp tools are issued on exchange basis as one for one from store unless
otherwise authorized by Vice President for new additional tools.
 No one is authorized to possess any additional quantity of machine parts or sharp tool in his/her custody
 Issue of machine parts or sharp tool must be executed with requisition properly signed by Department
Head.
 All the produced garments are passed thru the metal detector duly calibrated as per the Metal Detector
calibration process.
 Prevention of Sharp Tools:
 In the manufacturing operations, the use of staples, pins & Wires is strictly prohibited.
 In case where metal components need to be used, the control of use is ensured by maintaining the
records
 Any metal goods entering the factory are ensured as contaminant-free.
 The bulk trims are passed thru the metal detector prior to use
 Sharp tools Register

Quality Analysis & Improvement

1.0 Purpose & Scope:
To provide the guideline for analyzing the output of QA processes and recognize the areas for
improvement thereof for corrective / preventive actions as required.
2.0 Responsibility:
The individual process owner responsible for implementation of the respective process and the
user of the output of the process is responsible to determine, collect & analyze appropriate data
resulting from the QA processes to demonstrate the suitability and effectiveness of the quality
systems and to evaluate where continual improvement of the effectiveness of the quality systems can
be made.
3.0 Procedure:

 The data from the result of various QA processes is collected and analyzed as different stages to
provide the guideline for effectiveness of QA system and further improvement as follows:

 Pre-production Analysis:
Pre-production analysis is done by analyzing the results of the QA activities carried out before the
start of production of a particular style. This includes
 Size set report
Size set report focuses on the shortcoming of the size set prepared by the floor before start of the production of
a particular style. It highlights the issues related to workmanship, measurement, styling & the trims placement
to take required precaution during the bulk production.
 PP meeting
The buyer approved sample is reviewed in the pre-production meeting. While reviewing this, any issues
related to product safety, quality & productivity is identified, and necessary corrective & preventive action is
initiated accordingly to avoid these issues in the bulk production.
 Critical to Quality Report (CTQ)
 This process identifies critical points w.r.t. quality (CTQ) which if occurs might result in customer
complaint or return or might result in product failure preventing the product from being received
and/or distributed by the customer.
This report also highlights the possible “How” (actions to prevent) to the identified CTQs and strength of
the relationship between each CTQs and actions.
This report gives clear guideline on the priorities of the actions to be implemented during the bulk
production and what actions required to take care of critical to quality issues.
This is a kind of preventive actions taken to avoid the potential issues during the production.
 Trial Cut Report
Trial cut is after all the analysis on size set, pre-production meeting & CTQ to check the effectiveness of all
the actions decided during the previous analysis. Mainly the measurement is assessed during this stage apart
from the workmanship & trims placement. The trial cut report guides on correctness of bulk pattern and
settings in the line. If the measurement is found out of tolerance, the bulk pattern is amended accordingly
before proceeding for the bulk cutting. If any workmanship, styling issues recorded during the trial cut,
necessary adjustment is done in the line.
 During Production Analysis & Improvement:
During production analysis is done by analyzing the results of the QA activities carried out during the
production. This includes:

 Top 3 defects ( from the end line 100% )

The end line 100% inspection records are processed to identify top 3 defects over a period of time e.g. weekly,
monthly or specific range of dates to identify line wise / style wise weak areas. Based on this analysis,
specific corrective action can be taken in the line at needle point to avoid further occurrence of the defect.
This is a very much useful tool which guides specific action point for improvement during the production.
 Weak Product Checker Tracking ( from the AQL Audit ) Each product checker at final inspection stage
is provided with a “QC Pass” sticker bearing unique number. Each lot checked by the product checker
is subjected to the random audit on AQL. The defectives found during the audit are checked and the
sticker code is noted. This provides the information on which product checker overlooked the defects
and form the basis for selecting the checker for further training.

