Sewing Needle and Metal Detection -Product Safety inspection procedures and general instructions to suppliers regarding samples. It is essential that all suppliers comply and meet with our requirements for product safety inspection
These requirements fall into five categories.
Needle policy.
Metal Detection.
Component Testing.
Physical Examination.
Physical Design.
Needle policy:
A clear policy must exist within the factory for the issue of needles and there must be a procedure to deal with broken needles and needle recovery from garments. (see details section D safety manual.)
Sewing needles should only be installed by trained personnel and it should have sewing replacement policy
Sewing needles should suit the fabric type and speed of the sewing operation.
Sewing needles should be replaced at regular intervals and disposed of carefully.
Metal Detection:
We actively request that factories operate metal detection machinery, which is set up to detect the presence of “foreign metal” fragments . (ref. details in section D safety manual).
100% off production must be passed through an approved metal detector –hand held detectors are not acceptable for use for production stock.
Detectors must be capable of detecting ferrous metal.
The detector should be set at a sensitivity level which will always detect the approved 1.2mm ferrous standard.
Records of all metal contamination should be kept, using a contamination record, stating time, date and location.
The location of the detector in the factory should be approved by the metal detector supplier – this ensures there will be no interference which may upset the machines settings.
Metal detection should be seen as a last resort and not as a replacement for a well maintained needle policy.
Component Testing:
These should be made from a non-ferrous metal and be nickel free. It is a further requirement that all poppers and studs are applied with an automated machine and that the correct prong length and correct crimping force is used. All components must be non toxic and must comply with EN 71 part, 1, 2, 3 for the preceding and general product safety.
Physical Examination:
All garments contracted for Dunne’s are to be subjected to a 100% examination for dangerous items. These items include blades, scissors, pins or metal objects that may have come into contact with the garment during the manufacturing process. It is our requirement that all pockets, reversed hems, enclosed foot or similar garment features are checked for dangerous objects that may be concealed therein.
Physical Design:
The physical design of a garment will be reviewed and modified accordingly, so that it may better conform for enhanced product safety.
This deals with such things as to the length of draw-strings and loops, trims, appliqués etc…
Functional draw cords are not permitted for use on children’s garments up to & inc.age 9 years. It is a legal requirement that garments with a chest size smaller than 44 cms, do not have a functioning hood draw cord. No cords functional / decorative to be used up to and including age 9 yrs.
Draw cords fastening to the back are not permitted on any garment within the Children’s division.
The use of cut coil zips is not permitted. All zip s should have permanent plastic cob stops, which are free from sharp edges or protrusions & of one solid piece. Open ends zips to have ‘E’ shape top cob stop.
Garments must comply with all regulations pertaining to ‘Safety of Children’s Cl othing’ –
Minimum neck stretch measurement:
The following general requirements apply . All samples should be submitted with
(1) a sample card
(2) a size spec
(3) the garments must be pre-measured by the factor y and where applicable checked by agent / importer & findings indicated on the accompanying spec.
Normally the requirement for samples will be as follows:
(1) a buying sample/ an approval sample.
(2) a fit samples (sizes as per manual )
(3) a sealing sample before production.
(4) a production sample prior to shipment.
Written By - Engineer Amanullah, Kansai Sewing Machine Specialist, Ava Garments Ltd. Dhaka
Metal zips & pullers used for Younger & Older Children’s Garments Accessories /products should be of Non-Ferrous metal to allow them to pass through metal detection. Brass base. No Metal zips are to be used for any Nursery or Babies products.
Zip Requirements for Childrenswear
Zips must be plastic and have solid dtm top cob stops.
Claw top stops are not to be used on any Children’s zips.
Cut Coil Zips are not to be used in Children’s garments.
Plastic zippers must not use top stops that allow the slider to be removed from the stringer. E style cob stop required.
Zip Requirements
Bottom stops that are formed from welding the monofilament teeth are only allowed on invisible zippers
Top stops must not have any Injection Flashing remaining (see above ) they must be removed properly during manufacturing as they can cause scratches on a Childs skin.