On the job Training for Product Checker

 Based on the analysis of points of this procedure, the weak checkers are identified, and the training
need is generated. The floor QA executive initiates on the job training to improve the performance of
the product checker and the effectiveness of the quality systems
 Weekly Meeting & Weekly Goals
 Weekly quality meetings are conducted to review performance of the respective floor w.r.t quality and
effectiveness of the quality management systems. All the QA results are analyzed in this meeting.
Based on the current performance level, the goals are set for the next week ahead. All required action
are implemented for improvement and same is again reviewed during next weekly meeting.
 In-line Process Control
The main purpose of this activity is to identify the issues arising in the sewing line at early stages (at needle
point) and ensure the good quality garments are being produced. This report focuses on the troublesome
operation inside the sewing line and helps in taking appropriate action at the root cause point. This is a
very good tool for improving the process capability & effectiveness.
 In-line / Pre-final Audit Analysis:
 The in-line & pre-final audit is conducted by the team of trained / skilled QAs independent of the
production floor. The result of the audit is summarized by the team and analyzed to provide
the following information. This includes:
 Category wise / Unit wise pass/fail status
 The pass / fail status is provided by the pre-final statistics. This basically provides the information total
no. of audits and status w.r.t how many audits passed & how many failed with the reason category.
 Failure contribution analysis
This report guides on the areas which has contributed for the failures in the in-line / pre-final audit and
provides specific focused area for improvement.
 OQL % unit wise / buyer wise OQL stands for Observed Quality Level. This report provides
information about the DHU% on the basis of pre-final auditor’s observation / finding during the audit.
This provides direct comparison for floor quality level and/or product checkers effectiveness level.
  Improvement opportunity report
 This report is applicable only for the defects related to the workmanship as found during the in-line /
pre-final audit. This focuses on the specific area which is vital few and needs immediate
attention for improvement based on its contribution to the failure.
 Final Buyer Inspection Analysis:
The results of the final buyer inspection is processed and analyzed for further improvement opportunities.
This includes:
 Monthly Buyer wise inspection analysis.
The final inspection report for each buyer & unit is recorded analyzed. This information gives idea about
performance of the floor for each buyer on monthly basis.
Related Documents:

Size Set Report

PP Meeting Minutes
Trial Cut Report
Top 3 Defects
Pre-final Analysis
OQL %

SOP for Sticker allocation for finishing Quality checker

This below SOP is applicable for all the units in SFL and to be used in the finishing section only
1. Any person joining or already working in SFL will have a unique identification sticker number.
This number will be allocated on the serial basis in increasing order and will start from 001 till 999.
2. This number thus allocated will remain with the said QI till the time of his or her tenure in SFL.
3. If any person happens to leave the company, then that number can be allocated to another person
after making proper record in the number register.
4. Same QI cannot be allocated different numbers during their tenure in SFL, and the different Quality
checkers cannot have the same number allocated to them.
5. When any checker is transferred from one line to another then that checker will carry her number
along with her to the new location.
6. Every finishing line to maintain a daily attendance register line wise to understand which QI was
working in which line on a particular day.
7. All the people checking the garments will attach their sticker in the garment on a particular place as
advised by the finishing manager.
8. The getup QC will remove all other checker stickers and then put her individual number in the
garment, thus a garment will have only one sticker in it during packing.
9. The list of people and their individual sticker will be given to the store’s manager.
10. The store will issue the stocker directly to the checker based on the list given by the GM QA.
11. This way the security of the sticker is maintained throughout by the checker.

SOP FOR CORRECTIVE ACTION

Purpose:
To take corrective action for investigation resolution of the non-conformity arising out of product process or
system failure and / or due to any kind of customer complaint, which might affect safety, regulatory or quality
requirements and to avoid re-occurrence of such nonconformity in future

Responsibility:
The Unit Sr. Manager is responsible for implementation and monitoring of the process.
Procedure:
1. Any non-conformity related to product, process, system, or any customer complaint
2. The unit Sr. Manager along with the QAM call for a meeting with related people for discussion on failure.
3. All related person discuss and do the analysis of root cause for failure and come up with detailed corrective
action plan with specific responsibility and end date.
4.The action plan is implemented, and the effectiveness of corrective action plan is validated after due date

Any recheck is initiated under following circumstances:

If the final inspection is failed for workmanship, measurement or packing.

 If any inline or pre-final inspection conducted by central QA fails, the QA I/C in consultation
with floor QA I/C and Unit I/C analyze the audit report along with the defectives found and
decides to do the recheck.

 The QA In-charge discusses the issues found during the audit with the floor QA I/C and plan
for the recheck.
 For the recheck purpose, a dedicated team is formed, and one QA is assigned to monitor the
process.
 The failed audit report is discussed with the recheck team and defective garments are shown
as representative defects for easy understanding.
 Once recheck is completed, the recheck report is filled up and analyzed for further corrective
actions.
 Understanding Recheck Report:
 Recheck findings:
 The details of the defectives found during recheck is entered in the recheck report along with
the defect code, details of the defects, total number of defectives found and defectives as %
of checked quantity.
 This gives idea about the intensity of the problems in the initially offered lot and what defects
contributed much to the failure.
 Process Details:
 The top four worst performing processes are highlighted in this section.
 All the defective garments are segregated process wise and the top four processes are
identified to facilitate the necessary corrective action.

 Product Checker Details:

  Each product checker is given unique identification number sticker. Once a garment is checked
and passed by the product checker, he/she puts this sticker on designated area on the
garment.
 On completion of recheck, these numbers on the defective garments are noted to identify
which product checker has passed these defective garments.
 All these details are entered in recheck report to identify the worst performing product
checkers.
 This information acts as a guideline for identifying the weak checkers, generating training
needs for product checkers and/or also basis for product checker evaluation / concentration
test.
 Non-Shippable Garments Handling
 Recheck is a result of audit failure. During recheck, the defectives segregated may contain non
confirming garments which are un-shippable. This might lead to short shipment if not
attended immediately.
 The recheck report gives clear breakdown of un-shippable garments, based on which re-
cutting can be initiated to avoid any sort of short shipment.
 Understanding AOQL
 AOQL stands for Average Outgoing Quality Level which is an indication of quality level of
initially packed goods.
 This is calculated as total defectives found during the recheck process as % of lot size.
 This gives an idea about the AQL level on which the QA system has performed in the PO /
Style being rechecked.

Post Recheck Activities:

 As recheck is performed after a lot is failed, there are certain important activities to be
followed on completion of recheck which includes but not limited to the following:
 Re-audit of the lot at AQL 1.0 Level II
 Corrective action plan for preventing such failures in future
 Communicating to other floors to avoid such kinds of non-conformity
 Generating the training needs for the product checkers
 Re-cutting plan for replenishing the un-shippable goods in order to avoid the short shipment
 REFERANCES
o Recheck Report
o SOP for Corrective Action
 Standard Operating Procedure for Hazardous Risk Analysis:
Objectives:
To ensure that no hazardous substance gets shipped with the finished products of the as factory this
may pose a threat to the product or customer/wearer of the product.

Scope:

To establish a system/ policy to control/ prevent:

a) Physical Contamination
b) Chemical Content
c) Allergens
d) Packing Defects
e) Labeling Issues leading to product legality and to maintain safety, quality and
legality of the product
Procedure:

Product Legality:
a. For each buyer, one Merchandising Manager has been assigned to look
after legality before production commences.
b. The Merchandising Manager must ensure the legality for respective buyer.

Product Safety:

KTC is adhered to follow the SOP’s mentioned in its Quality Manual to ensure safety of
the product by means of controlling Needle Policy, Sewing Button Attachment Policy,
Sharp Tool Control Policy, etc.

Hazardous Chemicals:

a. Follow the Chemical Residue control Policy

b. Follow the MSDS (Material Safety Data Sheet)
c. Follow the general guidelines of Chemical Handling
d. Follow the test reports done by third party.
Any specific requirement of customer
1. Reports and Control:

All above mentioned points to be controlled and monitored by respective reports

 2. Corrective Action Plan and Follow Up:
The management will review the CAP and Follow up for any hazardous substance

Standard Operating Procedure for Jewelry Policy

Purpose:
To establish jewelry policy in organization to prevent any jewelry part to contaminate product

Scope:
The following procedures shall be adhered to by all company personnel to prevent possible
contamination of product

Program Requirements:

Control (1.0)

1.17 Policy will be applicable to all employees working in packing onwards process
departments who are involved in carton closing points.

1.18 They will be counseled at the time of joining and will be verbally
controlled by Supervisors.
1.19 They should not wear ornaments with hanging parts, extra
decorations, and additional ornaments.
1.20 As per basic human rights ground, however they can wear basic single
ring earrings and basic rings and watches; those are securely
tightened to body parts.
How to handle accident of contamination (2.0) action (2.1)
2.1.1 Immediately report to Supervisor and Manager in case any
jewelry part is found lost by anybody.
2.1.2 100% cartons pre-identified from each finishing row with
specific date must be re-checked.
An audit must be conducted by independent QA team.
 SOP for change in Material, Components, Design or Manufacturing
Process of a Product
1.0 PURPOSE:

To manage the changes, notifying customer and obtaining approval when there is a change in raw
materials, components and sub-assemblies, design or any visual changes, manufacturing
process/technique that could affect the end products safety, regulatory and quality requirements of
finished products

2.0 SCOPE:

This procedure is applicable for all the units of Simba Fashions Ltd.

3.0 PROCEDURE:

7.1 If the factory, sometimes need to change some of the in raw materials, components and sub-
assemblies, design or any visual changes, manufacturing process/technique that could affect the end
products safety, regulatory and quality requirements of finished products, this need to be discussed
with the Head of QA

7.2 Head of QA will validate the change (when appropriate, by 3 rd party test ) and discuss the changes
with respective merchandiser and will analyze if these changes affect the product meeting any of the
following requirements

3.1.1 Safety
3.1.2 Regulatory
7.2.3 Quality requirements
1.1 If any of the safety, regulatory or quality requirement is not getting affected due to the
proposed changes; the merchandiser will notify the same to the customer in written and
take written approval prior to implement these changes.