Gate / Rail Top Stops (split cob stops which allows slider to be removed on open end zips ) are NOT allowed.
In addition to the above it is essential that all zip teeth are securely attached to the zipper tape.
Zips should start 1cm down from top of neck line.
Zips should only be ordered from one of the list of nominated suppliers as shown in the QC supplier manual. See below contact
Safe Attachment of Poppers for Childrenswear
Auto only accept poppers from recognized supplier Data Sheet and Garment Check Report Two samples, representative of manufacturing must be sent to the popper supplier, who will check fabric thickness and manufacturing technique to advise accurate pinch settings and popper location.
The data sheet and one garment will be sent back to you providing the supplier is happy with the overall make up of the style. (Note you must send the following information to the popper supplier, style number and purchase order number so they are entered onto data sheet). The popper supplier will keep a garment for their records. A copy of the data sheet must be available if required.
The data sheet will not be submitted, if the popper supplier is not satisfied with the method of manufacturing, they will send you a Garment Check Report (GCR) giving full details of why the data sheet cannot be issued.
You must not start popper attachment until this data sheet has been received; you must follow all points on the garment check report and resubmit to the popper supplier for approval.
You must give notice to the popper supplier allowin g time for them to calibrate the machines to achieve the correct pinch settings for bulk product ion. It is your responsibility to ensure that the pinch setting does not deviate from the data sheet supplied by the popper supplier. The data sheet must be kept with the vernier calipers and pull test equipment on the production floor.
Production
Note: You must not start production without vernier calipers and the recommended pull test equipment in place.
Pinch settings must be completed and recorded every two hours during production. With corrective action taken should the range drift towards inner and outer limits, as set by the popper supplier. Pulltests are to be carried out at least three times daily and records kept. Should any garments fail, you must stop using the popper attachment machine immediately and inform the popper supplier without delay
Training
Operators must be trained on Popper attachment machinery Best practice of popper attachment
Photographs and details of the machine operator must be on a certificate issued by the popper supplier. It is your responsibility to ensure that safety guards or other working parts are not tempered with.
Storage and Work Area
The floor area must be clean and tidy around the popper attachment machinery. Do not overload the machine hoppers, as there is the risk of damaging the prongs and poppers as the cylinder rotates this can potentially also cause excess vibration of the machinery leading to poppers falling on the floor. This will waste you money. Popper storage must remain in cartons off the floor in racking. Never leave plastic bags containing poppers loose on the floor; there is a risk of dama ging the prongs and poppers. Poppers that are dropped on the floor must be place d in a separate polythene bag on the side of the machine and disposed of by the line supervisor (under no circumstances must they be used, as there is a high risk of the prong’s being bent / damaged posing a safety risk)
Auto insist that the Supervisor in charge or other person of responsibility have a separate certificate for training in the correct use of calipers, pull test, machine settings. Ensure machinery, dies and poppers are supplied by the same source. DO NOT MIX & MATCH and always refer to the data sheet provided if uncertain.
YKK, Morito and Prym offer technical support at noadditional cost. They are there to provide a service to you. Always refer back to your supplier for technical support and advice.
You are putting your production and the safety of the end user at risk if you deviate on any of the above issues.
Quality Control Final Inspection
It is vitally important that you have in place a system of control at your final inspection point. Here are some simple rules to follow:
Fasteners should not appear to be distorted or misshapen
Fasten and un-fasten all poppers to ensure good connection and check there is no sign offabric breaking down around the popper
Always turn through the feet of sleepsuits, pockets and mitts to ensure no poppers are floating loose inside.