1.2 On getting the approval copy from the customer, the Head of QA will authorize the
changes to be effected s.t.(where applicable) by revising production flow diagrams,
Manufacturing Control Plan, and revised product specification which outlines the steps to
be taken following the change approval from the client.
 STANDARD OPERATING PROCEDURE FOR HANDLING
BUYER COMPLAINTS
COMMON TYPES OF BUYER COMPLAINT:
A. QUALITY ISSUES B. HAZARD / CHEMICAL ISSUES
SCOPE:
FOR QUALITY ISSUES:
The Management has formed a committee which consists of the following members:
A. Merchandising Manager B. COO C. GM Quality D. AGM/GM Production E. Technical Manager
FOR HAZARD/ CHEMICAL ISSUES:
The Management has formed a committee which consists of the following members:
A. Country Manager / Merchandising Manager B. COO C. GM Quality D. AGM/GM Production
E. GM Washing F. LAB In-charge
ROLES AND RESPONSIBILITIES:
It is a responsibility of Country Manager / Merchandising Manager to inform concern department about the
buyer complaints.
COO will set for a meeting with the above persons to discuss and plan how to take action on a particular
complain.
GM Quality, GM Production, Technical Manager, GM Washing will act as team leaders for each concern
factories. They will further pass the message to lower levels. They will also investigate the subject and
forward details to committee for further action and prevention plan.
There will be follow-up for 7days to ensure that correction is taken place and not repeated.
Investigation format & follow-up chart is to be duly filled and filed.

COMMUNICATION:
FOR QUALITY ISSUES: COO

Manager-Merchandiser
FOR HAZARD / CHEMICAL ISSUES:

COO

Manager-Merchandiser

GM-Quality AGM/GM - Production

GM-WASHING LAB IN-CHARGE

PROCEDURES:
Investigation report will be carried out by the committee to identify the cause of a particular
complain.
Below procedure being followed by factory:
A. Complain
Merchandising Head will state the complain of the buyer
B. Investigation Committee will perform thorough investigation
C. Corrective Action Plan
D. Prevention
E. Follow-up by the complainant merchandising Head will follow-up on the result of
the investigation to further update buyer
In case of quality issues:
- Committee will review the previous audit report done by the QA Team
- Technical department will be asked to make comments.
- There will be a review to check if Merchandising department has made any comments with
regards to the same issue.
- If it is fabric related, lab in-charge will be asked and all the related reports will be checked and
reviewed like lab reports, fabric inspection reports.
In case of hazard / chemical issues:
Factory:
- Washing Managers will be requested to give comments / findings during production.
- Purchasing department / compliance department has all details about chemical histories and
compositions which will be reviewed.
- There will be verification of a particular complains depending on chemical and trace down the
suppliers where / when / how the items were bought.

CORRECTIVE ACTION PLAN:

For Quality Issue:
1. To carry out daily / weekly / monthly periodical check.
2. To follow-up constantly with concern the buyer requirements are met accordingly.
3. Team is formed consists of Merchandiser and Production People to meet every day 11am to
attend Sewing Review and Finishing Review to ensure that good quality garments are sewn and
Garments are packed properly. These garments are randomly picked-up from production.

PREVENTION:
For Hazard / Chemical Issue:
1. All hazardous chemicals must be identified by product and by chemical name.
2. Awareness of all hazardous chemicals and their bad effects (if misuse) also must be explained
accordingly.
3. Un-qualified / Un-experienced person should not be engaged on issuing, mixing, using on
garments.

SOP FOR SUPPLIER APPROVAL AND

PERFORMANCE
Non-Nominated Supplier:
1. Details analysis of the product range / machinery infrastructure to evaluate the capacity /
lead-time of the concerned supplier.
2. . Visit the supplier facility with merchandiser / finance to set the initial heads up / payment
procedure and the plant overall / general safety measures as well as compliance status.
3. Review the history of the supplier in terms of the other clients they are dealing with.
4. Emphasis on the internal quality checking procedure / if any loopholes immediately
implement the advisable system.
5. Make them aware of the ownership responsibility if any deviation in terms of quality /
delivery. Thanks
6. Effectiveness for implementing corrective action plan (CAP) in case of complains.
7. Renewal of the all sort of certificate in 2 years interval. Need to make sure of the same.
8. After taking the positive joint decisions we are agreed to place the order to the supplier
9. Requisition rcvd from merchandiser with all the relevant details.
10. Asked for the sample from supplier with specified parameters.
11. Sample provided by the supplier.
12. Sample will be checked by the merchants and getting feedback on the same.
13. Approval rcvd from merchants >>>>>>>If not approved need to resubmit again.
14. Placing the order with po / delivery schedule
15. Supplier feedback on the delivery schedule
16. Continue follow up/ tracking the po with supplier for avoids any delay in delivery.
17. Delivery rcvd in fly >>>>>> All the delivery challan has to verified by the store and put a KTC
chop for well rcvd >>>> purchase dept will provide all the challan copy with store seal to
account for the payment
18. Checking the quantity /quality by the gate / store QA to and confirm all ok >>>>>> If not
found ok we need to inform supplier and replacement has been done
19. Store provided bulk sample to merchants… sent for testing… rcvd report. 20. Sample
approved for production and issue to line from store.

Nominated Supplier:
1. Since buyer has assessed the supplier and nominates it thus we respect buyer and accept
the supplier as our approved Supplier.
2. Requisition rcvd from merchandiser with all the relevant details like specifications / input
date / etc
3. Approval rcvd from merchandiser >>>>>>> If not approved need to resubmit again. We will
communicate with supplier with corrections details.
4. Placing the order with po with item / delivery schedule.
5. Supplier feedback on the delivery schedule.
6. Continue follow up / tracking the po with supplier for avoids any delay in delivery.
7. Delivery rcvd in facility >>>>>>All the delivery challan has to verified by the store and put a
KTC chop for well rcvd by store >>>>>Purchase dept will provide all the challan copy with
store seal to account for the payment.
 8. Checking the quantity / quality by the gate / store QA to and confirm all ok >>>>>>if not
found ok we need to inform supplier and replacement has been done.
9. Store provided bulk sample to merchants >>>>>Sent for testing >>>>>Rcvd report.
10. Sample approved for production and issue to line from store.

Approved Supplier List

SL Business partner Type of If Signific Signed Signed Contract Address Validity commen
name business others, ance e BSCI code ETI Base person of social ts
partner please for the of code of certificat
including farms specify audited conduct conduct e (if f
any)

1 Paxar Bangladesh Accessories High Yes Yes 3/F Uday Towa,

Mr. Waliul
Ltd. Suppliers Gulshan-1212

2 Epyllion Unveil Label & High Yes Yes

Mr. Abul Mirpur-07, Dhaka-
Human Spirit Printing
Hayat 1216
Suppliers
3 SML Ltd. Label Supplier High Yes Yes H-98,R-#11, B#C,
Md. Shihab
AEPZ, Narayangonj

4 Dhaka Property Security High Yes Yes The Rab Apartment

Services Ltd. Supplier Md. Ferdous # C-02, House No-11
Gulshan Dhaka.

5 Shaftess Transport High Yes Yes 91, Kaji Nazrul Islam

International Supplier Mr. Salim Avenue, Karan
Bazzar Dhaka -1215

6 Sharmin Fright Transport High Yes Yes Md. Biozid House #279 (3rd
system Ltd. Supplier floor, Road#19( Lake
Road
.New D.O.H.S,
Mohakhali, Dhaka -
 1206

7 Rajib Enterprise Labor Supplier High Yes Yes Kadamtuli,

Md. Jasim Siddirganj,
Narayanganj.

8 Blue Creation Washing High Yes Yes Md. Sayid 387/1, Zitar More
Creation ,Kashimpur , Gazipur
Sadar,

9 Envoy Group Fabric Supplier High Yes Yes Mr. Shoriful Jamirdia, Bhaluka,
Mymensingh

10 Shariar & C&F AND High Yes Yes Mr. Kaysan Luna Chember
Brothers Ltd. TRANSPOR 2nd,6th floor, 108
Chittagong.

11 Foshan Nanhai Fabric Supplier High Yes Yes tnm8y5@16 3rd.floor next to
Deyao 3.com shansheng textile
city keqiao district
shaoxing,china

12 Yixing Lucky G&L Fabric Supplier High Yes Yes lq@luckytex 10 Zhuqiao Road
Denim co. tiles.cn Zhuqiao Industrial
Park Yixing, 214200
China
13 Oswal Denim Fabric Supplier High Yes Yes "Nahar Tower "
nahar@ow
Industrial Area - A
mnahar.
Ludhiana - 141 003
com
(INDIA)

14 LNJ Group Fabric Supplier High Yes Yes Bhilwara tower, A-

info.rswm@l
( RSWM Ltd.) 12, Sector - 1,
njbhil
Noida 201301 (NCR),
wara.com
Delhi, India,

15 Liberty Mills Ltd Fabric Supplier High Yes Yes Liberty Mills Limited
info@liberty
A/51-A, S.I.T.E,
millsli
Karachi- 75700,
mited.com
Pakistan.

16 Zaber & Zubair Fabric Supplier High Yes Yes Concord Baksh
Fabrics infozaber@z Tower, Plot 11/A,
nzfab. com Road 48, Gulshan 2,
Dhaka, Bangladesh.

17 Changzhou City Fabric Supplier High Yes Yes sales@hengf Ligong Rd.,
Hengfeng Co. Ltd eng.cc Diaozhuang
Industrial Zone,
Changzhou City,
Jiangsu Province.
China

18 Hua Jin Ltd Fabric Supplier High Yes Yes Room 518, Tower A,
New Mandarin Plaza
info@huajin No. 14 Science
- hk.com Museum Road
Tsim Sha Tsui East
Kowloon, Hong Kong

19 San Aurora Pacfic Fabric Supplier High Yes Yes Address: Unit 2607
Ltd. 26/F Fun Tower, 35
sapl@sanaur
Hung To Road, Kwun
ora.co m.hk
Tong, Kowloon, Hong
Kong

20 NZ Fabric Fabric Supplier High Yes Yes enquiry@mil 237 Blenheim Road,
lersho Riccarton,
me.co.nz Christchurch 8041

21 Azgard Nine Ltd. Fabric Supplier High Yes Yes info@azgard Ismail Aiwan-e-
9.com Science, Off:
Shahrah-e-Roomi,
Lahore- 54600,
 Pakistan.