Conclusion
Auto Quality Assurance Department requires that above procedures are implemented in your factory before order placement and you audit the system randomly. If you require any further assistance do not hesitate to contact the Quality Assurance Department. Zip Requirements for Childrenswear are described above in detail
Written By -Engineer Amanullah, Kansai Sewing Machine Specialist, Ava Garments Ltd. Dhaka
The following must be adhered to with regard to finish on any Children’s product where embellishments are used. No product will be accepted if deemed
unsafely finished. No hand sewing is to be used for embroideries / embellishments/ badges/ appliques /sequins or buttons for any products under 35 months. Machine lock stitch only accepted.
Single Jewel Stone.
Single jewel stone must be securely attached with Polyester double thread stitch on any fabric type & also glued where possible. .
A Vilene or self fabric backing placed on the inside of the product at the back of the stone, through which the stone is sewn to ensure a secure attachment base and the threads must be securely knotted off. Must withstand a strong manual pull test.
Acrylic Jewel stones must not have any burrs, sharp or rough edges that can cause injury and/or have a grating affect on the thread resulting on the thread fraying and the stone inevitably coming loose owing to thread break down.
All purpose Polyester Thread (100% Polyester ) or Cotton – wrapped
Polyester to be used for all applications.
Small Diamante Stones (Rhinestones)
All stones must be securely stuck to the main body of the product using either glue especially made for the purpose . These are very strong, dry completely clear and invisible and last a very long time, or using Hot-Fix (or Heat-Fix) which are stones backed with special glue and are set using an iron or a specially developed tool. The later is a much faster, easier and more economical method.
Stones must not be placed across seams or uneven surfaces or directly onto plastisol prints .All stones must withstand the ruler test for secure attachment. Any stone which loosens or starts to peel away, even slightly, is not acceptabl
Rhinestone Banding (strands)- e. A connected ‘Chain’ or row of individual stones where each stone is held in a plastic cup (metal not accepted for
Children’s products), must be securely sewn in spaces of 1cm and no floaters.
The fastener must be selected on the basis of compatibility with the fabric, style and thickness. Prong fasteners used for knitted fabrics and post for woven fabrics.
Fasteners /Ring Snaps must not be applied across seams or any other area of thickness variation. They must not be damaged in any way during application resulting in protruding burrs or sharp/damaged edges.
Fastener / Rivet attachment must be secure through at least 2 plies of fabric and withstand a pulling force of 90 Newtons.
Lightweight fabrics may require reinforcement to provide sufficient strength to withstand popper/stud application / wear and must pass through a min of 2 layers of fabric.
Studs / Rivets must be placed through a min of 2 layers of fabric and should not be placed across seams or any area of thickness variation. Should withstand a pull force of 90 Newton.
Bows
Bows must not have ribbon tails exceeding 5cm in length and ribbon ends must not ravel. Laser/Sonic cut ends only accepted. Heat Seal is not acceptable.
Bows must be securely attached to the product through the centre knot area ensuring the bow is secure and cannot come undone or come away from the product easily.
Glitter Prints
Glitter used on any area of a product print should not shed or transfer and should not have a harsh handle. Small particle glitter (securely applied) only to be used.
Written By - Robert Dkay, Manager, Golder Accessories Ltd. Narayangong
We sale Garments Safety Software , Safety Audit & Information Management System software, so contact us to get this software. An audit program attempts to evaluate the performance of various management processes by investigating plans and policies of management in the various fields of operation. It is the examination and scrutiny of various policies and actions of the management on the basis of certain standards.The system to a significant development in any part. It is not merely a communicating network but also generates intelligent response. It has a methodology of decision models built in it and is available to analyse and evaluate decision alternatives to suggest the optimal alternative.