22 Argon Denims Ltd Accessories High Yes Yes Plot-33, section 7,

info@argon
Suppliers Mirpur. Dhaka-1216,
denims. com
Bangladesh.

23 Zhejiang Rainbow Accessories High Yes Yes XIAOSHAN

Suppliers hzpigments ECONOMIC
@gmail. DEVLEOPMENT,HAN
com G
ZHOU, , , China

24 Haama Hk Ltd Fabric Supplier High Yes Yes sales@haam Haama Hong Hong,
a.com Room 506, Building
3, #58East Xinjian
Road, Minhang
district, Shanghai,
China 201199

25 Ananna Textile Fabric Supplier High Yes Yes Mr. Mahbub Dohs Mirpur-12,,
(Makreting Dhaka 1212
Manager) Bangladesh

26 Vardhman Textile Fabric Supplier High Yes Yes Chandigarh Road,

Ltd mngt@vard Ludhiana,
hman.c om Punjab-141010,
India.

27 HK Selection Ltd Fabric Supplier High Yes Yes Address: 3rd Floor,
info@aall-
Jonsim Place, 228
zyleman.co
Queen’s Road East,
m
Wanchai, Hong Kong.

28 Mg Macao Fabric Supplier High Yes Yes Room 9, 4F, Beverley

Commercial Commercial Centre,
service@bbc
Offshore Ltd 87- 105 Chatham
incorp
road South, Tsim Sha
.com
Tsui, Kowloon, Hong
Kong.

29 Osman Fabric Supplier High Yes Yes

Interlinings Ltd. info@osman Jahangir Tower 4th
tex.co m Floor, 10 Karwan
Bazar, Dhaka 1215

30 Grand textile ltd Accessories High Yes Yes Address: 7F, 657-9
Suppliers info@grandt Zhong Zheng Rd, Xin
extile. com Zhuang, New Taipei
City, 24257 Taiwan

31 Jiashan Zhanwang Accessories High Yes Yes Add: No. 23, Dashun
Garment Suppliers Xinjiang, Xitang
sunpeiqiang
Accessories Town, Jiashan
@126.c om
Factory County, Zhejiang
Province

32 Ecotrims Accessories High Yes Yes House # 25, Ground

Bangladesh Ltd. Suppliers tayob@ecot Floor, Road-04,
rimsbd. com Nikunja-1, Khailkhet,
Dhaka-1229

33 Trisan Trims Ltd Accessories High Yes Yes Address: H-01,

Suppliers Dakshin Dariapur,
info@trisant Genda Bus stand,
rims.c om Savar Upzila HQ,
Savar, Bangladesh
1340

34 Suchi Suha Fabric Supplier High Yes Yes Ma-53, Mina Garden
Garments bgiburhan@ (3rd Floor) West
Accessories Ltd gmail. com Merul Badda, Dhaka-
1212.
35 YIXING LUCKY G Fabric Supplier High Yes Yes Daisy NO.10 ZHUQIAO
AND L DENIM CO., 86-510- ROAD,ZHUQIAO
LTD 80192697 INDUSTRIAL
daisy@lucky ZONE,YIXING,JIANGS
textiles.cn U,CHINA

36 Avery Dennison Accessories High Yes Yes Avery Dennison 2-

Suppliers 4/F Binhai Business
Linda Center, No.9, Haining
lindam.lin@ 1st Street, West
ap.averyden Huanshi Road,
nison.com Nansha ETDZ,
Guangzhou, P.R.C.
511458

37 A&E Accessories High Yes Yes 22 American Street

Suppliers P.O. Box 507
Mt. Holly, North
Carolina United
statos 28120

SOP FOR ROVING QC

Standard Operating Procedures of Roving QC
Whenever a new style starts in a line Factory QA Manager Calls for a small meeting with The Roving QC, inline
QC and end line QC. Where he discuss the style with buyer approved red tag sample. He identifies all the
critical operations and allocates or assigns responsibility to roving qc and other qc accordingly

As the line layout is done for the new styles. Roving QC assigns a Quality identification number (QIN) to all the
machines. He hangs a tag on machine with QIN written on it.

Checking of trims

Roving QC will visually display merchandiser approved trim chart in the line, Though Trims inspection is done
by QC in stores but again he cross checks the trims with Trim chart. He also ensures that correct thread is used
for the operation.

As the input is taken and bulk production starts for the new style. They work accordingly to the responsibility
assigned by the QA manager.
Roving QC Check Procedure

1. The roving QC follows the QIN (Quality identification number) and randomly selects a check position.

2. He takes the last completed bundle of that operator and randomly select 7 pcs from the bundle to
check the bundle sequence and quality for that particular operation.

3. He checks the pcs for :

a. SPI, Thread tension – checks the SPI and sees that it is locked

b. Sewing defects like puckering, uneven stitch, broken stitch etc.

c. Measurement checks are done as per the technical meeting report.

*Technical report is made by the technical manager at pre production meeting.

d. Number mistakes – checks whether operator is following serial no. or not

e. Shading & Fabric Faults checks whether there is any fabric faults or parts shading.

4. If no defects are found he clears the operator and goes to the next random QIN and if any defect is
found.

5. He calls the Line manager or Supervisor and hand over the bundle to him and then hangs a Red color
tag on machine with ‘UNCLEARED OPERATOR’ written on it.

6. He also issues 3 red color cards to the operator for 1st, 2nd & 3rd follow up

7. The Supervisor then along with the operator checks the bundle and get the defective garments
repaired from the same operator the QC will recheck the garments and if found ok will do the follow
up 3 times. 3 times he will come and check the bundles and will collect the red color follow up card
which was earlier issued to the operator.

8. If all the 3 follow-ups are ok then only roving QC will remove the Red Tag from the machine and praise
the operator for her good work. And moves to the next QIN for same procedure.

9. If it is not ok the machine will be stopped and informed to all senior production persons. If required
the operator may be sent to the counselor who councils the operator.

Reports made by Roving QC

 Random Number table record.

 Random Inspection record.

 No of unclear operator.
  Bundle Control Sheet

SOP FOR QC TRAINING

Standard Operating Procedures of QC Training
QC – Training program and contents

This program is aimed to facilitate recruitment of fresher as trainees and train them internally to make up
position inside and End post Q.C’s in our Finishing & Sewing lines.

Training Duration:

A Training program is designed to run in a structured way for a period of 15 working days.

Conveners / Conductor

The program will be conducted by one person on full time basis from the (Q.A dept) (Training Manager)

Batch Size:

Training will be done in batches of 10 to 12 trainees.

Training Venue:

Training centre unit – 1

Training Schedule and contents:

The training will be completed over a period of 15 working days. The day wise schedule and training
contents are as follows:

Day - 1

 Introduction to Garments industry.

 Introduction to General and Overview all quality
 Introduction to “Quality its Importance and relevance.
 Visual presentation of various garments – Tops & Bottoms
 General introduction to various process in garments Manufacturing ( Cutting & Finishing)
 Round through the factory.
 Identification of various parts of Tops – visual presentation.
  Identification of patterns of different parts as appearing on markers.
Day -

 Introduction to Garments Bottom – Visual presentation.

 Identification of parts as appearing on Markers.
 Test- 1 On the first two days of learning.
Day - 3

 General Understanding of Machines and Stitches

This session is meant to educate the trainees on the different types of Sewing Machines in

Use and various Types of stitch and their properties

 Stitch Type
 Stitch Density
 Thread Tension
 Thread Size
 Needle Types and sizes.
 Machine Type:
 Back tacking, Seam Allowance, skip stitches and broken stitches.
Day - 4 & 5

 Understanding of various sewing defects.

 This Session is to expose trainees to the various kinds of defects they would come across in a Garment.
There will be physical presentation of defective garments along with detailed lecturing on the subject.
 Test -2 (On days 3, 4 & 5)
Day - 6

 Checking of Defects in Garments in Sequence.

This is a very important Session to Which would focus on the process of checking garments for various types of
defects on days 4 & 5. This will involve subjection trainees after proper orientation, to live situation of defects
identification on garments both Tops and Bottoms. They are also taught to carry out this in a desired sequence.
There are 16 section of TOP to be sequentially checked. There will be sticker’s numbers from 1 to 16 which the
trainees will be asked to paste in the sequence they cheek the garment. These cheeked pieces are reviewed to
see if the sequence is in line with the standard method of scanning a Garment.

Day-7
Measurement

 One of the important aspects of Quality Assurance besides Sewing and Fabric defects in the
measurement of different parts of garment. Q A team has to ensure all garments with specified
measurement that go into Garment, both TOPS and BOTTOMS, and training to measure and check
deviations if any.
 Test -3 (On Garment Cheek and Measurement)
Day - 8 & 9

 Understanding and generation of various Quality reports and DHU Calculation.

 Test -3 (On Garment Cheek and Measurement)
The test will be assessing the level of assimilation of whatever has been taught on days 8 & 9.
Day - 10

 Shade Differentiation
o To educate the trainees on the aspect of shade variations and the need to differentiate among
shades in the same color variation. They will be taught to segregate shade, make shade bands
and shade match.
 Our each sewing line is attaching shade labels. Need to explain them where shade labels are being
attach and how to identify wrong shade labels or right shade labels while checking the sewing line
garments.