Safety Software Audit Definition
Safety Audit is an audit to evaluate the policies and performance of safety systems with the intention to compare the same with some objective and predetermined standards. ATD Safety Audit System comprises of the following :
General Safety Audit
Safety Equipment Audit
Occupational Health & Safety Monitoring
Preventive Maintenance Audit
House Keeping Monitoring
Safety Training Software
ATD workers are provided with the general safety guideline during their operational training. After completion of the training program, the trainees are evaluated and certified by the concerned area in-charge, training co-ordinator and the trainer. Later the trained personnel are interviewed randomly regarding the operational as well as the safety issues by assigned person. If the Trainee fails to answer or perform properly he is decertified and sent back for specific training again. For detailed process refer to the “Safety Training Software ” manual
Form & Documents Used
Following forms and documents are used for the Training & General Safety Audit purpose :
Safety Training Software manual
Training Task Check List
Training Materials
Training Evaluation Form
Safety Equipment Audit Process
Safety Equipment Audit means examining the condition of the safety equipment placed at the workplace to ensure floor personnel safety and to conform by the Health & Safety Policy of ATD. The Admin Department of concerned unit of ATD performs this audit on a regular basis and maintains all the safety equipment, e.g. fire extinguishers, crow bar, etc. in proper condition.
Forms & Documents Used
Following forms and documents are used for the Safety Equipment Audit purpose :
Users’ manual of Safety Equipment
Maintenance Record of Safety Equipment
Safety Equipment Usage Records
Audit Form
Audit Report
Occupational Health and Safety Monitoring Process
Records of job related accidents and illnesses (incidents) are maintained by the Medical Inspection Team of concerned unit of ATD. These records include all incidents resulting in an incapacity to work for at least one full workday beyond the day on which the accident or illness occurred. Records must also include the total number of days of absence from work as the result of an incident. This information are reviewed and evaluated to improve the effectiveness of the health and safety program.
Forms & Documents Used
Following forms and documents are used for Occupational Health & Safety Monitoring :
Accident/Incident Records
Attendance Record
Medical Report(s)
Preventive Maintenance Audit Process
Since, Preventive Maintenance for all machines and equipment are done by the Maintenance and Utilities Departments of ATL, the performance of these departments are audited as per the ATL Audit Forum’s decision. For detailed audit process, refer to the ATL Internal Quality Audit System manual
Forms & Documents Used
Following forms and documents are used for Preventive Maintenance Audit :
Audit Form
Audit Report
House Keeping Monitoring Process
The primary responsibility of house keeping lies with the area in-charge. He has to ensure proper house keeping and cleanliness of his area. However, the Admin Department of concerned unit under ATD monitors the overall housekeeping of their factory premises. In case, any imperfection is found, the concerned are in-charge is immediately notified to take the corrective action.
Forms & Documents Used
In case, a major non-conformity is found during house keeping monitoring, the Admin Department may issue a Show Cause notice to the concerned person who can is responsible for the non-conformity with the set standards.
Information Management System Definition
An Information Management System is designed in a number of small modules. Some modules are used only once while others might be used in a large number of applications. The use of common modules considerably reduces the programming and designing effort in an information system, e.g., the Preventive Maintenance Record, safety audit software Reports, etc can cater needs for Maintenance, Production and other management operations.
Recording of Data
The Personnel & Administration Department of concerned unit under ATD maintains the records of significant environmental matters, including monitoring data, accidents and occupational illnesses, spills, fires and other emergencies.
Monitoring
All Safety related issues are monitored and audited as per schedule by the assigned personnel of Administration Department of particular unit under ATD. In case of any non-conformance with the set standard is found, immediately the Administration Department as well as the concerned departments of that particular unit are notified to take the corrective action immediately.
Data Analysis
Monitoring data are analysed and reviewed at regular intervals and compared with the operating standards so that any necessary corrective actions can be taken immediately.
Reporting Safety audit software
Records of monitoring result are kept in an acceptable format. These are reported to the responsible authorities and relevant parties, as and when required.
Safety Training Program
In order to ensure a safe and sound work environment, AUTO employees are trained on the hazards, precautions and procedures for the safe storage, handling and use of all potentially harmful materials relevant to each employee’s task and work area. Personnel are also trained in environmental, health and safety matters including accident prevention, safe lifting practices, safe chemical handling practices, and proper control and maintenance of equipment and facilities.