Day: - 11 & 12

 Training on the line lines with the line – Q.C’s

 Evaluation at the End to the Training Program.
There are 4 test conducted during the curse of the training program to evaluate trainees, performance during
the Training sessions. There test scores from the basis for decision to absorb them as En-post or Inside QC’s or
drop them.

These tests are for aggregate score of 100 distributed as follows:

TEST No. Marks

Test 1-------------20

Test 2-------------30
Test 3-------------30

Test 4-------------20

Trainees who score an aggregate score of 75% and above will be graded as “A”.

Trainees who score between 61 and 75% will be graded as “B”.

Trainees who score below 70% will be “C” grade performance.

All trainees who scoreless then 70% will be dropped from any further progress. All trainees to be eligible for
absorption should also score a minimum of 50% in each of the tests conducted.

B4 wash spec sheet SOP

Desired state
Current State
Error free B4
Error in B4 wash Measurement
wash measurement sheet

PP Pattern+ Add bulk fabric Shrinkage PP Pattern+ Add bulk fabric Shrinkage

Issue pattern & Spec sheet for size set Issue pattern & Spec sheet for size set

Floor give correction for size Floor give correction for size
set/PPR/Bulk set/PPR/Bulk

Alamgir makes B4 wash sheet based Alamgir makes B4 wash sheet based
on the corrections on the corrections

Spec sheet is sent to data entry to Spec sheet is sent to data entry to
make make
computer copy. computer copy.
 Sr. Technical mgr PP activitiy will cross
Excel sheet is issued to the floor
verify this measurement sheet

Verified Excel sheet is issued to the

floor

Yellow color is the added process from old

one

LAB TEST SOP

(For Testing Laboratories)

Laboratory: Simba Fashions Ltd. AEPZ, Bangladesh. Date(s) of Visit:

Facility: Testing Discipline(s): Chemical Page 1 of 1
Sl. Product(s) / Specific tests performed Test Method / Standard Range of Testing/ Uncertainty of
Material of test against which tests are Limits of Measurement
performed detection () at Value
I. TEXTILE (WOVEN & NON-WOVEN)

Color fastness to ISO 105 E01 : 2013 (Grade 1 to 5)

N/A
water Qualitative
y

AATCC 107 : 2013

Color fastness to ISO 105 X12 : 2016 (Grade 1 to 5)

N/A
rubbing /crocking Qualitative
 Signature & Name of Lab Representative Signature & Name of Assessor(s) Signature & Name of Lead
Assessor

Doc. No: Assessment Forms and Checklist (based on ISO/IEC 17025: 2005)
Issue No: Issue Date: Amend No: 00 Amend Date: Page No:

Internal Technical Audits SOP

1. PURPOSE:
The purpose of this Standard Operating Procedure (SOP) is to describe the process for conducting of
internal audits to assess the effective implementation of Good Manufacturing Practices and where
necessary propose and implement corrective actions

2. SCOPE:

The scope of this SOP applies the applies to the conducting of Good Manufacturing Practices internal
audits.
3. AUTHORITY AND RESPONSIBILITY:
Management ensures that Good Manufacturing Practices internal audits are periodically conducted.

Employees

All employees are responsible to adhering to this SOP.

4. Audit team

Internal audits are carried out by personnel independent of the activity being audited. Internal Auditors
need to be trained before being assigned for internal audits.

4.1 Planning of internal audits

When planning the internal audits, consideration is given to the status and importance of the processes
and areas to be audited, changes affecting the organization, as well as the results of the previous audits.
Internal audits are conducted at Quarterly of the year as per INTERNAL CHECKLIST
(SFL/QMS/CHL/001-00(17th July, 2021)

The organization’s own requirements will also form part of the audit criteria.

An Annual Internal Audit Calendar should be maintained. The calendar may be revised after each audit
based on the audit findings.

4.2 Audit process

Audits are carried out against audit criteria other relevant standards. Non-conformance reporting is
based on objective evidence.

When an actual/potential non-conformance is observed during an audit, both auditee and auditor must
agree on the following:

 Objective evidence
 Nature of observed deviation
 Corrective / preventive actions and due date, and
 Need for follow-up audits or verification and the due date.
4.3 Recording the Results of quality audits

Auditors record the observed non-conformities, deficiencies, and improvement opportunities in the
area / department being audited on the SFL/QMS/CHL/002-00(17th July, 2021) Internal Audit
Findings Notification. A formal audit report is compiled within 5 working days after completion of the
internal audit.

4.4 Follow up audits

When a non-conformance detected during audits is not addressed during the audit, follow-up audits
shall be conducted. Responsible personnel shall be assigned to keep track of open audit findings and
ensure that these are closed within the agreed time frame.
4.5 Closing of auditing findings

Once the corrective actions are completed and if further follow-up audit is not required, the audit
findings can closed.

The internal audit summary in the is also discussed in the subsequent management review meetings.