General Safety Training Program Content
Training program includes emergency response, including the location and proper use of emergency equipment, use of personal protective equipment, procedures for raising the alarm and notifying emergency response teams, including local and regional hospitals, and proper response terms, including local and regional hospitals, and proper response action for each foreseeable emergency situation.
The General Safety Training Program is a part of the operational training program of AUTO . It involves :
Knowledge on General Industrial Safety
Knowledge on Safety issues related to specific operational area(s) or machine(s).
General safety guideline.
General guidelines to use safety equipment.
Knowledge on First Aid Treatment.
Key contacts.
Emergency evacuation plan, etc.
Target Group
All workers, supervisors and staffs engaged in production operation.
Training Process
The trainee is given a tour of his/her primary work area. Trainer shows all the hazards associated with the are such as fire, chemical, thermal, mechanical and electrical hazards. He/she is given tips on what to do in case of an emergency. For detailed training process refer to the area specific training materials.
Maintenance Training Program Content
The General Safety Training Program is a part of the operational training program. It involves :
Knowledge on General Industrial Safety
Knowledge on Safety issues related to specific operational area(s) or machine(s).
General safety guideline.
General guidelines to use safety equipment.
Knowledge on First Aid Treatment.
Key contacts.
Emergency evacuation plan, etc.
Target Group
Maintenance personnel.
Training Process
The trainee is given a tour of his/her primary work area. Trainer shows all the hazards associated with the area such as fire, chemical, thermal, mechanical and electrical hazards. He/she is given tips on what to do in case of an emergency. For detailed training process refer to the area specific training materials.
Fire Fighting Training Program Content
The content for the Fire Fighting Training Program is as follows :
Concept of Fire : Definition & Types
Principle of Combustion of Fire
Concept of Fuel
Principle of Fire Extinguishing
Medium of Fire Extinguishing
Knowledge on Fire causes and consequences.
Use & Types of fire extinguishers.
Target Group
25% of total floor manpower.
Training Process
Different units under AUTO made arrangements with the “Fire Service & Civil Defence” to train their required number of personnel on Fire. For details regarding the training process on Fire, refer to the training handouts supplied by them during training program.
Certification
A badge is given to the trained personnel so that they can be easily identified in Safety Software, safety audit software and Safety Training Software
Written By - Robert Dkay, Manager, Golder Accessories Ltd. Narayangong
Function: The instrument is used for visual inspection of yarn like neps, thick and thin places etc.
The textile industry uses vegetable fibers (such as cotton), animal fibers (notably wool and silk), and a wide range of synthetic materials such as nylon, polyester, and acrylics. The production of natural fibers is approximately equal in amount to the production of synthetic fibers. Polyester accounts for about 50 percent of synthetics. (Chemical production of the polymers used to make synthetic fiber is not covered in this document.) The stages of textile production are: fiber production, fiber processing and spinning, yarn preparation, fabric production, bleaching, dyeing and printing, and finishing. Each stage generates wastes that require proper management.
The garments industry uses processed fabrics from textiles as their raw material. They have a wide range of products like readymade Shirts, T-shirts, Trousers, , etc. The stages of value addition for garments industry are : Sample and Marker making, Cutting, Sewing, Finishing, and Packing and Carton Making. Like textile industry, even these stages generate wastes during processing. Necessary action is required to control and dispose these wastes.
Textile production involves a number of wet processes that may use solvent and other volatile organic compounds (VOCs). Process wastewater is a major source of pollutants. It is typically alkaline and has high BOD5 (700 to 2000 mg/1) and COD (approximately 2000 mg/1), solids, oil and possibly toxic organic, and phenols form dyeing and finishing. Dye waste waters are frequently highly coloured and may contain heavy metals such as copper and chromium. Wool processing may release bacteria or other pathogens.
Thus, the small fabric parts generated during cutting procedure or the yarn particles or fluffs generated during further processing like sewing, inspection or finishing, are the main wastes of garments industry.
Written By - Robert Dkay, Manager, Golder Accessories Ltd. Narayangong
